Attachment 6 - REV A_R-245-0493 225 WLB.pdf

REVISION No. A . CHANGE No. .

TITLE

PROPELLER REPAIR SPECIFICATION

FOR BLADES USED ON 225 FT

CLASS WLB CUTTERS

R-245-0493

ORGINATED BY Andrew G. Ollerman DATE 10/20 .

ORGINATOR’S COMMAND Surface Forces Logistics Center (SFLC) .

DEPARTMENT / DIVISION Ice Breaker Buoy and Construction Tender Product Line (IBCTPL).

INTERNAL REVIEWER James Happe DATE 10/20 .

Spec R-245-0493 Rev A

10/21/20

PROPELLER REPAIR SPECIFICATION

FOR PROPELLER BLADES USED ON

225 WLB CLASS CUTTERS

1.0 SCOPE

1.1 This document sets forth the requirements for the inspection, repair, testing, preservation, packaging packing, and marking of bronze propeller blades used on 225 FT WLB Cutters.

1.2 CLASSIFICATION

1.2.1 Propeller Blade Set Type

a. Type 1 – Right Hand (RH), P/N 110252110.

1.3 GOVERNMENT FURNISHED PROPERTY (GFP) - The listed items are property of and managed by the USCG Surface Forces Logistics Center, Baltimore MD.

1.3.1 Propeller Blade Set – NSN 2010-01-421-8904, Right Hand.

1.4 GOVERNMENT FURNISHED EQUIPMENT (GFE) – The listed items are property of and managed by the USCG Surface Forces Logistics Center, Baltimore MD.

1.4.1 Dummy Hub, Propeller RH – ACN 2010-01-F04-0341.

2.0 APPLICABLE DOCUMENTS

2.1 DOCUMENT AVAILABILITY - To obtain the referenced documents see section 6.

2.2 GOVERNMENT DOCUMENTS - The following specifications and standards form a part of this specification to the extent specified herein. Unless otherwise specified, the documents listed here by number and date shall be those in the current Department of Defense Single Stock Point of Specifications and Standards (DODSSP) and supplements thereto.

2.2.1 SPECIFICATIONS

a. MIL-DTL-2845E(SH) - DATED 18 AUG 1999, Propulsion Systems, Boat and Ship; Main Shafting, Propellers, Bearings, Gauges, Special Tools, and Associated Repair Parts; Preservation, Packaging, Packing and Storage of.

2.2.2 STANDARDS

a. MIL-STD-167-1A(SHIPS) - DATED 02 NOV 2005, Mechanical Vibrations of Shipboard Equipment.

b. DOD-STD-2185(SH) - DATED 28 OCT 1986, Requirements for Repair and Straightening of Bronze Naval Ship Propellers.

c. MIL-STD-2035A(SH) - DATED 15 MAY 1995, Nondestructive Testing Acceptance Criteria.

2.3 OTHER GOVERNMENT DOCUMENTS - The following documents form a part of this specification to the extent specified herein. The documents listed shall be by title and effective date, unless otherwise documented.

2.3.2 SPECIFICATIONS

a. Coast Guard Drawing 225-WLB 245-203 REV B, DATED 11/17/95, CPP

PROPELLER BLADE RIGHT HAND

2.3.3 NAVSEA TECHNICAL PUBLICATIONS

a. NAVSEA TECHNICAL MANUAL, NAVSEA S9245-AR-TSM-010/PROP, Technical Manual Marine Propeller Inspection, Repair and Certification. NSN

0910-LP-012-5880, DATED 31 MARCH 1997.

b. T9074-AS-GIB-010/271 - DATED 30 APRIL 1997, Requirements for Nondestructive Testing Methods.

2.4 COMMERCIAL DOCUMENTS - The following documents form a part of this specification to the extent specified herein. The documents shall be the version listed by number and date from the referenced industry organization. Commercial documents may also be listed in the Department of Defense Single Stock Point of Specifications and Standards

(DODSSP).

