FinalRevisedSpec.doc

REVISION No. I . CHANGE NO. 1 .

PROPULSION SHAFT PURCHASE

SPECIFICATION FOR 110 WPB (AQ17)

P-243-0211

ORGINATED BY E.R. Fischer . DATE 12/96 .

UPDATED BY Wayne Nickel (Change 1) . DATE 08/07 .

ORIGINATOR’S COMMAND Engineering Logistics Center (ELC) .

DEPARTMENT / DIVISION Propulsion Machinery Branch (026) .

INTERNAL REVIEWER Steve Hardsock . DATE 08/07 .

SWORB APPROVAL . DATE .

PURCHASE SPECIFICATION, PROPULSION SHAFTS

FOR 110 FOOT WPB (AQ17)

1.0 SCOPE

1.1. This specification provides the requirements for the manufacture, testing, inspecting, preservation, packing, packaging and marking of propulsion shafts used on the 110’ WPB vessels.

1.2. Government Furnished Equipment (GFE)

1.2.1. To be released by the Contracting Officer after contract is awarded.

a. RING & PLUG GAUGE SET, NSN: 5220-01-F06-0800.

2.0 APPLICABLE DOCUMENTS

2.1. General – The documents listed in this section are specified in sections 3, 4, and 5 of this specification. This section does not include documents cited in other sections of this specification recommended for additional information or as examples. While every effort has been made to ensure the completeness of this list, document users are cautioned that they must meet all specified requirements cited in sections 3, 4, and 5 of this specification, whether or not they are listed.

2.1.1. Government Documents – The following specifications, standards, publications, and handbooks form a part of this specification to the extent specified herein. Unless otherwise specified, the versions in effect are those listed in the GSA Index of Federal Specifications, Standards and Commercial Item Descriptions or the current Department of Defense Single Stock Point of Specifications and Standards, (DODSSP), and supplements thereto, cited in the solicitation or contract.

2.2. Military Specifications

2.2.1. 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. MIL-PRF-680 Dated, 26 Oct 2006, Performance Specification, Degreasing Solvent.

2.2.3. MIL-PRF-121 Dated, 30 Apr 2001, Performance Specification, Barrier Materials, Greaseproof, Waterproof, Flexible, Heat-Sealable.

2.2.4. MIL-PRF-16173 Dated, 7 Sept 2006, Performance Specification, Corrosion Preventive Compound, Solvent Cutback, Cold-Application.

2.3. Coast Guard 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.

2.3.1. Drawings

a. USCG DWG. 110 WPB 243-006 Rev. A, Dated, 21 April 1997, 110 WPB A, B, & C Classes, Propulsion Shafting Details.

2.3.2. Specifications

a. USCG-ELC SPECIFICATION D-000-100 REV G, Dated, 02/06, Bar Coding for USCG Engineering Logistics Center Material. See section 5.5 of this specification.

2.4. Other Government Documents

a. NAVSEA TECHNICAL MANUAL, NAVSEA S9243-A5-MMD-010, Technical Manual for GAGES, PLUG AND RING, PROPELLERS AND PROPULSION SHAFTING; REPAIR, INSPECTION, CERTIFICATION AND USE. NSN 0910-LP-587-9500, Dated, 30 NOV 1995

2.5. Commercial 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.

2.5.1. Society of Automotive Engineers (SAE)

a. SAE-J-448A Dated, 6/63 Surface Texture Standard.

2.5.2. American National Standards Institute (ANSI)/ National Conference of Standards Laboratories (NCSL)

a. ANSI/NCSL Z540-1-1994 Dated, 1994, Calibration Laboratories and Measuring and Test Equipment - General Requirements.

2.5.3. American Society for Testing Materials (ASTM)

a. ASTM-A-564-04 Dated, 01 Mar 2004, Standard Specification for Hot Rolled and Cold-Finished Age-Hardening Stainless Steel Bars and Shapes.

2.6. Document Availability – To obtain the referenced documents see section 6.1.

2.7. Specification 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, unless otherwise specified herein. Nothing in this specification, however, supersedes applicable laws and regulations unless a specific exemption has been obtained.

3.0 REQUIREMENTS

3.1. General – The Contractor shall provide all labor and materials required to manufacture, test, inspect, preserve, and package the propulsion shafts as outlined on the applicable drawing.

3.1.1. The shafting required herein shall be as specified in ASTM A564 Type 630 H1150 Class A.

3.1.2. The shafting shall have a minimum ultimate tensile strength of 135,000 psi, elongation of not less then 16%, and tensile yield strength of 105,000 psi.

3.1.3. The shafting tapers shall be machined by a computer numerically controlled (CNC) lathe in accordance with the GFE gauge set.

