Attachment 8 - 2010012222440_PrpFxdPtchRprLH_110A_R.pdf

WBN_0520

WORK ITEM 1: 2010-01-222-2440, Fixed Pitch Propeller, Repair 2010-01-222-2441, Fixed Pitch Propeller, Repair

1. SCOPE

1.1 Intent. This work item sets forth the requirements for the Receipt, Inspection, Overhaul, Preservation, Packing, Marking, Bar-Coding and Shipping of right and left hand propellers used on U.S. Coast Guard

110' Coastal Patrol Boats.

1.2 Government furnished property (GFP). The listed items are property of and managed by the USCG

Surface Forces Logistics Center, Baltimore MD and will be issued to the Contractor as issuance of a contract or contract delivery order.

MTI ITEM DESCRIPTION NSN

P/N

CAGE

QTY

(EA.)

ESTIMATED COST

($/UNIT)

Y *** Propeller, Left Hand NSN: 2010-01-222-2440

P/N: 110-WPB-245-001-LH

CAGE: 81340

Y *** Propeller, Right Hand NSN: 2010-01-222-2441

P/N: 110-WPB-245-001-RH

CAGE: 81340

Y * Ring and Plug Gauge

Set

NSN: 2010-01-F06-0800

P/N: 110 WPB 243-100-1

CAGE: 04624

Y * Prop Test Kit NSN: 2010-01-F06-0656

P/N: 110PROPTESTKIT

CAGE: 04624

Y *** Shipping Crate, Reusable

NSN: N/A

PN: N/A

CAGE: N/A

*Government-loaned property, which shall be returned to the Coast Guard upon completion of the contract.

**New or refurbished equipment that the Government may provide for installation in place of existing equipment.

***Government-furnished property, which is to be supplied by the Coast Guard.

2. REFERENCES

COAST GUARD DRAWINGS

Coast Guard Drawing 110 WPB 243-006 Rev. C, Dated 4/23/09 – 110’ Island Class Cutters

Propulsion Shaft Details.

Coast Guard Drawing 110 WPB 245-4 Rev. A, Dated 4/9/2009 – Propeller Details

Coast Guard Drawing 110 WPB 245-5 Rev. - , Dated July 29, 1996 – Assembly of Oil Injection

Equipment.

Coast Guard Drawing 110 WPB 245-6 Rev. ¬- , Dated 2/5/2005 – Hydraulic Assembly for

Installing / Removing Prop Hub and Gear Coupling.

COAST GUARD PUBLICATIONS

Surface Forces Logistics Center Standard Specification 0740 (SFLC Std Spec 0740), 2018, Welding and Allied Processes

OTHER REFERENCES

ABS Rules for Survey After Construction 2011 - Guide for Bronze and Stainless Steel Propeller

Castings, Part 7 Appendix Section 10

ANSI/ASQ Q9001, Dated 10/01/2015 – Quality Management Systems – Requirements – T860E

ASTM E1417/E1417M, Dated 6/15/2016 - Standard Practice for Liquid Penetrant Testing

DODD 4140.01-M-1, Dated 9/07/2007 – Compliance for Defense Packaging: Phytosanitary

Requirements for Wood Packaging Material (WPM)

DOD-STD-2185(SH), Dated 10/28/1986 – Requirements for Repair and Straightening of Bronze

Naval Ship Propellers.

ISO 484-2:2015(E), Dated 12/01/2015 – Shipbuilding-Ship Screw Propellers-Manufacturing

Tolerances - Part 2: Propellers of Diameter Between 0.80 and 2.50 m Inclusive, Second

Edition

ISO/IEC 17025:2017, Dated 11/2017 – General requirements for the Competence of Testing and

Calibration Laboratories – Third Edition

MIL-DTL-2845E (SH), Dated 9/18/1999 – Propulsion Systems, Boat and Ship; Main Shafting, Propellers, Bearings, Gauges, Special Tools, and Associated Repair Parts; Preservation, Packaging, Packing and Storage of

MIL-PRF-121G w/Amendment 1, Dated 10/10/2019 – Performance Specification, Barrier

Materials, Greaseproof, Waterproof, Flexible, Heat Sealable

MIL-PRF-16173E(SH) w/INT Amendment 2, Dated 10/19/2017 – Performance Specification, Corrosion Preventative Compound, Solvent Cutback, Cold Application

MIL-PRF-680C, Dated 3/25/2010 – Performance Specification, Degreasing Solvent

MIL-STD-129R w/Change 2, Dated 9/27/2019 – Department of Defense Standard Practice:

Military Marking for Shipment and Storage

MIL-STD-167-1A, Dated, 11/02/2005 – Department of Defense Test Method Equipment, Mechanical Vibrations of Shipboard Equipment

SAE International, SAE J 448, Dated 08/2011 – Surface Vehicle Standard, Surface Texture

SAE AMS-T-22085, Dated 6/1/1999 – Tapes, Pressure-Sensitive, Adhesive, Preservation and

Sealing

2.1 Document availability. The documents listed in this section are referenced in sections 3, 4 and 5 of this work item and drawings stated in this Work Item. To obtain the referenced documents see section

6.1.

