P-245-75(F)WLR.doc

REVISION ---- .

CHANGE No. ----- .

TITLE

PURCHASE SPECIFICATION FOR PROPELLERS

USED ON U.S. COAST GUARD 75 FT WLR

“F” CLASS VESSELS

P-245-75WLR(F)

ORGINATED BY MIKE GASKINS DATE 07/24/2007 .

ORGINATOR’S COMMAND ENGINEERING LOGISTICS CENTER (ELC)

DEPARTMENT / DIVISION EQUIPMENT MANAGEMENT DIVISION (CODE 026).

INTERNAL REVIEWER DATE .

SOWRB APPROVAL DATE .

PURCHASE SPECIFICATION FOR PROPELLERS

USED ON USCG 75 FT “F” CLASS VESSELS

1.0 SCOPE

1.1. This document sets forth the requirements for the manufacture, testing, inspection, preservation, packaging and marking of Right Hand (RH) and/or Left Hand (LH) propellers used on U.S. Coast Guard 75 foot “F” Class Vessels.

1.2. CLASSIFICATION

1.2.1. Propeller Types

a Type 1 - Left Hand (LH), P/N 46X51 LH b Type 2 – Right Hand (RH),P/N 46X51 RH

2.0 APPLICABLE DOCUMENTS

2.1. GENERAL – The documents listed in this section are specified in sections 3, 4, or 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, or 5 of this specification, whether or not they are listed.

2.2. GOVERNMENT DOCUMENTS

2.2.1. SPECIFICATIONS, STANDARDS, AND OTHER GOVERNMENT DOCUMENTS – The following specifications, standards, and other government documents which includes publications, handbooks, and drawings, 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.

2.2.2. 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 b COAST GUARD SPECIFICATION D-000-0100 - DATED 10/91 REV G 02/06, Bar Coding for USCG Engineering Logistics Center Procured Material

2.2.3. STANDARDS

a MIL-STD-2035A(SH) - DATED 15 MAY 1995, Nondestructive Testing Acceptance Criteria b DOD-STD-2185(SH) - DATED 28 OCT 1986, Requirements for Repair and Straightening of Bronze

Naval Ship Propellers

2.2.4. OTHER GOVERNMENT DOCUMENTS

a USCG Drawing No. 75-WLR-F-245-003 REV 2, DATED 10/9/90, entitled 75’ CUTTER CLASS “F” PROPELLER, FAIRWATER, & GUARDS (6 BLADE) b NAVSEA TECHNICAL MANUAL, NAVSEA S9245-AR-TSM-010/PROP - DATED 31 MARCH 1997, Technical Manual Marine Propeller Inspection, Repair and Certification, NSN 0910-LP-012-5880 c T9074-AS-GIB-010/271 - DATED 16 FEB 1999, Requirements for Nondestructive Testing Methods

2.3. COMMERCIAL DOCUMENTS

2.3.1. American Bureau of Shipping (ABS)

a ABS PART 7 SECTION 10: Guide for Bronze and Stainless Steel Propeller Castings - DATED 2008

2.3.2. 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

2.3.3. American National Standards Institute (ANSI)/National Conference of Standards Laboratories (NCSL) a ANSI/NCSL Z540-1-1994 - DATED 1994, General Requirements for Calibration Laboratories and Measuring and Test Equipment

2.3.4. American Society For Quality Control (ASQC)

a ANSI/ASQC Q9003-1994 - DATED 1994, Quality Systems - Model for Quality Assurance in Final Inspection and Test

2.4. DOCUMENT AVAILABILITY - To obtain the referenced documents see section 6.1.

2.5. ORDER OF PRECEDENCE - In the event of a conflict between the text of this specification and the references cited herein, the text of this specification takes precedence. Nothing in this document, however, supersedes applicable laws and regulations unless a specific exemption has been obtained.

3.0 REQUIREMENTS

3.1. GENERAL – The Contractor shall provide all equipment, labor and materials to manufacture, test, inspect, preserve, package, pack and mark Left Hand (LH) and/or Right Hand (RH) 75 FT WLR vessel propellers for the U.S. Coast Guard in accordance with the referenced drawing and data provided within this specification.