2.4.1 American Bureau of Shipping (ABS)

a. Guide for Bronze and Stainless Steel Propeller Castings Dated 2006.

2.4.2 Society of Automotive Engineers (SAE)

a. SAE-J-448A - DATED JUNE 1963, Surface Texture Standard.

b. SAE-AMS-T-22085 - DATED 01 JUNE 1999, Tapes, Pressure-Sensitive, Adhesive, Preservation and Sealing – FSC 7510.

2.4.3 International Standard Organization (ISO)

a. ISO/IEC 16388-2007 Information technology — Automatic identification and data capture techniques — Code 39 bar code symbology specification.

b. ISO 9001, Dated 15 Sep 2015, Quality Management Systems – Requirements

c. ASQ/ISO/IEC 17025:2005, General requirements for the Competence of Testing and

Calibration Laboratories

2.5 ORDER OF PRECEDENCE - In the event of a conflict between the text of this specification and the references cited herein, this specification shall take precedence.

3.0 REQUIREMENTS

3.1 GENERAL - Using DOD-STD-2185, this specification, and USCG DWG 225-WLB 245-203 the Contractor shall provide all labor and material required to refurbish each propeller blade to a serviceable condition.

3.1.1 Serviceable condition is defined as being capable of functioning and performing in the same manner as an identical new propeller although it may not have the appearance of newness.

3.2 GOVERNMENT FURNISHED EQUIPMENT (GFE) and GOVERNMENT

FURNISHED PROPERTY (GFP) - The Contractor shall provide protective storage for the GFE and GFP when not in use, and safe handling when in use.

3.2.1 The storage area shall, at a minimum, be closed on all sides, dry, and locked when unattended.

3.3 MATERIAL - Each propeller blade is constructed of ABS-4. The Contractor shall determine the alloy by chemical composition analysis prior to any repairs.

3.4 TEST & INSPECTION DATA REQUIREMENTS, RECEIVING INSPECTION

REPORT - Each propeller blade set received by the Contractor shall be inspected upon receipt and a report outlining the required repairs and pricing submitted to the Contracting Officer for approval. No further work is authorized until the submitted report is approved.

3.4.1 The Receiving Inspection Report shall contain, at a minimum, the following data.

a. Include the data required in 5.2 (container repair/replacement).

b. Propeller blade radius.

c. Pitch at the following sections - (0.5 thru 0.95 radius).

d. Average pitch of each blade at the following sections - (0.5 thru 0.95 radius).

e. Blade section width at the following design radius - (0.4 thru 0.95 radius).

f. Thickness at point of maximum thickness (PMT), at the following design radius

- (0.4 thru 0.95 radius).

g. Track

h. Fairing rod clearances.

i. Surface finish of blade surfaces, fillets, and palms.

j. Surface inspection (Visual and 100 percent dye penetrant examination).

k. Material composition.

l. Blade bolt and dowel pin hole dimensions.

m. Center dimension between dowel pin holes.

n. Bolt hole contact faces – Parallel measurement dimensions.

o. Blade palm dimensions.

p. Seal face surface finish.

q. Estimated time required for repairs.

r. Estimated total labor and material cost of repairs.

3.4.2 If at any time during the pre-repair inspection or authorized repairs, the Contractor determines the propeller blades may be beyond economical repair, the Contractor shall immediately notify the Contracting Officer and provide a description of the propeller condition.

3.5 SURFACE INSPECTIONS

3.5.1 A visual inspection shall be performed on all exterior surfaces in accordance with MIL-STD-2035, section 4.

a. All visual defects, even though deemed acceptable, shall be documented on the inspection report.

3.5.2 The Contractor shall perform a dye penetrant inspection over 100 percent of the blade surfaces including the palm top and bottom surfaces, and fillets in accordance with T9074-AS-GIB-010/271. The acceptance criteria of MIL-STD-2035 Table IV shall be used for evaluations.