3.1.4. The Contractor shall conduct a visual inspection of the GFE Ring and Plug Gauge Set upon receipt to verify condition and usability. The Contracting Officer shall be notified immediately of any damage including dents, dings, scratches, corrosion, or distortion of the critical test surfaces that could affect accuracy related to intended purpose. No repairs shall be conducted to GFE Ring and Plug Gauge Set without prior authorization from the Contracting Officer.

a. Contractor shall submit a GFE inspection report to the Contracting Officer.

3.1.5. The Contractor shall conduct shaft forging run-out readings and document TIR. All shaft forgings shall be straightened to within .010” TIR prior to machining.

3.2. Government Furnished Equipment (GFE) – The Contractor shall provide protective storage for the GFE listed in section 1.2 of this specification 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. Straightening – Any shaft straightening required before, during and after machining shall be done using the COLD STRAIGHTENING, press method only. Shafts shall be supported approximately 1 to 2 feet on each side of the bend center and positioned so that the high spot of the bend is upward (at 12 o’clock).

3.3.1. Contractor shall submit a straightening procedure for approval to the Contracting Officer.

3.4. Dimensions – All dimensions and dimensional tolerances shall be as indicated on the specified drawing.

3.4.1. If not, specified tolerances shall be as listed below:

a. Fractional dimensions +/- 1/64”.

b. Decimal dimensions (xx) +/-0.01”, (xxx) +/-0.001, (xxxx) +/-0.0005”.

3.5. Surface Finish Standards – All shaft surface finishes shall be 32 micro-inches or better in accordance with SAE-J-448A “Surface Texture Standard” reference 2.5.1.a. unless otherwise specified on drawing 110 WPB-243-006.

3.6. Measurement Procedures – Run-out readings using a dial indicator shall be taken by supporting the shaft on precision rollers (two total) at twenty three inches (23”) from each end of the shaft, or between lathe centers. (No additional supports shall be used.)

a. All dial indicators shall be rigidly supported above the shaft, allowing no movement of the indicator body whatsoever while measurements are being taken.

1. The indicator(s) shall be in contact with the shaft under inspection for the entire rotation and set in the middle of their range.

3.6.2. Run-out readings shall be determined as follows; Conduct a dial indicator survey of the shaft run-out at stations 24” apart to determine the magnitude and location of any bend.

a. At each station mark the position of the maximum run-out on the periphery of the shaft.

3.7. Run-out, Concentricity & Taper Inspection – Unless otherwise specified on Drawing 110-WPB-243-006, the run-out and concentricity shall be as specified below.

3.7.1. Shaft Total Indicated Run-out (T.I.R) - The outside diameter of each shaft section shall be concentric with the axis of rotation to within 0.005 T.I.R.

3.7.2. Taper Concentricity - Shall be concentric with the axis of rotation within 0.002” T.I.R.

3.7.3. Taper/Draw fit shall be performed using the GFE Ring Gauge. NAVSEA manual S9243-A5-MMD-010 sections 3.1 & 3.3 as applicable shall be used to perform the blue check to certify the shaft tapers unless otherwise specified herein.

a. Blue fit shall be performed by suspending the ring gage from an overhead crane at a level altitude and advancing it on to the shaft taper until it is 3” - 4” from the seated position. With both hands forcefully advance this ring gage to the seated position.

b. With the ring gage still supported by the crane using a hydraulic jack remove the ring gage from the shaft. CAUTION - DO NOT stand in front of the shaft while removing the ring gage.

c. The draw dimension shall be taken by suspending the ring gage from an overhead crane at a level altitude and advancing the ring gage to the seated position on the shaft taper. Lightly tap the ring gage with a rubber, wood, or plastic mallet to insure the gage is fully seated. Measure from the counterbore of the ring gage to the end of the shaft for the draw dimension. Draw shall be the dimension stamped on the data plate inside the gage box ± 2mm or ± 0.078”.

d. Acceptance criteria for blue fit contact impression percent shall be as follows; a contact impression shall be 95% within a 1/2” circumferential band within 1” of the ends of the taper: no gaps shall completely cross the bands. An average of 75% minimum contact for the remainder of the taper.

e. Ring and Plug Gauge – After the completion of all planned testing or when 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 in accordance with MIL-PRF-680, 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.

1. The Contractor shall conduct a visual inspection of the GFE Ring and Plug Gauge Set to verify condition. The Contracting Officer shall be notified immediately of any damage including dents, dings, scratches, corrosion, or distortion of the critical test surfaces that could affect accuracy related to intended purpose. No repairs shall be conducted to GFE Ring and Plug Gauge Set without prior authorization from the Contracting Officer.

NOTE: If the Ring and/or Plug Gauge will not be used for periods exceeding 30 days, refer to section 5.1 of this specification for inspecting, cleaning, preservation and storage requirements.