3.2. MATERIAL - Each propeller shall be manufactured from ABS Type 4 Nickel Aluminum Bronze consisting of the chemical composition and tensile properties listed in ABS Part 7 Section 10 entitled Guide for Bronze and Stainless Steel Propeller Castings (dated 2008).

NOTE: This requirement supersedes the material listed on USCG Drawing No. 75-WLR-F-245-003 REV 2, DATED 10/9/90, entitled 75’ CUTTER CLASS “F” PROPELLER, FAIRWATER, & GUARDS (6 BLADE).

3.2.1. The Contractor shall perform a material chemical composition analysis and a tensile properties test for each propeller casting. The documented results shall be submitted to the Coast Guard Contracting Officer for review/approval.

3.2.2. All material chemical composition analysis and tensile property tests shall be made by a laboratory meeting the calibration requirements in section 4.6 of this specification.

3.3. TEST AND INSPECTION PLAN - The Contractor shall submit a test and inspection plan to the Contracting Officer for approval. 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, and this specification.

3.4. CONSTRUCTION OF PROPELLER CASTINGS – Each propeller casting shall be constructed in accordance with ABS Part 7 Section 10 entitled Guide for Bronze and Stainless Steel Propeller Castings (dated 2008), and USCG DWG. NO. 75-WLR-F-245-003 REV 2, DATED 10/9/90, entitled 75’ CUTTER CLASS “F” PROPELLER, FAIRWATER & GUARDS (6 BLADE).

3.4.1. Each propeller casting shall be formed with one continuous pour.

3.4.2. Each casting shall include a provision to allow for an integrally cast coupon. This coupon shall be tested for it’s chemical composition and tensile properties referenced in 3.2.1. of this specification.

3.5. PROPELLER FINISHING – Each propeller may 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.

3.5.1. The tolerances specified at the design sections shall apply to all hydrodynamic surfaces.

3.5.2. The Contractor shall demonstrate a manufacturing or inspection process that ensures tolerances for all hydrodynamic surfaces are met.

3.5.3. Dimensional Inspection shall be in accordance with this specification and USCG DWG. NO. 75-WLR-F-245-003 REV 2, DATED 10/9/90, entitled 75’ CUTTER CLASS “F” PROPELLER, FAIRWATER & GUARDS (6 BLADE).

3.6. DIMENSIONAL TOLERANCES

3.6.1. Propeller tolerances shall be in accordance with USCG DWG. NO. 75-WLR-F-245-003 REV 2, DATED 10/9/90, entitled 75’ CUTTER CLASS “F” PROPELLER, FAIRWATER & GUARDS (6 BLADE) and this specification.

3.6.2. Blade thickness at each 10 percent station shall be within plus or minus 0.030” or plus or minus 1.00 percent of the maximum thickness of the blade section.

3.6.3. Blade section half width at each design radius shall be plus or minus 0.15 percent of maximum section width.

3.6.4. Blade section half width between adjacent design radii shall be within 0.15 percent of maximum section width.

3.6.5. Pitch deviation at each design section shall not exceed plus or minus 1.00 percent.

3.6.6. Pitch variation between adjacent design sections on each blade shall not exceed 0.50 percent.

3.6.7. Average Pitch deviation of all design sections on each blade shall not exceed plus or minus 0.75 percent.

3.6.8. Angular spacing of the blade center axes shall be plus or minus 0.25 degrees.

3.6.9. Clearance under the fairing rod shall not exceed .030 inches and shall not vary at a rate greater than .005 inches per inch.

3.6.10. Propeller radius shall be plus 0.000 inches or minus 0.5 percent. NOTE: This tolerance supersedes the tolerance cited in drawing number 75-WLR-F-245-003.

3.6.11. Axial variation of Blade Center Axis relative to other blades at the .95 radius shall be plus or minus

0.250 inches.

3.7. WELD REPAIRS - If the castings require any weld repairs, welding procedures, welders, and welding operations shall be qualified in accordance with S9074-AQ-GIB-010/248 OR approved in accordance with the procedures outlined in ABS Guide for Bronze and Stainless Steel Propeller Castings (dated 2008), paragraph 3.7.2.