3.5.3 The Contractor shall document all defects resulting from the visual and dye penetrant inspections. All defects or indications shall be indicated by type and size on visual inspection sheets. A separate visual inspection sheet shall be submitted for each of the following: the blade pressure face, the blade suction face, the fillets, and the palm top and bottom surfaces.

3.6 PROPELLER REPAIRS - Repairs shall be made utilizing the following methods in declining order of preference:

3.6.1 Straightening

3.6.2 Material removal (grinding). The material removal shall be limited to the minimum required to achieve the repair.

3.6.3 Clad welding

3.7 BOLT HOLE THICKNESS – After final machining, the minimum thickness of each blade bolt hole shall not be less than 2.256 inches.

3.8 SEALING SURFACE MACHINING – The sealing surface of each propeller blade shall be machined to remove seal wear and restore surface finish. The surface finish shall be 16 micro inches or better unless otherwise stated on the applicable OEM drawings and specifications.

3.9 REPAIR TOLERANCES - Each propeller blade shall be repaired within the repair tolerances listed in NAVSEA S9245-AR-TSM-010/PROP TABLE 6-1, class II, and the applicable OEM drawings and specifications.

3.10 QUALIFICATION OF WELDING PROCEDURES - Welding procedures, welders, and welding operations shall be qualified in accordance with DOD-STD-2185.

3.10.1 Welding on the pressure face in the critical area shall not be undertaken without prior approval of the Contracting Officer.

a. The critical area is described as the pressure face of the blade between the fillet and the .4 radius and starting at the leading edge encompassing 80% of the chord length taken at the 0.4 radius. (Reference Figure 1 of DOD-STD-2185).

3.10.2 Welding repairs of the propeller blades shall meet the requirements of DOD-

STD-2185.

3.10.3 As found in American Bureau of Shipping, Guide for Bronze and Stainless Steel Propeller Castings dated 2006, all references to Surveyor or the ABS Materials Department in Houston for the purpose of this contract, shall be the Contracting Officer for the Coast Guard Engineering Logistics Center.

3.10.4 The Contractor shall document all welding performed on the visual inspection sheets for each blade. Each weld shall be dimensionally identified by location, length, width, and depth.

3.11 SURFACE FINISH - Surfaces of the propeller blades and palms shall be ground fair and polished in accordance with SAE-J-448A as follows.

a. Propeller blade surfaces - 63 micro inches or better.

b. Propeller blade fillets – 125 micro inches or better.

c. Propeller sealing surfaces – 16 micro inches or better. It has been reported that hand stoning is required to obtain the 16RMS surface finish.

3.12 BALANCING - Each propeller blade set shall be single plane balanced in accordance with MIL-STD-167-1A, paragraph 5.2.2 as stated herein. All balancing shall be accomplished by means of balancing equipment, which requires rotation of the work piece. The minimum detectable unbalance of the balancing machine used shall be below the residual unbalance specified herein. The residual unbalance in each plane of correction shall not exceed the value determined by calculating the following formula:

U = 4000W/N2

N = Maximum operating speed of unit. (254 RPM)

U = Maximum allowable residual unbalance in oz.-inches.

W = Weight of rotating part in pounds.

3.12.1 Material removed to effect balancing shall be taken from the suction face of the heavy blade. Care shall be taken to keep a fair surface.

a. The area from which metal is taken shall not come within 10 percent of the chord length to the leading or trailing edges.

3.12.2 The actual amount of unbalance for each propeller blade set shall be documented on each final inspection report.

3.12.3 A Dummy Hub and mandrel assembly, to facilitate balancing and dimensional inspection of pitch and track, will be furnished to the Contractor by the Government under stock number 2010-01-F04-0341. Centers of the propeller shall be 90 degrees apart, plus or minus 15 minutes of circular arc.

3.12.4 The Contractor shall inspect and check the balance of the Dummy Hub prior to use. The Dummy Hub shall be inspected to ensure square-ness and that the dowel pin locations are in accordance with OEM drawing and Specifications. The Coast Guard Quality Assurance Representative shall be present during this inspection. The balance check of the Dummy Hub shall be in accordance with the requirements as stated in section 3.12 of this specification.

