P-243-0211_Rev__J_(110_Shaft_Purchase_-_Final).pdf

REVISION No. J . CHANGE NO. .

PROPULSION SHAFT PURCHASE

SPECIFICATION FOR 110 WPB

P-243-0211

Originated By: E.R. Fischer . Date: 12/96 .

Updated By: Wayne Nickel (Rev. J) . Date: 7/12 .

Originator’s Command: Surface Forces Logistics Center (SFLC) .

Department / Division: Patrol Boat Product Line (PBPL) .

Engineering Review: Mike Soost, SFLC Eng. SES . Date: _ 6/27/12 .

SFLC QA Review: Dan Dressel . Date: 6/28/12 .

PLSSR Approval: CDR Michael Ciaglo . Date: 7/27/12 .

PLDixon Typewritten Text

HSCG40-13-R-11003 ATTACHMENT 1

USCG – SFLC

DATE – 12/96

P-243-0211

REVISION J, 7/12

1.0 SCOPE

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

1.2. Government Furnished Property (GFP)

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, 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-680C dated, 25 Mar 2010, Performance Specification, Degreasing

Solvent.

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

2.2.4. MIL-PRF-16173E E/INT AMD 1dated, 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.

P-243-0211

REVISION J, 7/12

2.3.1. Drawings

a. USCG DWG. 110 WPB 243-006 Rev. C, dated, 4/23/2009, 110 WPB A, B & C Classes, 110’ Island Class Cutters Propulsion Shaft Details.

2.3.2. Specifications

a. USCG-SFLC 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 J448 dated, 8/1/2011, Surface Texture Standard.

2.5.2. National Conference of Standards Laboratories (NCSL)

a. NCSL Z540.3 dated, 8/3/2006, Requirements for the Calibration of Measuring and Test Equipment.

2.5.3. American Society for Testing Materials (ASTM)

a. ASTM A564/A564M dated, 10/1/ 2010, Standard Specification for Hot Rolled and Cold-Finished Age-Hardening Stainless Steel Bars and Shapes.

2.5.4. American Society For Quality (ASQ)

a. ASQ Q9001 dated 1/1/2008, Quality Management Systems – Requirements – T860E

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.

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REVISION J, 7/12

3.0 REQUIREMENTS

3.1. General – The Contractor shall provide all labor and materials required to manufacture, test, inspect, preserve, package and pack 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 to 29.825:1 and verified with the government furnished ring gauge.

3.1.4. 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 Property (GFP) – The Contractor shall provide protective storage for the GFP listed in section 1.2 of this specification when not in use, and safe handling when in use.

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

3.2.2. The Contractor shall conduct a visual inspection of the GFP Ring and Plug Gauge Set upon receipt to verify condition and usability. The Contracting Officer shall be notified immediately via Condition Found Report (CFR) 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 GFP Ring and Plug Gauge Set without prior authorization from the Contracting Officer.

a. Contractor shall submit a GFP inspection report to the Contracting Officer within five (5) days of receipt.

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). At no time shall the shaft be straightened/pressed upon using the machined taper areas as a support.

3.3.1. Contractor shall submit a straightening procedure for review and approval to the

Contracting Officer prior to contract award. Once approved, the straightening procedure need not be resubmitted unless changes are requested.

P-243-0211

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 Ra

(Roughness Average) or better in accordance with SAE J448 “Surface Texture Standard” reference 2.5.1.a. unless otherwise specified on drawing 110 WPB-243- 006.

3.5.1. Certified Thread Ring Gages (Go/No-Go) shall be used to verify all external threads.

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 within 0.0075 inch (0.015 inch run-out).

The change in eccentricity in any 48 inches shall not exceed 0.0025 inch (0.005 in runout)

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

T.I.R.

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3.7.3. Taper/Draw fit shall be performed using the GFP 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. 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”.

** CAUTION: DO NOT STAND IN FRONT OF THE RING GAUGE

WHEN REMOVING FROM SHAFT **

b. 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.

3.7.4. 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.

a. The Contractor shall conduct a visual inspection of the GFP Ring and Plug Gauge Set to verify condition. The Contracting Officer shall be notified immediately via CFR 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 GFP 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 Data Requirements

3.9.1. 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.

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

b. Finished Shaft

1. Concentricity, Eccentricity, and Total Indicated Run-out (TIR) measurements taken and recorded demonstrating the shaft is in accordance with section 3.7 of this specification.

a If concentricity, eccentricity, and/or TIR are out of tolerance and shaft straightening is required, all pre-straightening 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.

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

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

3.11. Final Inspection and Test Report – A detailed final inspection and test report shall be submitted to the Contracting Officer via CFR for approval prior to scheduling SFLC quality assurance personnel. A copy of the inspection and test report shall be turned over to the Coast Guard Quality Assurance representative upon arrival for final inspecting and testing. The inspection and test report shall contain the following information as a minimum:

a. Contractor name, address and telephone number.

b. Contract number and delivery order number as applicable.

c. Shaft serial numbers

d. Inspection sheets showing dimensional data and test results

e. Name of the person conducting the testing.

f. Test equipment used, nomenclature, serial number, and calibration date.

3.11.2. The inspection report shall depict the final condition of the shaft after all work has been completed.

3.11.3. All defects if any, even those deemed acceptable, shall be documented on the inspection report.

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3.12. 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

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 ASQ-Q9001 and available for review by the Coast Guard.

4.1.1. The Contractor shall submit a Quality Assurance Plan for review and approval to the Contracting Officer prior to contract award. Once approved, the Quality Assurance Plan need not be resubmitted unless changes are requested.