3.7.1. No weld repair is authorized unless prior approval is received from the Contracting Officer.

3.7.2. Welding on the pressure face of any propeller casting 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 blades 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).

b Welding repairs of propeller castings shall meet the requirements of DOD-STD-2185(SH) or ABS Part 7 Section 10 entitled Guide for Bronze and Stainless Steel Propeller Castings (dated 2008).

3.8. SURFACE FINISH - Surfaces of the propeller blades and hub shall be ground fair and polished in accordance with SAE-J-448 to meet the following requirements:

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

3.8.2. Propeller Hub - 125 micro inches or better.

3.9. BALANCING - Each propeller shall be single plane balanced. All balancing shall be accomplished by means of balancing equipment, which requires rotation of the work piece. The sensitivity of the balancing equipment shall be such that it can easily detect a residual unbalance of at least 25% of the value established below. 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. (446 RPM)

U = Maximum allowable residual unbalance in oz.-inches

W = Weight of rotating part in pounds.

3.9.1. 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.

3.9.2. The actual amount of unbalance for each propeller shall be documented on each Final Inspection Report.

3.10. SURFACE INSPECTIONS

3.0 A visual inspection shall be performed on all exterior blade surfaces in accordance with MIL-STD-2035(SH), section 4.

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

3.10.2. The Contractor shall perform a dye penetrant inspection over 100 percent of the blade surfaces including the hub in accordance with T9074-AS-GIB-010/271. The acceptance criteria of MIL-STD-2035(SH) Table IV (Appendix 1 of this specification) shall be used for evaluations.

3.10.3. 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 fillet, and the hub.

3.11. TEST AND INSPECTION DATA REQUIREMENTS, FINAL INSPECTION REPORT – The Contractor shall perform final dimensional, balancing, visual, and dye penetrant surface inspections for each propeller manufactured and record this data on a final inspection report. This report shall accurately reflect the final condition of each propeller.

3.11.1. The final inspection report shall contain, at a minimum, the following data:

a Propeller blade radius.

b Pitch at the 0.3 through 0.95 radii.

c Average pitch of each blade at the 0.3 through

0.95 radii.

d Blade section half widths at the 0.3 through 0.95 radii.

e Thickness at every 10 percent station for each blade section from the 0.3 through 0.95 radii.

f Leading and trailing edge profiles at the 0.3 through 0.95 radius.

g Rake h Track i Angular spacing of blade center axes.

j Fairing rod clearances k All propeller hub dimensions including taper and keyway l Surface finish of blade and hub areas m Surface inspection (visual and 100 percent dye penetrant) n Material composition o Balancing Data

3.11.2. The Final Inspection Report shall be submitted to the Contracting Officer for review. If this report is determined to be acceptable, the Contracting Officer will authorize ELC’s Quality Assurance Branch to schedule final inspections/tests outlined in section 4.4. of this specification.

3.12. PROPELLER STAMPING - Each propeller shall be stamped on the aft end of the hub clear of the fillets with the information outlined below.

3.12.1. STAMPINGS

a Serial Number – As provided by the Contracting Officer b Ship Class – 75FT WLR “F” c Diameter – 46” d Pitch – 51” e Manufacturer & Date of Manufacture f Weight – As determined by Contractor after final finishing g Blade Material – ABS Type 4

3.12.2. The stampings shall be at least 1/4" high, neat and legible.

3.13. NOTIFICATIONS & INSPECTIONS - The Contractor shall be responsible for notifying the Contracting Officer at least ten (10) calendar days prior to inspections or monitored testing required herein.

4.0 QUALITY ASSURANCE (Q.A.)

4.1. GENERAL - The Contractor shall provide and maintain an inspection system which shall ensure each item offered to the Government for acceptance conforms to contract requirements. The system shall be documented and meet the requirements of ANSI/ASQC-Q9003.

4.2. RESPONSIBILITY FOR INSPECTION - The Contractor shall be responsible for the performance of all inspection requirements as specified herein. The Contractor may use his own or any other facilities for the performance of the inspections and tests, unless disapproved by the government.

NOTE: The government reserves the right to perform any of the inspections and tests set forth in this specification at any time.