2.2 Specification order of precedence. The Applicable Documents described are required to be adhered to in fulfilling the contract. In the event of a conflict between the text of this specification and the references cited herein, this work item shall take precedence. Nothing in this document, however, supersedes applicable laws and regulations unless a specific exemption has been obtained.

3. REQUIREMENTS

3.1 General. The Contractor shall provide storage for the GFP when not in use, and safe handling when in use.

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

3.1.2 GFP inspection. The Contractor shall conduct a visual inspection of the GFP Ring and Plug Gauge

Set and Test Shaft Kit upon receipt to verify condition and usability as well as condition of the shipping containers. The Contracting Officer (KO) shall be notified immediately of any damage or missing parts including dents, dings, scratches, corrosion, or distortion of the critical test surfaces that could affect accuracy related to intended purpose.

3.1.2.1 The Contractor shall not test the GFP plug gauge using the GFP ring gauge included in the set without authorization from the KO or a Coast Guard representative on site.

3.1.2.2 The Contractor shall assemble the Hydraulic Rig Assemblies in accordance with Coast Guard

Drawing 110-WPB-245-5.

3.1.2.3 The Contractor shall provide the hydraulic fluid needed to operate the GFP Propeller Test Kit.

The hydraulic fluid type shall be as specified on Coast Guard Drawing 110-WPB-245-6.

3.1.2.3.1 During the duration of the contract, the Contractor shall be responsible for replacing, renewing, or refurbishing any damaged Propeller Test Kit components. The Contractor shall maintain the Propeller

Test Kit in satisfactory working order.

The KO shall be notified of any GFP parts or repairs needed to keep in satisfactory working order.

3.1.2.3.2 At the conclusion of the contract, the Contractor shall drain the hydraulic fluid from the low and high pressure pump rigs and hydraulic nut prior to shipment back to the Coast Guard.

3.1.2.4 Propeller test kit certification. The Contractor shall comply with the General Notes of Coast Guard

Drawing 110-WPB-245-6 pertaining to the certification and replacement requirements of the testing equipment.

3.1.3 Material. The propellers under this work item were manufactured to meet the requirements of ABS

7, Section 10, Type 4.

3.2. Test and inspection plan. The Contractor shall submit a test and inspection plan to the KO for approval prior to contract award. This plan shall include the specific inspections and tests specified herein, and all tests and inspections made by the Contractor to verify conformance to every requirement and tolerance as specified in the cited drawings, technical publications, this work item and 110 Propeller

Inspection Compliance Forms.

3.2.1 The Test and Inspection Plan will remain in effect throughout the contract period. Any changes to the Test and Inspection Plan shall be sent to the KO for approval.

3.3. Propeller inspection. The Contractor shall carefully remove each propeller from the GFP crate, clean and remove all growth and dirt to facilitate a thorough inspection to determine all the necessary work required for overhaul to return the propeller(s) to a serviceable “A” condition as defined below. An Open, Inspect and Report (OIR) shall be submitted to the KO within ten (10) days of receipt of GFP. The OIR shall include all inspection findings, test results as specified in this work item, including a breakdown of estimated cost of labor and materials for any overhaul work or testing including repair or replacement of the shipping crate. The OIR shall also include a breakdown of estimated cost of labor and materials for any overhaul work that is beyond the scope of work in this work item. No further work shall proceed until authorized by the KO in writing.

3.3.1 The hub bore inspection in accordance with paragraph 3.10 shall be accomplished before any other inspections or tests called out in the work item. If the propeller fails this inspection the Contractor shall not perform any additional tests or inspections without approval of the KO.

NOTE

Serviceable “A” condition is defined as an overhauled propeller meeting all work item requirements and design dimensions in accordance with Coast

Guard drawing: 110 WPB 245-4 Rev. A and being capable of functioning and performing in the same manner as an identical new propeller although it may not have the appearance of a new propeller.

3.3.2 The Contractor shall use the provided “110 Propeller Inspection Compliance Form” to record the results of their measurements and tests. The form may be filled out electronically or by hand, however the form shall be turned in to the KO electronically i.e. electronic form or scanned document. The Contractor shall use the parameters and tolerances specified on the Coast Guard provided 110 Propeller Inspection

Compliance Form.

3.3.3 OIR information. The OIR shall contain the following information as a minimum:

Contractor name, address and telephone number

Date of Inspection

Contract number and delivery order number as applicable

Name of personnel conducting inspections

Propeller(s) serial number(s)

110 Propeller Inspection Compliance Form showing all inspection, dimensional data and test results.

Estimated cost to complete propeller overhaul including cost to repair or replace shipping container

Estimated cost to complete work that is beyond the scope of this work item, if applicable

3.3.4 If at any time while performing the pre-repair inspection or during authorized repairs the Contractor believes the propeller may be beyond economical repair (BER), the KO and Contracting Officer’s

Representative (COR) shall be notified immediately and provided a description of the propeller’s condition to support this assessment.

3.4 Propeller disposition. The Coast Guard will review the OIR or BER condition and determine if the propeller(s) will be overhauled or scrapped due to the extent of necessary work and determine disposition.

Disposition options are as follows:

Contractor to scrap on site and provide credit to the Coast Guard based on current U.S.

NIBRAL scrap prices.

