Spec_Rudder_R-562-0399_Rev__K_121113.pdf

REVISION: K Date: 12/11/2013

USCG WPB-110

SPECIFICATION FOR RUDDER OVERHAUL

R-562-0399

ORGINATED BY: ED Brubaker DATE: 1/9/2003 .

ORIGINATOR’S COMMAND: Surface Forces Logistics Center (SFLC)

DEPARTMENT / DIVISION: Patrol Boat Product Line (PBPL)

UPDATED BY: Wayne Nickel (Rev. K) DATE: 10/31/13 .

REVIEWED BY: Jeff Wong, PBPL Engineering DATE: 12/11/13 .

SFLC QA REVIEW: Brad Clemons, SFLC QA DATE: 10/30/13 .

PLSSR REVIEW: DATE: .

1. SCOPE:

1.1 General: The Contractor shall provide all equipment, labor and materials to receive, inspect/report, overhaul, test, inspect, preserve, package, pack, mark and bar-code rudders in accordance with the referenced drawing(s) and data provided within this statement of work to return the rudder(s) to a serviceable “A” condition.

NOTE

Serviceable “A” condition is defined as a reconditioned rudder meeting all required design specifications and design dimensions in accordance with Coast Guard drawing: 110C-WPB-562-001 and being capable of functioning and performing in the same manner as an identical new rudder although it may not have the appearance of a new rudder.

1.2 Government-Furnished Property:

ITEM DESCRIPTION NSN/PN QTY ESTIMATED

COST

($/UNIT)

Rudder NSN: 2040-01-223-2674 27 ea $10,000.00

Shipping Crate, Reusable N/A 1 ea $350.00

Rudder Lock Nut NSN: 5310-01-462-4610 1 ea $105.83

Rudder Sealing Kit NSN: 2040-01-566-3109 27 ea $412.25

1.3 ALL GFP MUST BE STORED INDOORS IN A LOCKED, ENVIRONMENTALLY

CONTROLLED LOCATION AT THE CONTRACTORS FACILITY. Any new crates fabricated per this statement of work shall be safe guarded and stored in the same place as other GFP.

1.4 All GFP shall be returned to the Coast Guard Surface Forces Logistics Center before contract close out. The address is:

U.S. Coast Guard

Surface Forces Logistics Center

2401 Hawkins Point Rd, Bldg. 88

Baltimore, MD 21226

2. Applicable Documents:

2.1 The below-listed documents form a part of this specification to the extent specified herein. Approval/publication dates or revision dates/numbers are also identified, to ensure that same document versions are used at time of specification writing and during contract execution.

2.2 All Coast Guard drawings, technical publications, and standard specifications will be provided to contractors by the Coast Guard at an appropriate time, or upon request, free of charge. Other Government documents may be accessed – free of charge – as follows:

a. MIL/DOD/CID Specifications:

http://www.assistdocs.com/search/search_basic.cfm

b. Commandant Instruction Manuals: http://www.uscg.mil/directives/default.asp

c. Public Laws, Code of Federal Regulations, U.S Codes, and other Federal

Government laws: www.gpoaccess.gov

2.2.1 The Government is aware of the following internet web links where contractors may procure commercial specifications:

a. American Welding Society (AWS): http://www.awspubs.com/index.php

b. ANSI, ASTM, IEEEE, NFPA, ASME, SAE Standards:

http://www.techstreet.com/

c. NFPA: http://www.nfpa.org

d. SSPC Standards and pictorial guides:

http://shopping.netsuite.com/sspcmarketplace

2.3 Coast Guard Drawings:

a. Coast Guard Drawing 110C WPB-562-001, Rev. G, Rudder Details (sheets

# 1, 2 & 4)

2.4 Coast Guard Publications:

a. Coast Guard Commandant Instruction (COMDTINST) M10360.3, (series)

Coatings and Color Manual

b. Surface Forces Logistics Center Specification D-000-0100, Rev. G, Change 1, Bar