3.8. Welding – No welding shall be permitted on any shaft.

3.9. Test/Inspection Reports

3.9.1. All reports prepared for submission shall contain at a minimum the data listed herein.

a. Prime Contractor Company Name, address, telephone number.

b. Testing Contractor (if different from above).

c. Contract & Delivery Order No.

d. Test equipment used, Nomenclature, S/N, Calibration date.

e. Shaft serial number.

f. All test and inspection information required herein for each Contract Line Item Number (CLIN).

3.10. Test & Inspection Data Requirements

3.10.1. Each shaft shall be tested/inspected as specified herein:

a. Rough Shaft

1. Mechanical properties as specified in section 3.1.2 of this specification and ASTM A564.

2. TIR of forging when received by Contractor and after rough machining, if necessary, prior to machining.

b. Finished Shaft

1. Total Indicated Run-out (TIR) in accordance with section 3.7 of this specification.

a If TIR is out of tolerance and shaft straightening is required all pre-straightening TIR readings shall be re-checked to ensure they are within required specification.

2. Taper Inspection (both ends) shall be in accordance with section 3.7.3 herein and contact impression requirements in accordance with NAVSEA S9243-A5-MMD-010 section 3.4 as applicable.

3. Dimensional Inspection in accordance with the drawing 110-WPB-243-006.

c. Inspection Report Submittal

1. The completed inspection report shall be submitted to the Contracting Officer for approval. If this report is determined to be acceptable, the Contracting Officer will authorize ELC Quality Assurance personnel to schedule final inspections and testing as outlined in section 4.6 of this specification.

3.11. Marking – All shafts shall be marked with a stamped-in serial number at least 1/8” high as directed on each delivery order.

3.11.1. Each face of the shaft shall be stamped with the serial number and prefix letter “A” on one face, “B” on the other face.

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

4.0 QUALITY ASSURANCE

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 ANSI/ASQC-Q9003 and available for review by the Coast Guard.

4.1.1. The Contractor shall submit a Quality Assurance Plan for approval by Contracting Officer.

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 ANSI/NCSL Z540-1. The program shall be documented and traceable to the National Institute of Standards (NIST).

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

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 set forth in this specification where such inspections 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 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.

4.6. Tests and Inspections – The inspections/tests required here and in the appropriate subsection in section 3 are the minimum required and are not intended to supplant any controls, examinations, inspections or tests normally employed by the Contractor to assure the quality of the propulsion shafts.

4.6.1. Shaft Tests & Inspections – The following tests, inspections and documentation shall be witnessed or observed by an ELC Quality Assurance Representative IAW section 3.10.1 of this specification.

a. Rough Shaft

1. TIR for shaft forging when received by Contractor and after rough shaft machining to .010” or below if necessary.

b. Finished Shaft

1. TIR.

2. Straightness.

3. Small End Taper outside diameter.

4. Dimensional.

4.7. Failure Responsibility – If a shaft fails to pass any inspection or test, the Contractor shall report the failure and their recommended fix to the Contracting Officer. If approved, the corrective action on the materials or processes shall be taken in accordance with this section.

a. The Contracting Officer reserves the right to totally reject any failed shaft without considering any suggested corrective action.

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

c. After all corrective actions have been completed; the inspection/test shall be continued or repeated at the option of the Contracting Officer.

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

e. All corrective actions shall be documented as part of the Contractor’s inspection system, and submitted for approval to the Contracting Officer.

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

4.7. Test and Inspection Reports – One copy of any required inspection, test or tolerance check shall be sent to the Contracting Officer.

4.7.1. A copy of any test, inspection or tolerance check shall also be turned over to the Quality Assurance representative upon his arrival at the Contractor’s plant.

4.8. Packing Inspection – The Contracting Officer shall be notified prior to the packaging and marking of the completed units in accordance with section 3.12 of this specification.

4.9. GFE Inspection – At the request of the Contracting Officer, Coast Guard Quality Assurance personnel will inspect GFE to assure compliance of section 3.7.e of this specification.

4.9.1. A final inspection will be conducted by Contractor and Coast Guard Quality Assurance Personnel to validate compliance with section 5.1 of this specification prior to return shipment of GFE to the Coast Guard.

5.0 PRESERVATION, PACKAGING & MARKING – Each shaft and GFE Ring and Plug Gauge Set shall be cleaned, preserved, packed and marked as specified herein.

5.1. Inspection and Preservation of GFE – The Ring and Plug Gauge set shall be inspected, cleaned, preserved and packed in accordance with MIL-DTL-2845 Section 3.18.