Propeller(s) to be re-packaged in the original shipping container (unless replaced), properly marked per section 5.6 and returned to SFLC Baltimore, MD at the address listed in section

5.8.

3.5 Welding certifications. The Contractor shall have welders qualified in accordance with SFLC STD

Spec 0740. Certification documentation shall be maintained and available to the KO, COR or Coast

Guard Quality Assurance personnel (QA) for review at any time during the contract period.

3.5.1 Welding on the pressure face critical areas shall not be undertaken without prior approval of the KO, except as outlined in the second bullet below.

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(SH)).

Welding required to repair cavitation erosion in the critical area, but not to include the blade fillets located between the 0.2 and the 0.25 radius, shall be undertaken as the Contractor deems necessary.

3.5.2 Welding repairs of the propellers shall meet the requirements of DOD-STD-2185(SH).

3.6 Propeller overhaul. Overhaul shall be made utilizing the following methods in declining order of preference:

Reshaping

Material Removal (grinding)

1. Material removal shall be limited to the minimum required to achieve the repair

Clad Welding

3.7 Overhaul tolerances. Each Propeller shall be overhauled to Class 1 tolerances as listed in per ISO

484/2-1981(E), USCG DWG. 110 WPB 245-4 and as noted in section 3.10.

3.8 Propeller finishing. Each propeller shall be finished using Computer Numerical Controlled (CNC) machining using equipment that can be programmed for automatic contouring of hydrodynamic surfaces or in the conventional casting manner that employs hand grinding and finishing for obtaining required blade contour and profile dimensions.

3.8.1 The design data and applied tolerances shall apply to all hydrodynamic surfaces.

3.8.2 The Contractor shall measure and inspect all propeller surfaces and dimensions using electronic measuring equipment, accurate to within .001”, as much as practicable. The Contractor shall demonstrate a manufacturing or inspection process that ensures tolerances for all hydrodynamic surfaces are met. The use of calibrated marine propeller inspection systems such as Prop Scan, Hale Measurement Recording

Instrument (MRI), digital laser scanning or an equivalent system will be acceptable. A combination of systems will also be acceptable. The Contractor shall submit their measurement method and system as part of the Test and Inspection Plan of 3.2 to the KO for approval.

3.8.3 The geometrical and dimensional Inspection shall be in accordance with this work item, USCG

DWG. NO. 110 WPB-245-4 and ISO 484/2, Class 1.

3.9 Ring and plug gauge, test shaft kit. Prior to and immediately following all planned testing the

Contractor shall conduct a visual inspection of the GFP Ring and Plug Gauge Set and Test Shaft Kit to verify condition. The KO shall be notified immediately of any damage or missing parts including dents, dings, scratches, corrosion, or distortion of the critical test surfaces that could affect accuracy related to intended purpose.

3.9.1 If a short term storage period of less than 30 days is anticipated, the Contractor shall clean the applicable Ring or Plug Gauge with a petroleum based solvent meeting the requirements of MIL-PRF-

680 Type II, coat with a preservative in accordance with MIL-PRF-16173, grade 2, and re-stow the ring or plug gage in its designated position within the shipping container. A neutral barrier material conforming to MIL-PRF-121G, type 1, shall be applied to all wood surfaces that come in direct contact with either gauge.

3.9.2 If the contract is at its conclusion or during long term storage periods exceeding 30 days, the Ring and Plug Gauge set shall be thoroughly inspected and cleaned with a petroleum based solvent in accordance with MIL-PRF-680 Type II, and then completely coated with a preservative that conforms to

MIL-PRF-16173, grade 4 and re-stow the ring or plug gage in its designated container.

3.9.3 The Test Shaft Kit shall be packaged and packed as it was received by the Contractor after completion of each delivery order for safe storage.

3.9.4 The Contractor shall not conduct repairs to the Ring and Plug Gauge Set or Test Shaft Kit without prior authorization from the KO. The Contractor shall provide the KO with a report identifying the reason necessary for repairs, a total cost estimate and time line to complete repairs.

3.9.5 At the completion of the contract, QA personnel will inspect all GFP prior to return to the Coast

Guard. After inspection, QA personnel will report the condition of all GFP to the KO. The Contractor will be required to return all GFP to a ready for use “A” condition prior to return.

3.10 Hub bore inspection. The Contractor shall demonstrate that the finished hub bore for each propeller meets dimensional requirements by utilizing the Government-furnished plug gage referenced in 1.2 to perform the inspections outlined below.

3.10.1 Position the propeller with its bore axis vertical and the large taper uppermost. The propeller shall be supported on the bottom of its boss by a soft washer (wood, alloy, etc) with 3/4 inch minimum clearance for the plug gauge small end to pass through. The soft washer is used to protect the propeller from damage during the testing process.

3.10.2 The plug gauge shall be rigged so that it can be suspended over the bore of the propeller and dropped when required.

NOTE

When moving the plug gauge into position prior to dropping, the Contractor shall take every safety precaution making sure the GFP plug gauge is not prematurely dropped causing personal injury or damage to the GFP plug gauge.

3.10.3 Prior to dropping the plug gauge it shall be spotlessly clean and free of oil. The plug gauge shall then be evenly coated with 0.0002” - 0.0004” marking blue on the entire taper. The thickness of the marking blue shall be verified using a wet film thickness gauge.