3.12.5 The blades shall be balanced as a set of 4 and marked to ensure assembly in the same position in which they were balanced.

3.12.6 The blades shall be numbered 1 through 4 and installed on the Dummy Hub consecutively and counter to the direction of rotation.

3.12.7 The propeller blades shall be removed and rotated 90 degrees on the Dummy Hub. The balance shall be re-checked to ensure that any corrections indicated do not include any effects of unbalance or bending of the Dummy Hub assembly.

3.13 TEST & INSPECTION DATA REQUIREMENTS, FINAL INSPECTION REPORT -

After completion of all welding, stress relieving and repairs, the contractor shall perform final dimensional, balancing, and visual and dye penetrant surface inspections for each propeller blade set. The final inspection report shall depict the final condition of each propeller blade set.

3.13.1 The report shall be submitted to the Contracting Officer for approval, and approval shall be obtained prior to authorization to ship each repaired propeller blade set.

3.13.2 The Final Inspection Report shall contain, at a minimum, the following data.

a. Propeller blade radius.

b. Pitch at the following sections - (0.5 thru 0.95 radius).

c. Average pitch of each blade at the following sections - (0.5 thru 0.95 radius).

d. Blade section width at the following design radius - (0.4 thru 0.95 radius).

e. Thickness at point of maximum thickness (PMT), at the following design radius

- (0.4 thru 0.95 radius).

f. Track

g. Fairing rod clearances.

h. Surface finish of blade surfaces and palms.

i. Surface inspection (Visual and 100 percent dye penetrant examination).

j. Material composition.

k. Blade bolt and dowel pin hole dimensions.

l. Center dimension between dowel pin holes.

m. Bolt hole contact faces – Parallel measurement dimensions.

n. Blade palm dimensions.

o. Seal face surface finish.

p. Include all balancing data as required in section 3.12.

3.13.3 Areas of each propeller blade that have not been affected by the repair work do not have to be re-inspected for the final report provided the propeller was not stress relieved. However, inspection data for the entire propeller shall be included in the final dimensional inspection report.

3.14 STAMPING - Each propeller blade shall be stamped with the listed information, or the presently stamped information shall be changed if incorrect.

3.14.1 The stampings shall be at least 1/4” high legible printing, or the same height of the existing stamping if only corrected.

3.14.2 The stampings shall include at a minimum the items listed.

a. Company Name

b. Date of Repair Completion

c. Blade Number

d. Stress Relieved Date (if applicable)

e. Blade Set Serial Number (supplied by the Contracting Officer if none exists)

f. Direction of Rotation (LH or RH)

g. Type of Material

h. Weight

3.15 NOTIFICATIONS & INSPECTIONS - The Contractor shall be responsible for notifying the Contracting Officer at least seven (7) calendar days prior to any inspections or monitored testing required herein.

4.0 QUALITY ASSURANCE (Q.A.)

4.1 GENERAL - The contractor shall maintain an inspection system which shall insure that each item offered to the Coast Guard for acceptance or approval conforms to the contract requirements. The inspection system shall be documented and meet the requirements of ISO 9001 and available for review by the Coast Guard.

4.2 RESPONSIBILITY FOR INSPECTION - The Contractor is responsible for the performance of all inspection requirements as specified herein. The Contractor may use his own or any other facility for the performance of the inspections and tests, unless disapproved by the Government. The Government reserves the right to perform or witness any of the inspections and tests set forth in this specification at any time.

4.3 RESPONSIBILITY FOR COMPLIANCE - All items shall meet the provisions of Sections 3 & 5. The inspections set forth in this specification shall become part of the Contractor’s overall inspection system or quality program. The absence of any inspection requirement in the specification shall not relieve the Contractor of the responsibility of assuring that all products or supplies submitted to the Government for acceptance comply with all requirements of the contract. Sampling for quality conformance does not authorize submission of known defective material (either indicated or actual) nor does it commit the Government to acceptance of defective material.