Coding for SFLC Stocked Material

c. Surface Forces Logistics Center Standard Specification 0740 (SFLC Std Spec

0740), 2012, Welding and Allied Processes

d. Surface Forces Logistics Center Standard Specification 6310 (SFLC Std Spec

6310), 2012, Requirements for Preservation of Ship Structures

2.4 Other Government Documents:

a. MIL-PRF-16173E w/ Int. Amendment 1, Sep 2006, Corrosion Preventive

Compound, Solvent Cutback, Cold- Application http://www.assistdocs.com/search/search_basic.cfm http://www.uscg.mil/directives/default.asp http://www.gpoaccess.gov/ http://www.awspubs.com/index.php http://www.techstreet.com/ http://www.nfpa.org/ http://shopping.netsuite.com/sspcmarketplace

b. DOD 4140.01-M-1, 7 Sep 2007; Compliance for Defense Packaging: Phytosanitary

Requirements for Wood Packaging Material (WPM)

2.5 Commercial Documents:

a. SAE International, SAE J 448-2011 Standard, Surface Texture

b. National Conference of Standards Laboratories NCSL Z540-3, Dated

1/1/2006 Requirements for the Calibration of Measuring and Test

Equipment

c. American Society for Quality Control ASQC Q9001, 1/00 Edition, Quality

Management Systems – Requirements

d. The Society for Protective Coatings (SSPC)/NACE International (NACE), Joint Surface Preparation Standard SSPC-SP 10/NACE No 2, 2007, Near-

White Blast Cleaning

e. American Society for Testing and Materials A1011/ A1011M Rev A, 9/07

Edition, Standard Specification for Steel.

f. Application Guide Ecospeed for Steel Surfaces is available in the following link:

http://www.hydrex.be/upload/techpdf/pdfs/Ecospeed_technical_information_.pdf

g. Technical Information Ecospeed is available in the following link:

2.6 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 Inspection: The Contractor shall carefully remove the rudder from the GFP crate and conduct a thorough inspection to determine all the necessary repairs to return the rudder to a serviceable “A” condition. A Condition Found Report (CFR) shall be submitted to the Coast Guard Contracting Officer (KO) within ten (10) days of receipt of GFP. The

CFR shall include all inspection findings, test results as specified below, including any recommended repairs to return the rudder to serviceable “A” condition. The CFR shall also include a breakdown of estimated cost of labor and materials for any repair work that is beyond the scope of work in this specification. No further work shall proceed until authorized by the KO.

3.1.1 Paint Removal: Abrasive grit blast all coated rudder surfaces to SSPC-SP

10/NACE No. 2 using grit conforming to MIL-A-22262 with a 3.0-4.0 mil profile. All pipe plugs shall be installed prior to grit blasting.

3.1.2 Visual Inspection: Visually inspect the rudder for the following:

a. Excessive wear on the stock bearing journal surfaces.

b. Straightness of stock and blade.

c. Key and Keyway excessive wear.

d. Any worn or damaged threats.

e. Corrosion and other mechanical defects.

3.1.3 Rudder Blade Inspection: The Contractor shall:

3.1.3.1 Detection of Previously Applied Double Skin: Determine if any rudder delivered for repair has an existing double skin layer. An easy means of determining the existence of double skin is by Ultrasonic Test (UT) or by measuring the blade thickness at the trailing edge which will measure approximately ¼” thicker than the drawing thickness dimension.

3.1.3.2 Ultrasonic Test. Perform ultrasonic testing to the rudder to measure blade plate thickness. Take 20-30 UT shots on each side and log readings and location on CFR.

Degradation in excess of 25% will render the rudder non-repairable.

3.1.4 Air Pressure Test: The Contractor shall conduct an air pressure test on the blade section after all the paint and primer are removed as per 3.1.1. Using a calibrated pressure gauge, test shall be performed at 1-1/2 PSI for a period of 30 minutes. If any pressure loss is noted, check porosity areas, plug threads, and all welds using a soapy water solution to expose leaky areas. The active formation of air bubbles on the blade surface indicates the presence of cavitation erosion damage. This condition needs to be repaired prior to acceptance. A second air test will need to be performed in order to ensure the void does not leak. All traces of soapy water solution shall be removed.

3.1.4.1 Rudders That Show Cavitation (erosion) Damage, Through Double Skin Surface:

Double skinning is considered a one-time process that shall not be repeated via a third skin layer. It is not considered cost effective or practical to strip off and replace the existing double skin layer.

a. Any rudder showing cavitation damage through the double skin surface shall be determined as unserviceable with all further work discontinued on that rudder.