3.10.4 The plug gauge shall be suspended centrally in the bore of the propeller with a drop distance of four (4) inches. Too much (thick) marking blue will result in an evident hydraulic bounce leaving the plug gauge free. If this happens the procedure must be repeated with a lighter even smear of marking blue until positive seating is achieved.

3.10.5 The plug gauge must be withdrawn carefully to ensure that the blue marking is not touched or otherwise marked. The hydraulic nut will be needed to break out the plug gauge.

3.10.6 Ideal contact is with blue removal contact witness markings throughout the plug gauge length. The limits of acceptability are as follows:

95% between the forward end of the propeller hub and the first oil groove with no breaks extending across the band

95% between the aft end of the propeller hub and the first oil groove with no breaks extending across the band

At least 80% of the remaining surface area

3.11 Hub bore fit. Using GFP Test Shaft, USCG DWG. 110 WPB 245-5 and the following procedure.

3.11.1 Cover the exposed threads at shaft end with nylon or P.V.C. tube and assemble propeller to dummy shaft and ensure complete contact between the conical surfaces by a light, but positive, axial force.

3.11.2 Check that the hydraulic nut is fully assembled, (i.e., gland fully compressed home into nut body).

Secure by screwing the hydraulic nut to the shaft end and screw until the gland face of the nut abuts the face of the propeller.

3.11.3 With each pump relief valve tap closed and the respective pipe to securing nut slackened; operate each pump handle in turn to vent the respective system.

NOTE

Propeller draw can be determined by measuring the distance between the propeller hub face and the fixed hydraulic nut body. “Draw” is defined as the axial distance the propeller must travel up the taper in order to affect the interference between the propeller and the shaft necessary to transmit the designed torque. Required draw is 0.182 - 0.192 inches.

3.11.4 The hydraulic nut pump should now be operated to register in the order of 1,450 – 2,900 psi. This should discourage oil from the expansion pump from leaking past the taper ends to atmosphere on initial pressurization.

3.11.5 The expansion pressure pump should now be increased gradually to 12,000 - 16,000 lbs. in a manner such that the rate of pressure on the nut is increased at the same time to 6,000 - 8,000 lbs. or until satisfactory depth is reached.

3.11.5.1 With a propeller that has been manufactured to the relevant plug gauge and shaft to the relevant ring gauge, i.e., a well-executed pressure joint, both the designed pressures should be reached at the time that the “draw” is attained.

3.11.5.2 In the event that either pump leads with a pressure rate more rapid than is necessary, it is always advisable that:

The hydraulic nut pressure rate should never exceed the relative expansion pressure rate

It should be that the expansion pressures are in advance of the nut relative pressure

Pressure required between shaft and propeller when fitting propeller is 11,600 psi (minimum)

Pressure required at hydraulic nut when propeller has taken up full draw (0.182 - 0.192 inches) to be approximately 4,440 -7,500 psi

3.11.6 The expansion pressure should now be released gradually to zero by careful control of the pressure pump relief valve tap. The above control will protect the gauge indicator pointer.

3.11.6.1 At the precise time that the pressure is released from the nut, measure the distance between the propeller hub face to the small end of the shaft taper. The acceptable distance is 0.177", +0.0944", -

0.0344” per drawing 110WPB 243-006 sheet 2.

3.11.6.2 Should no movement of the test shaft be observed after ten minutes the test is satisfactory.

Prepare the hydraulic equipment to remove the propeller. Return all plugs and caps to hydraulic connections to prevent the entry of dirt.

3.11.7 For the removal of the propeller, assuming that all preparatory work has been carried out up to the point of connecting hydraulic line proceed as follows:

Assemble hydraulic nut to shaft. Allow one thread between the propeller face and the hydraulic nut. This will allow for the shaft to be released once the pressure is put into the hub

(see next step)

Commence pumping oil into the propeller body until oil issues between boss and shaft at forward end of propeller boss. Do not exceed 25,000 psi

Commence pumping oil to the hydraulic nut until propeller is released

Following removal, all hydraulic connections shall have plugs refitted to prevent entry of dirt

3.12 Documentation. The Contractor shall conduct all measurements and tests as shown on the 110

Propeller Compliance Forms under the guidance of ISO 484/2, Class 1 (as applicable). Record and compare the measurements using the 110 Propeller Compliance Forms.

3.13 Surface finish. Surfaces of the propeller blades, fillets and hub shall be ground fair and polished in accordance with SAE J448.

3.13.1 The propeller blade surface roughness from R 0.2 to tip shall not exceed 63 micro-inches Ra.

3.13.2 Propeller hub exterior surface shall not exceed 125 micro-inches Ra.

3.13.3 Remove high spots, burrs, abrasions, nicks, corrosion, and foreign matter from propeller keyways, glands, hub bores, flanges, and mating surfaces.