4.4 INSPECTIONS/TESTS - The inspections and tests required herein are the minimum necessary and are not intended to replace any controls, examinations or tests normally employed by the Contractor to assure the quality of the product. The following are required and shall be monitored by a Government Quality Assurance Representative. The Contractor shall have the applicable OEM drawings and specifications available to verify that the propeller repairs meet contract requirements.

4.4.1 Dimensional inspections shall be in accordance with sections 3.7, 3.9, and 3.13.2.a, b, c, d, e, f, and g of this specification.

4.4.2 Surface inspections shall be in accordance with sections 3.5, 3.8, and 3.11 of this specification.

4.4.3 Balancing inspection shall be in accordance with section 3.12 of this specification.

4.4.4 Stamping inspection shall be in accordance with section 3.14 of this specification.

4.5 TEST AND INSPECTION REPORTS - One copy of any inspection, test or tolerance check report shall be sent to the Contracting Officer.

4.5.1 A copy of any test, inspection or tolerance check report shall also be turned over to the Coast Guard Quality Assurance Representative upon arrival at the Contractor’s plant.

4.5.2 Any inspection, test or tolerance check report submitted shall have all out of tolerance readings circled.

4.6 CALIBRATION SYSTEM - The contractor as well as any subcontractors shall be required to maintain a test equipment calibration program in compliance with ASQ/ISO/IEC 17025. The program shall be documented and traceable to the National Institute of Standards

(NIST).

4.6.1 The calibration system records shall be maintained for inspection for the duration of any contract referencing this specification.

4.7 PACKING INSPECTION - The Contracting Officer shall be notified prior to the preservation, packaging, packing, and marking of the completed units in accordance with section 3.15.

5.0 PRESERVATION, PACKAGING, PACKING, & MARKING

5.1 PRESERVATION & PACKAGING

5.1.1 Prior to preservation, each propeller blade shall be cleaned by any process or combination of processes, which will accomplish thorough cleaning without damage to the propeller blades.

a. After cleaning, tape conforming to SAE AMS-T-22085 and strippable compound preservative shall be applied to each propeller blade in accordance with MIL-DTL-2845 paragraph 3.14.1.3.

b. After the application of strippable compound, galvanized sheet metal blade edge protectors shall be installed, using corrosion resistant hardware, in accordance with MIL-DTL-2845, paragraph 3.14.1.4.

c. A plywood cover shall be used to cover the bottom side of the palm to protect the seal area during shipment and storage of the propeller blades. This cover shall be attached using bolts through the blade bolt holes and plywood washers in contact with blade machined surfaces.

5.1.2 The GFE supplied Dummy Hub shall be preserved as it was received for return to the Coast Guard.

5.2 PACKING - Each propeller blade shall be individually packed in accordance with MIL- DTL-2845 paragraph 3.14.2.1, Figure 3.

5.2.1 If propeller blade bolt holes are used to secure the propeller blades, care shall be taken to prevent damage to the propeller blade bolt holes.

5.2.2 If the Contractor deems the containers the propeller blades were received in to be in compliance with 5.2 of this specification, the containers can be reused.

5.2.3 The GFE supplied Dummy Hub shall be packed in the original shipping container.

5.2.4 Should new containers be required, the Contractor shall notify the Contracting Officer within fifteen days after receipt of the GFE and GFP.

5.3 MARKING - Each preserved, and packed propeller blade or GFE shall be marked in the upper left-hand side of the two longest sides, (two opposite sides if square) of each container.

The lettering shall be black painted stencil and permanently affixed to each container. The lettering shall be at least 1” high, and be applied on a highly contrasting background.