This does not include leakage through welds addressed in 3.1.4.2.

b. Contractor shall cite all rudders that show the existence of porosity through the double skin layer in a CFR.

3.1.4.2 Indicated Leakage through Welds: Rudders shall be serviceable if leakage is only found coming through welds but not through the skin surface. If air leaks are found through welds only, then the Contractor shall include the extent of weld leakage to the

Contracting Officer in the CFR with recommended repairs and cost. The Coast Guard shall determine if double skinned rudders having leaking welds should be repaired or scrapped based on the extent of leaks and cost to repair.

a. The air pressure test shall be repeated on rudders that undergo weld leakage repair work (see 3.1.4). The cost of additional air test if required shall be covered under the repair.

3.1.5 Any rudder the Contracting Officer deems not repairable shall be returned to the

Coast Guard at the address listed in 1.4 and shall be marked in “H” condition as described in 5.5.

3.2 Welding Certifications: The Contractor shall have welders qualified in accordance with American Society of Mechanical Engineers (ASME), Section IX, 2008, Qualifications Standard for Welding and Brazing, and Welding and Brazing Operators per SFLC STD Spec 0740. Certification documentation shall be maintained and available to the Contracting Officer for review at any time during the contract period.

3.3 Rudder Stock Repairs:

3.3.1 Lower Stock Repair: Starting at the top of the .750” radius where the stock meets the rudder blade, undercut the stock diameter 3/16”, and clad weld build up with stainless steel in accordance with CG drawing (sheet 1).

3.3.2 Upper Stock Repair: Machine to undercut the upper bearing stock journal, including the upper and lower seal journal areas stock diameter up to 1/8”, and build up by clad welding with grade 308 stainless steel material. Machine the built up areas back to the original Coast Guard drawing dimensional tolerances. The surface finish indicated on the drawing shall be in accordance with SAE J 448-2011 Standard. Polish all machined surface to a 32 RMS or smoother.

3.3.3 Keyways: All keyways shall be weld filled using grade 308 stainless steel and re-machined to the original Coast Guard drawing dimensional tolerances.

3.3.4 Thread Repairs: All existing threads shall be machined off to 1/32” under root of threads and built up with grade 308 stainless steel weld and new threads machined. The nut listed in section 1.2 is available for use by the Contractor for the purpose of thread machining and proper fit.

3.3.5 Length Tolerance: The allowed length tolerance for each segment of stock diameter shall be +/- 1/64” (.0156”).

3.4 Blade Section Requirements for Single Skinned Rudders:

3.4.1 Rudders delivered without double skin application shall be double skinned as part of the Contractors overall repair work.

3.4.2 Rudder blade shall be double skinned with new 1/8” thick ASTM A1011 steel plate.

a. The new skin shall be formed tight against the original blade skin to follow the exact contour and curves of the rudder blade.

b. The double skin layer shall be attached through the use of continuous fillet and plug welds to form a watertight seal.

3.4.3 Air Pressure Test: Contractor shall conduct an air pressure test of newly double skinned rudders in accordance with that as described in 3.1.4, paying particular attention to welded areas. Any leakage found during the air pressure test shall be corrected by welding with an additional air pressure test conducted after weld repairs are complete.

This process shall be repeated until all leakage has been corrected.

3.4.4 Surface preparation. Abrasive grit blast the new double skinned surfaces to SSPC-

SP 10/NACE No. 2 using grit conforming to MIL-A-22262 with a 3.0-4.0 mil profile.

All pipe plugs shall be installed prior to grit blasting.

3.5 Preservation:

3.5.1 Flow Coating (Interior): The rudder internal cavity shall be filled and drained

(flow coated) with corrosion preventative compound that conforms to MIL-PRF-16173

Grade 3. Replace pipe plugs with new stainless steel plugs in accordance with drawing

110C WPB 562-001 Rev. G Rudder Details upon completion of flow coating. Flow coating of the internal rudder blade section shall be accomplished after all other repairs are complete.