3.11.4 Chase and tap exposed threaded areas.

3.11.5 Polish surfaces in way of packing rings.

3.14 Balancing. After completion of all required overhaul processes, each propeller shall be single plane balanced in accordance with MIL-STD-167-1A (Imbalance shall not exceed 7.1 oz-in). The residual unbalance in each plane of correction shall not exceed the value determined by calculating the following formula: U = 4000W/N2 where:

U = Maximum allowable residual unbalance in N-m

W = Weight of rotating part in Kg (340 kg estimated)

N = Maximum operating speed of unit (800 RPM)

Prior to performing any balance tests, the Contractor shall demonstrate the sensitivity of the balance machine using a weight determined from the following formula: Ws =

0.1(U)/r where:

Ws = Sensitivity Weight

U = Propeller Residual Unbalance Tolerance r = radial location of the weight

3.14.1 The addition of this weight shall be easily detected and discernible to the balance machine operator.

3.14.2 The mandrel or concentric rings used to support the propeller during balancing shall not exceed a total indicated run-out (TIR) of 0.025 mm (.001”).

3.14.3 Material removed to affect balance shall be taken from the suction face on as large an area as practicable and shall not approach the leading or trailing edges within (10) ten percent of the blade width.

3.14.4 Care shall be taken to assure that removal of material shall not cause the tolerances for thickness, surface contour, edge contour, width or pitch to be exceeded.

3.14.5 There shall be no machining, welding or material addition or removal to the propeller after final balance check is completed.

3.14.6 The actual amount of unbalance for each propeller shall be documented on each Final Inspection

Report.

3.15 Surface inspection. A visual inspection shall be performed on all exterior blade surfaces in accordance with USCG-SFLC Standard Specification 0740.

3.15.1 The Contractor shall perform a dye penetrant inspection over 100 percent of the blade surfaces including the hub in accordance with ASTM E1417, 2005, Standard Practice for Liquid Penetrant Testing per SFLC STD Spec 0740. Acceptance criteria per ABS Part 7, Section 10, Table 1 shall be used for evaluations. The inspection shall be performed by a certified Level II NDT Technician.

3.15.2 The Contractor shall document all propeller defects resulting from the visual and dye penetrant inspections. These defects shall be indicated by type and size on visual inspection sheets. Each propeller will require individual inspection sheets for the pressure face of the blades, suction face of the blades, the fillets, and the hub.

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

3.15.3 A copy of the dye penetrant inspection report shall be turned in to the KO for review and approval.

3.16 Final inspection report.

3.16.1 The Contractor shall perform final dimensional, balancing, visual, and dye penetrant surface inspections for each repaired propeller and record this data on a final inspection report. Included in the final report shall be the completed 110 Propeller Inspection Compliance Form with all final measurements recorded. The final inspection report shall accurately reflect the final condition of each propeller.

3.16.2 The Final Inspection Report shall be submitted to the Contracting Officer for review and approval.

If this report is determined to be acceptable, the KO will authorize SFLC’s QA Branch to schedule final inspections/tests outlined in section 4.6 of this work item.

3.16.3 The Final Inspection Report shall contain, at a minimum the following data:

Contractor name, address and telephone number

Date of Inspection

Contract number and delivery order number as applicable

Name of personnel conducting inspections

Propeller serial number

110 Propeller Inspection Compliance Form showing all inspection, dimensional data and test results.

Surface Inspection, NDT Report

3.14 Workmanship. Propeller(s) shall have a professional, like-new appearance, be polished and free of dirt, grease, burrs, sharp edges or other discrepancies.

3.15 Photo documentation. The Contractor shall provide Photo Documentation to the KO during in-process welding repairs of the casting (if applicable) and any discontinuities of the propeller casting during dye penetrant inspection. Each photograph shall include the propeller serial number and date the photograph was taken. The color photographs shall be taken with a digital camera and the images provided electronically in “jpg format” to the KO during the overhaul phases outlined below.

3.15.1 Photo Documentation Phases:

During the dye penetrant inspection showing any linear/non-linear discontinuities of the propeller casting.

During overhaul of the whenever welding is required propeller casting.

3.16 Warranty. Standard manufacturer’s warranty applies to items overhauled under this work item.

3.17 Notifications and inspections. The Contractor shall be responsible for notifying the KO at least ten

(10) calendar days prior the Contractor being ready for any QA inspections or testing as required herein.

The propeller(s) require a one hundred percent QA inspection.

4. QUALITY ASSURANCE

4.1 General. The Contractor shall maintain an inspection system, which shall insure each item offered to the Coast Guard for acceptance or approval conforms to the contract requirements. The inspection system shall be in accordance with ANSI/ASQC Q9001, documented and available for review by the Coast

Guard.

4.2 Records. The Contractor shall maintain records of all inspections and tests. The records at a minimum shall indicate the nature and number of observations made, the number and type of deficiencies found, and the corrective action taken.

4.3 Calibration system. The Contractor as well as any subcontractors shall be required to maintain a test equipment calibration program in compliance with ISO/IEC 17025. The program shall be documented and traceable to the National Institute of Standards (NIST).

4.4 Responsibility for inspection. The Contractor shall be responsible for the performance of all inspection requirements specified herein. The Contractor shall provide space, personnel, and test equipment for the conduct of all inspection requirements. All inspection and testing shall be performed at the Contractor’s plant or at other facilities acceptable to the Coast Guard. The Coast Guard reserves the right to verify or have performed any of the inspections that are deemed necessary to assure that supplies and services conform to the prescribed requirements.