5.3.1 This marking shall consist of the STOCK NUMBER, ITEM NAME, PART

NUMBER, BLADE SERIAL NUMBER, BLADE SET SERIAL NUMBERS, BLADE

NUMBER, CONTRACT NUMBER, SHIPPING WEIGHT (in lbs.,), condition code i.e.

CONDITION A, QUANTITY and UNIT OF ISSUE (1) SE and the words COAST

GUARD ELC MATERIAL.

5.3.2 The shipping container for the GFE supplied Dummy Hub shall be marked as indicated in section 5.3.5.c.

5.3.3 Each propeller blade container shall have the “BLADE SET” marking, which shall also include the blade number and marking indicating this is box of 4.

5.3.4 Each propeller blade container shall have the other three blade serial numbers of the set listed. This marking shall be worded as follows: THE OTHER THREE BLADE SERIAL NUMBERS THAT MAKE UP THIS SET INCLUDE: List the serial numbers.

5.3.5 See below for marking lay out.

a. Type 1 – BLADE SET, RIGHT HAND

STOCK NUMBER 2010-01-421-8904

ITEM NAME BLADE SET,PROPELLER, SHIP

PART NUMBER 110254003

BLADE SERIAL NUMBER As marked on blade.

BLADE SET SERIAL NUMBERS list serial numbers of the three other blades that make up this set.

BLADE NUMBER As received or as balanced.

SHIPPING WEIGHT As Determined by Contractor

CONTRACT NUMBER

CONDITION CODE CONDITION A

QUANTITY & UNIT OF ISSUE 1 - SE

COAST GUARD SFC MATERIAL

REUSABLE CONTAINER DO NOT

DESTROY

b. DUMMY HUB RH

STOCK NUMBER 2010-01-F04-0341

ITEM NAME HUB, DUMMY RH

PART NUMBER DUMMY HUB 225 WLB

SHIPPING WEIGHT As Determined by Contractor

CONTRACT NUMBER

CONDITION CODE CONDITION A

QUANTITY & UNIT OF ISSUE 1 - EA

COAST GUARD SFLC MATERIAL

REUSABLE CONTAINER DO NOT

DESTROY

5.4 BAR CODING - U.S. Coast Guard requires bar coding of the NSN, IAW ISO/IEC 16388-2007

Code 39 Symbology.

5.4.1 The Bar Code Label can be applied separately or as part of the marking required in 5.3.

6.0 NOTES

6.1 GOVERNMENT & COMMERCIAL DOCUMENT SOURCES

6.1.1 GOVERNMENT DOCUMENTS

a. Department of Defense Single Stock Point

(DODSSP Documents)

700 Robbins Avenue

Building #4, Section D

Philadelphia, PA 19111-5094

215-697-2667/2179

FAX: 215-697-1462

b. DOD & Navy Publications and Forms (Other Than

DODSSP)

Naval Publication and Forms Center

5801 Tabor Ave.

Philadelphia, PA 19120

215-697-2000

6.1.2 COMMERCIAL DOCUMENTS

a. American Bureau of Shipping (ABS)

ABS Plaza

16855 Northchase Drive

Houston, TX 77060

281-877-6000, FAX 281-877-6001

www.eagle.org

b. Society of Automotive Engineers, Inc. (SAE)

400 Commonwealth Drive

Warrendale, PA 15096

412-776-4841

FAX 412-776-5760

www.sae.org

c. American Society For Quality Control (ASQC)

611 East Wisconsin Avenue

Milwaukee, Wisconsin 53202

414-272-8575, FAX 414-272-1734

d. American National Standards Institute (ANSI)

25 West 42nd Street

(Between 5th and 6th Avenues)4th Floor

New York, NY 10018

212—642-4900

FAX 212-398-0023

www.ansi.org http://www.eagle.org/ http://www.sae.org/ http://www.ansi.org/

6.1.3 OTHER GOVERNMENT DOCUMENTS

a. USCG Surface Forces Logistics Center

MAIL STOP # 026

2401 Hawkins Point Road

Baltimore, MD. 21226-5000

Attn: IBCTPL