4.3. RESPONSIBILITY FOR COMPLIANCE - All items shall meet the requirements of this specification. 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 requirements 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 will be monitored by a Government Quality Assurance Representative.

4.4.1. Dimensional inspections in accordance with section 3.6 of this specification.

4.4.2. Surface inspections in accordance with section 3.10 of this specification.

4.4.3. Balancing inspection in accordance with section 3.9 of this specification.

4.4.4. Stamping inspection in accordance with section 3.12 of this specification.

4.4.5. Preservation, packaging and marking in accordance with 5.0 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 provided to the Coast Guard Quality Assurance Representative upon arrival at the Contractor's plant.

4.5.2. All out of tolerance readings on any inspection, test or tolerance check report submitted to any Coast Guard representative shall be easily identified through highlighting, color coding, shading, circling or other prominent marking.

4.6. 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).

4.6.1. 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 at least seven (07) calendar days prior to the preservation, packaging, packing, and marking of the completed propellers.

5.0 PRESERVATION, PACKAGING & PACKING, & MARKING

5.1. PRESERVATION & PACKAGING

5.1.1. PROPELLERS: Type 1 – Left Handed (LH), P/N 46X51 LH and Type 2 – Right Handed (RH), P/N 46X51 RH a 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.

b 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-2845(SH), paragraph 3.14.1.3.

c After the application of strippable compound, galvanized sheet metal blade edge protectors shall be installed in accordance with MIL-DTL-2845(SH), paragraph 3.14.1.4.

5.2. PACKING

5.2.1. PROPELLERS: Type 1 – Left Handed (LH), P/N 46X51 LH and Type 2 – Right Handed (RH), P/N 46X51 RH a Each propeller shall be individually packed in a new Contractor furnished multiple trip wooden container consisting of a skid type base and a one piece container cover (ends, sides, and top fastened together). Construction shall be in accordance with MIL-DTL-2845(SH), paragraph 3.14.2.2.2.

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

5.3.1. This marking shall consist of the STOCK NUMBER, ITEM NAME, PART NUMBER, SERIAL NUMBER, SHIPPING WEIGHT (in lbs.), CONTRACT NUMBER, CONDITION CODE ie. CONDITION A, UNIT OF ISSUE with QUANTITY (1) and the words COAST GUARD ELC MATERIAL.

5.3.2. MARKING LAYOUT

a TYPE 1 - PROPELLER, LEFT HAND (LH)

STOCK NUMBER 2010-01-501-5465

ITEM NAME PROPELLER, LH

PART NUMBER 46X51 LH

SERIAL NUMBER As provided by Contracting Officer SHIPPING WEIGHT As determined by Contractor

CONTRACT NUMBER As indicated on the contract

CONDITION CODE CONDITION A

QUANTITY & UNIT OF ISSUE 1- EA

COAST GUARD ELC MATERIAL

REUSABLE CONTAINER DO NOT DESTROY

b TYPE 2 – PROPELLER, RIGHT HAND (RH)

STOCK NUMBER 2010-01-501-5459

ITEM NAME PROPELLER, RH

PART NUMBER 46X51 RH

SERIAL NUMBER As provided by Contracting Officer

SHIPPING WEIGHT As determined by Contractor CONTRACT NUMBER As indicated on the contract

CONDITION CODE CONDITION A

QUANTITY & UNIT OF ISSUE 1- EA

COAST GUARD ELC MATERIAL

REUSABLE CONTAINER DO NOT DESTROY

5.4. BAR CODING - Bar code labels shall be supplied on all CLIN's except for those that require data submissions only.

5.4.1. All bar coded labels shall be in accordance with ELC specification D-000-0100 REV G, dated 02/06.

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.