4.5 Responsibility for compliance. All items shall meet the provisions of sections 3 & 5. The inspections set forth in this work item shall become part of the Contractor’s overall inspection system or quality program. The absence of any inspection requirements in the work item 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.

4.6 Tests and inspections. The inspections/tests required here and in section 3.0 are the minimum required and are not intended to supplant any controls, examination, inspections or tests normally employed by the

Contractor to assure the quality of the item in question.

4.6.1 Contractor shall have the latest versions of the drawings, work items, tolerances, compliance forms and approved test procedures available for inspection, if necessary.

4.6.2 Pitch measurements: All inspections MUST be achieved via high accuracy electronic pitch measurement.

NOTE

Drop-Type Pitchometers are NOT an acceptable method for performing the inspections on Coast Guard propellers.

4.6.3 The following are required and will be witnessed by QA Representative(s):

Welder certifications in accordance with section 3.5

Propeller finishing and dimensional inspections in accordance with section 3.8

GFE condition and storage in accordance with section 3.9

Hub bore inspection in accordance with section 3.10

Hub bore fit in accordance with section 3.11

Surface finish in accordance with section 3.13

Balancing inspection in accordance with section 3.14

Surface Inspection, NDT Report in accordance with section 3.15

Workmanship in accordance with section 3.17

Preservation, packing, marking and shipping in accordance with 5.0

4.6.4 The Propeller(s) inspection requires 100% verification to assure compliance with the applicable drawings, propeller inspection compliance form and this work item.

4.6.5 For the safety of Coast Guard personnel and shop workers, QA inspections shall be completed indoors away from normal shop work, operating machinery, loud noise, welding (arching) and grinding operations.

4.7 Failure responsibility. If a propeller fails to pass any inspection/test, the Contractor shall report the failure and the recommended fix to the KO. If approved, the corrective action on the materials or processes shall be taken in accordance with this section.

The KO reserves the right to totally reject any failed item without considering any suggested corrective action.

The inspection/testing shall be discontinued until all corrective action has been taken.

After all corrective actions have been taken the inspection/tests shall be continued or repeated at the option of the KO.

Acceptance shall be withheld until re-inspection has been shown that the corrective action was successful and the item satisfactorily passes all inspections and tests.

All corrective actions shall be documented as part of the Contractor's inspection system and submitted for approval to the KO.

Each corrective action report shall include, but not be limited to the cause of each defect, corrective action suggested, and the steps taken to prevent a recurrence of each defect.

4.8 Tests and inspection reports. One copy of any required inspection, test or tolerance check done on each delivery order shall be sent to the KO.

4.8.1 Quality assurance representative. A copy of any test, inspection or tolerance report shall be turned over to the SFLC QA Representative upon arrival at the Contractor’s plant.

4.9 Packing inspection. The KO shall be notified prior to the packaging and marking of the completed units in accordance with section 3.20 of this work item.

5. PRESERVATION, PACKING, MARKING, AND SHIPPING

5.1 General. Each propeller, GFP Ring and Plug Gauge and Test Shaft Kit shall be cleaned and individually preserved, packed, marked and bar-coded in its own reusable skid type shipping container, or a new reusable skid type shipping container if approved. Preservation, packaging, packing, marking and bar-coding will be inspected by Coast Guard SFLC QA personnel at Contractor’s facility.

5.2 Preservation. Prior to preservation, each propeller shall be cleaned by any process or combination of processes which will accomplish thorough cleaning without damage to the propeller(s).

5.2.1 After cleaning, tape conforming to SAE-AMS-T-22085, TYPE II and strippable compound preservative shall be applied to each propeller in accordance with MIL-DTL-2845E (SH) section

3.14.1.3.1.

5.2.2 After the application of strippable compound, galvanized sheet metal blade edge protectors shall be installed in accordance with MIL-DTL-2845E (SH) section 3.14.1.4. The edge guards shall be held in place with all stainless steel grade hardware.

5.2.3 Plastic flange plugs/caps shall be inserted in the LE and SE of the bore openings.

5.3 Packing. Under the observation of the Coast Guard QA representative the propeller shall be secured to the wooden skid in accordance with Appendix A. The Contractor shall enclose a copy of the electronic measuring results on each propeller. The results shall be placed into an envelope and marked for the “PE or EPO”. The cover of the skid type shipping container shall then be carefully placed over the propeller and secured using the lag bolts.

5.3.1 The GFP supplied Test Shaft Kit and Gage Set shall be packaged and packed to the same condition as they were received.

5.4 New reusable wood crate. When authorized by the KO, the Contractor shall construct a new reusable skid type shipping container manufactured IAW Appendix A of this work item.

5.5 Wood packing material (WPM) requirements. New reusable shipping containers shall meet the

Phytosanitary Requirements for WPM in accordance with paragraph C2.1.1 of DODD 4140.01-M-1, Compliance for Defense Packaging. WPM is defined as wood pallets, skids, load boards, pallet collars, wooden boxes, reels, dunnage, crates, frames and cleats. Packaging material exempt from the requirements are materials that have undergone a manufacturing process such as corrugated fiberboard, plywood, particleboard, veneer and oriented strand board (OSB). All new purchases of WPM shall be constructed from heat treated (treated to 56° C. core temperature for 30 Minutes) lumber and certified by an accredited agency recognized by the American Lumber Standard Committee (ALSC).