3.5.2 Rudder Exterior Coating:

3.5.2.1 Rudder Surface Preparation. All rudders shall be cleaned and readied for coating as described below.

a. Inspect the previously blasted surfaces to sure they still meet the SSPC-SP10 standard. If not, sandsweep or blast the surfaces again with abrasive grit to meet SSPC-SP 10/NACE No. 2 using grit conforming to MIL-A-22262 with a

3.0-4.0 mil profile. All pipe plugs shall be installed prior to grit blasting.

b. Clean entire substrate surface using Salt Away or equal product.

c. After cleaning, test substrate for the presence of any chlorides.

d. Rewash and retest as needed.

3.5.2.2 Rudder Blade Coating. The Contractor shall preserve the entire rudder blade exterior surfaces by applying one of the two coating systems designated by the KO.

Painting of the blade section shall be accomplished after all other repair work and interior flow coating is complete.

3.5.2.2.1 Ecospeed.:

a. The coating system shall be applied indoor with proper environmental, ventilation, and temperature controls as specified by the coating OEM. The paint contractor shall have a minimum of 5 years experience dealing with the

Ecospeed coating application. Observe all the Ecospeed OEM safety precautions.

b. Coating Application: Application to be completed in accordance with

Application Guide Ecospeed for Steel Surfaces, and Technical Information

Ecospeed. Record environmental readings before each application (to include ambient temperature, substrate temperature, relative humidity and weather conditions) listed below. Refer to the appropriate Ecospeed product instruction for use for acceptable readings. If overcoat windows are missed, the substrate must be re-blasted as in accordance with the instruction for use.

1. Inspect blasted substrate, recording and keeping Testex tape readings in a project log book.

2. Mix and apply one full coat of catalyzed Ecospeed coating to a DFT thickness of 20 mils (WFT thickness of 24 mils) in accordance with

Application Guide Ecospeed for Steel Surface.

3. After the first coat is cured for recoating, approximately 3 hours at a temperature of 68 °F, apply a strip coat of Ecospeed to all edges and corners.

4. After the strip coat is cured, apply another full coat of Ecospeed at 20 mils

(WFT thickness of 24 mils) to the entire first coated surface.

3.5.2.2.2 Ameron.:

a. The coating system shall be applied with proper environmental, ventilation, and temperature controls as specified by the coating OEM. The paint contractor shall have a minimum of 5 years experience dealing with the Ameron coating application. Observe all the Ameron OEM safety precautions.

b. Inspect blasted substrate, recording and keeping Testex tape readings in a project log book. Apply two coats of Ameron Amerlock 400 (black) or equivalent high turbulence paint, 10-11 mils dry film thickness each, to achieve a total of not less than 20 mils dry film thickness. Observe the curing time of recoating before apply the second coat.

3.5.2.3 Paint Data Sheet: Paint data sheets shall be prepared to certify the paint type and mil thickness used on the rudder blade. The paint data sheet shall be packed with each overhauled rudder and a copy provided to the Contracting Officer.

3.6 Final Inspection and Test Report: A detailed Final Inspection and Test Report shall be submitted to the Contracting Officer for approval prior to scheduling Coast Guard

SFLC Quality Assurance personnel. The report shall the final condition of the rudder after all work has been completed. 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. Rudder 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.

g. Pressure test certification.

h. Float coat application.

i. All required documentation concerning preparation and application of all coatings.

3.7 Notifications and Inspections: The Contractor shall be responsible for notifying the

Contracting Officer at least ten (10) calendar days prior the contractor being ready for any Quality Assurance (Q.A.) inspections or testing as required herein. The rudders require a one hundred percent Coast Guard Quality Assurance inspection.

4.0 QUALITY ASSURANCE

4.1 Inspections & Tests (Completed Units): The inspections & 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.

4.1.1 Contractor shall have the latest versions of the drawings, specifications, tolerances, approved test procedures and test equipment calibration certificates available for inspection, as necessary.

4.1.2 The following are required and will be monitored by a CG-SFLC Quality

Assurance Representative:

a. Overall dimensional tolerances are in accordance with the drawing.

b. Surface texture (stock section).

c. Weld inspection.

d. Air pressure test.

e. Paint thickness check.

f. Paint data sheets.

g. Float coat application.

h. Blade straightness in reference to the centerline on the drawing.

i. Slade packing kit secured and marked in crate.

j. Packing, packaging, marking and bar-coding of rudder prior to shipping.