6.0 NOTES

6.1. GOVERNMENT & COMMERCIAL DOCUMENT SOURCES

6.1.1. GOVERNMENT DOCUMENTS

a. DOD & Navy Publications & Forms (Other Than DODSSP) Naval Publication and Forms Center

5801 Tabor Ave.

Philadelphia PA. 19120

215-697-2000

b. Department of Defense Single Stock Point (DODSSP)

Building 4, Section D

700 Robbins Avenue

Philadelphia, PA 19111-5094

215-697-6396/6257 FAX 215-697-9398

www.dodssp.daps.dla.mil

6.1.2. COMMERCIAL DOCUMENTS

a American Bureau of Shipping (ABS) ABS Plaza 16855 Northchase Drive Houston, TX 77060

PH: 281-877-6000

FAX: 281-877-6001

Website Address: http://www.eagle.org b Society of Automotive Engineers, Inc. (SAE) 400 Commonwealth Drive Warrendale, PA 15096-0001

PH: 1-877-606-7323

FAX: 4-776-5760

Website Address: http://www.sae.org c American Society For Quality (ASQ) PO Box 3005 Milwaukee, Wisconsin 53201

PH 414-272-8575

FAX 414-272-1734

Website Address: http://www.asq.org d American National Standards Institute (ANSI) 25 West 43rd Street New York, NY 10036

PH 212-642-4900

FAX 212-398-0023

Website Address: http://www.ansi.org

6.1.3. OTHER GOVERNMENT DOCUMENTS

a USCG Engineering Logistics Center MAIL STOP #026 BLDG 31 2nd FL.

2401 Hawkins Point Road Baltimore, MD. 21226-5000 410-762-6503 Attn: Code 046

TABLE IV. Acceptance standards for inspection of bronze propellers.9 Location of discontinuities Type of discontinuities2 Maximum acceptable discontinuity size (inches)1,3 Discontinuity acceptance standards Allowable areas of concentration

6 x 6 Area of concentration6,7 Maximum No.8,9 Maximum spacing between aligned discontinuities 4,5

CASTINGS

A band located around the periphery of each blade on both the pressure and suction faces with a width equal to

10 percent of the width of the blade measured at the 0.

radius, but not to exceed

6-inches; and an area mea‑ sured from (and including) the hub fillet to 0.4 radius on the pressure face only.

5 percent of propeller surface area with distribution limited by a maximum of 5 percent for each blade surface.

The remaining surfaces of the blades.

D

whichever is less

WELDMENTS

area.

See footnotes on following page.

APPENDIX 1

TABLE IV FOOTNOTES

1. Liquid penetrant inspection shall be performed as an aid to visual inspection in locating discontinuities. Only discontinuity size shall be used as a basis for rejection.

2. A linear discontinuity is one in which the length is greater than or equal to three times the width.

3. Any linear discontinuity over 1/16 inch in length located within a peripheral band 1 inch wide;

and whose major dimension is oriented normal to the blade edge shall be repaired.

4. Maximum spacing is the distance separating two adjacent discontinuities in terms of the major dimension of the larger discontinuity (D). Aligned non-linear discontinuities shall consist of four or more discontinuities in a line. Aligned linear discontinuities shall consist of two or more discontinuities whose major dimensions are oriented in a line. However, when the total length of the aligned discontinuities does not exceed the maximum length permitted for a single discontinuity, these aligned discontinuities shall be considered as one discontinuity, and shall not be cause for rejection.

5. When the major dimension of clustered discontinuities does not exceed the maximum size permitted for a single discontinuity, these clustered discontinuities shall be considered as one discontinuity and shall not be cause for rejection. Scattered discontinuities, separated from the cluster by 1/8 inch or more shall not be considered as part of the cluster..

6. Randomly dispersed casting discontinuities whose major dimensions are 1/16 inch or less shall not be counted in determining total number of discontinuities within an area of concentration.

7. More than six discontinuities whose major dimensions are greater than 3/32 inch in any 6 by 6-inch area of the propeller surface constitute an area of concentration. Each area of concentration shall be separated from an adjacent area of concentration by a minimum of 18 inches.

8. The total number of non-linear discontinuities may be increased to the combined total, or part thereof, represented by the absence of linear discontinuities.

9. For used propellers not originally inspected to the requirements of this standard, the allowable number of discontinuities in each area of concentration may be increased 15 percent for each blade surface, and the minimum spacing between adjacent aligned linear discontinuities may be reduced to 2D provided that: (a) the discontinuities do not exceed the limits of any other requirement of this standard, and (b) the discontinuities have shown no deleterious effects in service.

APPENDIX 1 (cont.)