5.5.1 WPM markings. All shipping containers shall have the appropriate markings in accordance with

DODD 4140.01-M-1, Compliance for Defense Packaging Ref. 2 paragraph C2.5.

5.5.2 Newly manufactured skid type shipping containers shall be secured and stored per section 3.1.

5.6 Marking. Each packaged and packed propeller shall be marked in the upper left-hand side of the two longest sides, (two opposite sides if square facing the forklift driver) of each shipping container. The container lettering shall be black waterproof painted stencil. The lettering shall be at least 1” high, and be applied on a highly contrasting, painted white background. The lag bolts shall be highlighted in red with a stencil saying “Remove cover by removing lag bolts in Red”. The lid shall also have heavy duty lifting eyes in two corners of the lid.

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

NUMBER, CONTRACT NUMBER, SHIPPING WEIGHT (in lbs.), CONDITION CODE ie.

CONDITION A, UNIT OF ISSUE with QUANTITY (1) and the words U.S. COAST GUARD SFLC

MATERIAL.

a. Marking layout (ready for issue) “A” condition Left Hand Propeller.

NATIONAL STOCK

NUMBER

2010-01-222-2440

ITEM NAME

PROPELLER, LH

PART NUMBER

110-WPB-245-001-LH

SERIAL NUMBER (See Propeller)

CONTRACT NUMBER (See Contract)

SHIPPING WEIGHT (LBS)

As Determined by Contractor

CONDITION CONDITION A

QUANTITY & UNIT OF

ISSUE

1 – EA

OTHER DATA AS

DIRECTED

U.S. COAST GUARD SFLC

MATERIAL

b. Marking layout (ready for issue) “A” condition Right Hand Propeller.

2010-01-222-2441

ITEM NAME

PROPELLER, RH

PART NUMBER

110-WPB-245-001-RH

SERIAL NUMBER (See Propeller)

CONTRACT NUMBER (See Contract)

SHIPPING WEIGHT (LBS)

As Determined by Contractor

CONDITION CONDITION A

QUANTITY & UNIT OF

ISSUE

1 – EA

OTHER DATA AS

DIRECTED

U.S. COAST GUARD SFLC

c. Marking layout (scrap) “H” condition Left Hand Propeller.

2010-01-222-2440

ITEM NAME

PROPELLER, LH

PART NUMBER

110-WPB-245-001-LH

SERIAL NUMBER (See Propeller)

As Determined by Contractor

CONDITION CONDITION H

QUANTITY & UNIT OF

ISSUE

1 – EA

OTHER DATA AS

DIRECTED

U.S. COAST GUARD SFLC

d. Marking layout (scrap) “H” condition Right Hand Propeller.

2010-01-222-2441

ITEM NAME

PROPELLER, RH

PART NUMBER

110-WPB-245-001-RH

SERIAL NUMBER (See Propeller)

CONTRACT NUMBER (See Contract)

SHIPPING WEIGHT (LBS)

As Determined by Contractor

CONDITION CONDITION H

QUANTITY & UNIT OF

ISSUE

1 – EA

OTHER DATA AS

DIRECTED

U.S. COAST GUARD SFLC

e. Marking layout “A” condition Propeller Test Shaft Kit.

2010-01-F06-0656

ITEM NAME

PROP TEST KIT

PART NUMBER

110PROPTESTKIT

SERIAL NUMBER (See Kit)

As Determined by Contractor

CONDITION CONDITION A

QUANTITY & UNIT OF

ISSUE

1 – EA

OTHER DATA AS

DIRECTED

U.S. COAST GUARD SFLC

f. Marking layout “A” condition Propeller Ring and Plug Gauge Set.

5220-01-F06-0800

ITEM NAME

GAGE SET, TYPE 1

PART NUMBER

110CWPB-243-003-1

SERIAL NUMBER (If Applicable)

CONTRACT NUMBER (See Contract)

SHIPPING WEIGHT (LBS)

As Determined by Contractor

CONDITION CONDITION A

QUANTITY & UNIT OF

ISSUE

1 – EA

OTHER DATA AS

DIRECTED

U.S. COAST GUARD SFLC

MATERIAL

5.7 Barcoding. U.S. Coast Guard requires bar coding of the NSN, IAW MIL-STD-129R. See paragraph

5.4.1.2.1, page 51 of MIL-STD-129R for identification linear (Code 39) and 2D (PDF417) bar code markings and locations.

5.7.1 The Bar Code Label can be applied separately or as part of the marking required in 5.6.

5.8 Shipping. Unless otherwise directed, the Contractor shall ship and deliver the propeller(s) to the government address specified in paragraph 5.8.1. Notify the KO and COR about the shipment (07) days in advance. Provide timely shipping information to KO and COR including the name of the shipping company, date of shipment leaving Contractor’s facility, and expecting arrival date and time at the government facility. No shipment shall arrive outside of government normal business hours as determined by the KO.