5.1.1. At the conclusion of the contract 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, and then completely coated with a preservative that conforms toMIL-PRF-16173, grade 4.

a. The Contractor shall conduct a visual inspection of the GFE Ring and Plug Gauge Set to verify condition and usability. The Contracting Officer shall be notified immediately of any damage including dents, dings, scratches, corrosion, or distortion of the critical test surfaces that could affect accuracy related to intended purpose. No repairs shall be conducted to GFE Ring and Plug Gauge Set without prior authorization from the Contracting Officer.

b. Prior to securing the Ring and Plug Gauge in 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 the gauge.

5.2. Preservation Shafts – All shafts shall be cleaned prior to preservation. Preservation shall be in accordance with MIL-DTL-2845 using commercial requirements under section 1.2 for preservation and cushioning.

a. Each completed shaft shall be cleaned with a solvent conforming to specification MIL-PRF-680B Type1.

b. Preservative coatings shall not be used.

5.3. Packing – Each completed shaft shall be packed in accordance in accordance with MIL-DTL-2845 section 3.8.1 Level A.

5.3.1. Preliminary wrap shall not be used, but cushioning at support saddles shall be used.

5.3.2. The box construction type shown in figures 15 & 16 can be used for any shaft specified herein up to 5” in diameter with material sizes adjusted accordingly in MIL-DTL-2845 table IV.

5.2.3. Place PVC tubing over all threads and tapers and secure in place.

5.3. Common Carrier Preparation – All packaged shafts shall be loaded on a flat steel trailer with wooden floor only. No aluminum trailers are authorized. Trailer “Shall Not” contain bow and/or arches. Shafts are very sensitive and shall lay flat.

a. No shimming of shafts is authorized.

5.4. Marking – The marking described herein shall be placed on the longest two sides of each box (on opposite ends) and include the requirements of section 5.5 and Figure 1 of this specification.

5.4.1. All markings shall be done via machine-made stencils where applicable, the lettering shall be at least 1/2” high, in black print lettering on a highly contrasting painted background.

5.4.2. This marking shall consist of the STOCK NUMBER, ITEM NAME, PART, CONTRACT, DELIVERY ORDER, and SERIAL NUMBERS, GROSS WEIGHT (in lbs.,) condition code ie. CONDITION A, unit of issue with quantity (1) and the words COAST GUARD ELC MATERIAL.

5.4.3. See the marking layout below, and as required on figure 1.

a. MARKING LAYOUT

STOCK NUMBER

2010-01-445-7940

ITEM NAME

SHAFT, PROPULSION

PART NUMBER

110WPB 243-002/AQ17

CONTRACT NUMBER

See Contract

GROSS WEIGHT

As Determined by Contractor

CONDITION CODE

CONDITION A

QUANTITY & UNIT OF ISSUE

1- EA

COAST GUARD ELC MATERIAL

DISPOSABLE CONTAINER

SERIAL NUMBER/REPAIR DATE

S/N as directed”

PACKING DATE

As Determined by Contractor

5.5. Bar Coding – Bar code labels shall be supplied on all CLIN’s except for those that require data submissions only.

5.5.1. All bar coded labels shall be in accordance with ELC specification D-000-0100 REV G, DATED 2/06, ref. 2.3.2.a.

a. The actual labels shall be Type “V”, Grade “A”, Style “2”, Composition “b” with plastic laminate.

b. Each label shall contain encoded data for the Stock Number.

c. The marking required in 5.4 of this specification can be applied separately or as part of the Bar Code Label.

6.0 NOTES

6.1. Coast Guard and Commercial Document Sources

6.1.1. Coast Guard Documents

a. USCG ENGINEERING LOGISTICS CENTER

2401 Hawkins Point Road

Baltimore, MD. 21226-5000

410-762-6416

Attn: Ashley Pezeshkian Contracting Branch, Code 046 www.uscg.mil/hq/elcbalt

6.1.2. Commercial Documents

a. Society of Automotive Engineers, INC. (SAE)

400 Commonwealth Drive

Warrendale, PA 15096

1-877-606-7323

FAX: 1-724-776-0790

www.sae.org

b. American Society for Testing & Materials (ASTM)

100 Barr Harbor Drive

West Conshohocken, PA 19428

610-832-9500

FAX: 610-832-9555

www.astm.org

c. American National Standards Institute (ANSI)

25 W. 43rd Street (Between 5th and 6th Avenues) 4th Floor

New York, NY 10036

212-642-4900

FAX: 212-398-0023

www.ansi.org

d. American Society of Quality Control (ASQC)

600 N. Plankinton Ave.

Milwaukee, WI 53203 800-248-1946

FAX: 414-272-1734

www.asq.org 6.1.3 Other Government Documents a.

Department of Defense Single Stock Point (DODSSP)

Building 4, Section D

700 Robins Avenue

Philadelphia, PA 19111-5094

215-697-6396/6257

FAX: 215-697-9398

www.assist.daps.dla.mil/quicksearch