5.0 PACKING, PACKAGING, MARKING AND DELIVERY

5.1 Packing: Each rudder shall be individually packaged in its own reusable wood box, or a new reusable shipping container.

5.2 New Reusable Shipping Container: When a change request is authorized by the KO, the Contractor shall construct a new reusable shipping container as follows:

5.2.1 The wooden box shall be constructed using 2” x 8” framing and ¾” plywood top and bottom. Particle board, flake board, OSB etc. will not be acceptable. The box shall be skid mounted and constructed with a removable lid secured with corrosion resistant wood screws to allow easy access and removal of the rudder without damage to the box.

5.2.2 Wood Packing Material (WPM) Requirements: The new shipping container shall meet the Phytosanitary Requirements for WPM in accordance with DOD 4140.01-M-1, Compliance for Defense Packaging Ref. 2 paragraph C2.1.1. 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).

5.2.3 WPM Markings: All new shipping containers shall have the appropriate markings in accordance with DOD 4140.01-M-1, Compliance for Defense Packaging Ref. 2 paragraph C2.5

5.2.4 Newly manufactured shipping containers shall be secured and stored per 1.3.

5.3 Packaging. The Contractor shall package the each overhauled rudder as follows:

5.3.1 The stock section shall be encased in PVC piping for protection from damage during shipping and handling. Pipe shall be long enough to cover the entire length of the stock and extend approximately one inch beyond the top of the stock. Pipe shall be secured to the stock in such a manner to prevent slipping off.

5.3.2 The rudder stock shall be supported in the box by use of cradles and blocking that will not allow shifting of the rudder within the box. The lower blade end shall be supported with 2”x6” wood planks covered in ½” minimum thickness resilient rubber or foam to prevent blade paint damage. The box shall be banded in a minimum of two locations.

5.3.3 Papack one (1) Rudder Sealing Kit (GFM) with installation tool, Ref. 1.2, in the box with each rudder. The kit shall be secured to prevent movement during handling and multiple shipments. The kit shall be clearly marked in permanent ink with NSN and description.

5.4 Marking: Shipping container shall be stenciled with the information laid out below.

Markings shall be placed on each side of the two longest sides of the container so it will be visible to a forklift driver during storage and shipment. Stencil shall be applied directly on the container and a minimum of ½ inch height black characters on a highly contrasting painted background, using permanent waterproof ink or enamel paint.

Required marking for (ready for issue) “A” Condition rudders:

National Stock Number: 2040-01-223-2674

Item Name: RUDDER

Drawing Number: 110C WPB 562-001

Shipping Weight: Contractor Provide

Coast Guard Contract Number See Contract

Delivery Order Number: See Contract

Statement: COAST GUARD SFLC MATERIAL

CONDITION "A", 1 EACH

Required marking for (scrap) “H” Condition rudders:

National Stock Number: 2040-01-223-2674

Item Name: RUDDER

Drawing Number: 110C WPB 562-001

Shipping Weight: Contractor Provide

Coast Guard Contract Number See Contract

Delivery Order Number: See Contract

Statement: COAST GUARD SFLC MATERIAL

CONDITION "H", 1 EACH

5.5 Bar Coding: A bar coded label, in accordance with SFLC specification D-000-0100 shall also be applied. The Bar Code Label can be applied separately or as part of the marking required in 5.4 of this specification.

a. The actual labels shall be Type "V", Grade "C" Style "2", Composition "a" with or without plastic laminate.

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

5.6 Shipping: The Contractor shall ship, and deliver the overhauled rudder to the government address specified in para. 1.4. Notice the Contracting Officer representative

(COR) and KO about the shipment 7 days in advance. Provide timely shipping information to 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 be arrived outside of government normal business hours as determined by the KO.

6. NOTES

None

Revisions Record

This page is used to record specification revisions, which may have occurred subsequent to a Revision J (Rev-J) package. Information listed is intended to provide contractors and field unit personnel a means to ensure all the current specification revision pages are present when reviewing or utilizing this specification package.

DATE REV# WORK

ITEM#

CHANGES MADE

NOTE: All work item and paragraph numbers listed above for a given revision correspond to same numbers in the previous revision. This revised specification is self-contained with all of the above listed changes incorporated.

NOTE: Revision record is a Coast Guard internal record. The revision will show the weakness of the spec where the change were made, and should not be published.