5.8.1 Address. Unless otherwise specified, the Contractor shall ship, and deliver all parts to the following government addresses:

US Coast Guard

Surface Forces Logistics Center

2401 Hawkins Point RD, Receiving Room - Bldg. 88

Baltimore, MD 21226

5.8.2 Coast Guard acceptance. Acceptance will be made at destination by a government representative.

Acceptance will be contingent upon representative's verification of no damage in transit, correctness and completeness of order and Contractor’s conformance to preservation, packaging, packing, marking and bar-coding requirements.

6 NOTES

6.1 Document sources.

6.1.1 Government document sources.

Department of Defense Single Stock Point (DODSSP)

Building 4, Section D

700 Robbins Avenue

Philadelphia, PA 19111-5094

215-697-2667/2179

FAX 215-697-1462

DOD & Navy Publications & Forms (Other Than DODSSP)

Naval Publication and Forms Center

5801 Tabor Ave.

Philadelphia, PA 19120

215-697-2000

USCG Surface Forces Logistics Center

2401 Hawkins Point Road

Baltimore, MD. 21226-5000

Phone: 410-762-6649

ATTN: Contracting Branch, CPD1

6.1.2 Commercial document sources.

ASTM International

1916 Race Street

Philadelphia, PA 19103-1187

Phone: 215-299-5585

Fax: 215-977-9679

American National Standards Institute (ANSI)

1430 Broadway

New York, NY 10018

Phone: 212-642-4900

International Standard Organization (ISO)

1, ch. De la Voie-Creuse

CP 56 - CH-1211 Geneva 20

Switzerland

Phone: +41 22 749 01 11

Fax: +41 22 733 34 30

American Society of Mechanical Engineers (ASME)

Two Park Avenue

New York, NY 10016-5990

Phone: 800-843-2763

The Society for Protective Coatings (SSPC)

800 Trumbull Drive

Pittsburg, PA 15205

Phone: 1-877-281-7772

Fax: 412-444-3591

Society of Automotive Engineers (SAE)

400 Commonwealth Drive

Warrendale, PA 15096

Phone: 724-776-4841

Fax: 724-776-0790

6.2 Appendix A.

SKID TYPE SHIPPING CONTAINER

GENERAL DESCRIPTION

The Skid Type Shipping Container is an internally reinforced wooden box consisting of two parts; a skidded base and one piece cover (hood). It is usually specified for contents up to

1000 pounds in weight and is designed to meet the following requirements: allow attachment of the item(s) directly to the skid base; provide protective shrouding of the container contents, facilitate fork lift handling, promote durability and protection through maximum reinforcement, and permit reusability for multiple shipments. The side, end, and top panels are assembled to become a one piece cover (hood) which is then lowered over the secured load and bolted to the skid base.

HOOD REQUIREMENTS

The one piece hood , consisting of the two sides, two ends, and top, shall be fabricated using nominal 2”x10” pressure treated lumber. All built-up pieces used for fabricating the sides, ends, and top shall be connected using stainless steel corrugated fasteners (3/4”x1”) spaced every 6 inches. Internal dimensions shall be calculated to allow a minimum of 2” clearance at any point between the contents and the container. The hood sides shall be reinforced on the interior with battens and diagonals using nominal 2”x6” pressure treated lumber. The hood ends shall be reinforced on the exterior using cleats. The hood shall be assembled using 12D hot dipped galvanized nails spaced approximately 3-4 inches apart. All nails that pass through battens, diagonals, cleats or other areas shall be clinched. Four lifting eyes shall be fabricated from galvanized flat bar to facilitate removal/installation of the hood. One lifting eye shall be bolted to each top corner using appropriate galvanized fasteners. Refer to

Figure 1 to view general appearance of hood.

SKID BASE REQUIREMENTS

The one piece skid base, consisting of 3 skids, 2 headers, and a load bearing floorboard shall be fabricated using pressure treated lumber. The 3 skids shall be fabricated using nominal

4”x4” lumber cut to length, beveled 45 degrees on each end to facilitate sliding when necessary. The load bearing floor board shall be fabricated using 3/4'” pressure treated plywood and two 4”x4” floor joists. The plywood shall be nailed (10-12D hot dipped galvanized nails) or screwed (2” stainless steel flathead screws) to the skids. The two floor joists shall be placed at 90 degrees to the skids and positioned as necessary at the center point of the base to accommodate the propeller load. These joists shall be through bolted to the skids using galvanized ½” carriage bolts/washers/nuts. The end headers shall be fabricated using nominal 2”x 4” pressure treated lumber cut to length. The end headers shall also be through bolted to the skids using galvanized ½” carriage bolts/washers/nuts. Refer to Figure

1 to view general appearance of skid base.

FINAL ASSEMBLY REQUIREMENTS

The propeller shall be bolted to the skid base. The Contractor and the Contracting Officer shall mutually agree on the best method to satisfy this requirement given available securing points and the criticality/protection of the hub bore finish. The cover (hood) shall be fastened to the skid base using stainless steel hex head 3/8”x 5” lag screws spaced evenly around the cover perimeter with a minimum of four lag screws provided for each side.

STRAPPING

Prior to shipment, the box shall be banded with 2 metal straps, each encircling the shipping container passing between the skids. Each strap shall be galvanized or stainless steel, ¾” wide with a minimum thickness of .023”. Each strap shall be positioned and secured within 9” of the box end.