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 and 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 NCSL Z540-3. 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 – Responsibility for Inspection – Contractor shall be responsible for the performance of all inspection requirements specified herein.

Contractor shall provide space, personnel and test equipment to conduct all inspection requirements. All inspection and testing shall be performed at the Contractor’s facility prior to the Coast Guard’s acceptance of the contracted items. The Coast Guard reserves the right to verify or have performed any of the inspections set forth herein where such inspections are deemed necessary to assure that supplies and services conform to prescribed requirements. Contractor shall notify the Contracting Officer prior to the scheduled commencement of any inspections required by this overhaul specification.

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

P-243-0211 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 at the designated Contractor facility by an SFLC Quality Assurance Representative IAW section 3.9 of this specification.

a. Finished Shaft

1. Material certifications and properties.

2. Dimensional readings

3. Concentricity, eccentricity, and TIR: shaft and tapers

4. Blue-fit

5. Surface Finish

6. Shaft Stampings

7. Thread functionality.

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.

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

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

4.9. Packing Inspection – The Contracting Officer shall be notified prior to the packaging, marking and bar-coding of the completed units in accordance with section 3.12 of this specification if completed at a different time from the QA inspection.

4.10. GFP Inspection – At the request of the Contracting Officer, Coast Guard Quality

Assurance personnel will inspect GFP to assure compliance of section 3.7.e of this specification.

4.10.1. 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 GFP to the Coast Guard.

5.0 PRESERVATION, PACKAGING & MARKING – Each shaft and GFP Ring and Plug

Gauge Set shall be cleaned, preserved, packaged, packed and marked as specified herein.

5.1. Inspection and Preservation of GFP – The Ring and Plug Gauge set shall be inspected, cleaned, preserved, packaged 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 GFP Ring and Plug

Gauge Set to verify condition and usability. The Contracting Officer shall be notified via CFR 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 GFP 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. Cleaning and Preservation

5.2.1. Each completed shaft shall be cleaned with a solvent conforming to specification

MIL-PRF-680B Type 1.

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5.2.2. Preservative coatings are not required and shall not be used on the shafts.

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 of MIL-DTL-2845 can be used for any shaft specified herein up to 5” in diameter with material sizes adjusted accordingly in accordance with MIL-DTL-2845 table IV.

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

5.4. Common Carrier Preparation – All packaged shafts shall be loaded on a flatbed steel trailer with minimal camber and wooden floor only. No aluminum trailers are authorized. Shafts are very sensitive and shall lay as flat and straight as possible.

5.4.1. Shafts shall be loaded on the deck of the trailer only with no other items loaded on top of the crates.

5.4.2. Shim and secure crates as necessary to keep shafts in a flat, straight position.

5.4.3. Carrier shall re-adjust shims as necessary if other shipped items are loaded and offloaded changing the camber of the trailer.

5.5. 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.

5.5.1. 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.

5.5.2. This marking shall consist of the STOCK NUMBER, ITEM NAME, CONTRACT NUMBER, DELIVERY ORDER if Applicable, SERIAL NUMBER, GROSS WEIGHT (in lbs.,) condition code ie. CONDITION “A”, unit of issue with quantity (1) and the words COAST GUARD SFLC MATERIAL DISPOSABLE

CONTAINER.

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

a. MARKING LAYOUT

STOCK NUMBER 2010-01-445-7940

ITEM NAME SHAFT, PROPULSION

CONTRACT NUMBER See Contract

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DELIVERY ORDER See Contract, if applicable SERIAL NUMBER See Contract

GROSS WEIGHT As Determined by Contractor

CONDITION CODE CONDITION A

QUANTITY & UNIT OF ISSUE 1- EA

THE WORDING COAST GUARD SFLC MATERIAL

DISPOSABLE CONTAINER

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

5.6.1. All bar coded labels shall be in accordance with SFLC 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 5.5 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) 762-6162

Attn: Walter Mack Contracting, CPD1 Walter.A.Mack@USCG.Mil

6.1.2. Commercial Documents

a. Society of Automotive Engineers, INC. (SAE) 400 Commonwealth Drive Warrendale, PA 15096-0001

(877) 606-7323 Fax: (724) 776-0790 www.sae.org

b. National Conference of Standards Laboratories (NCSL) mailto:Walter.A.Mack@USCG.Mil�

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2995 Wilderness Place Suite 107 Boulder, CO 80301-5404

(303) 440-3339 Fax: (303) 440-3384 www.ncsli.org

c. American National Standards Institute (ANSI) 25 W. 43rd Street, 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 http://www.ncsli.org/� http://www.ansi.org/�

FIGURE 1

DELIVERABLE LIST

CLIN DESCRIPTION QUAN

U/I

COST

EACH

TOTAL

COST

0001 For Approval, GFP Inspection and report in accordance with specification P-243-0211 section 3.2.2.a.

1 EA $ NSP . $ NSP .

0002 For approval, Final Inspection and Test Report on each shaft in accordance with specification P-243-0211 sections 3.11.

10 EA $ NSP . $ NSP .

0003 Shaft, Propulsion, Stock No. 2010-01- 445-7940, manufactured, tested, inspected, packaged, marked and bar-coded in accordance with specification P-243-0211.

40 EA $ . $ .

DELIVERY SCHEDULE

CLIN QUAN WITHIN

0001 1 EA 05 calendar days after receipt of

GFP.

0002 10 EA 55 calendar days from receipt of delivery order.

Coast Guard Review

05 Calendar days after receipt of report for Coast Guard Review

10 EA 20 calendar days from approval of CLIN 0002.