P-562-0100.doc

Construction Specification for

225 Ft. WLB Rudder Blade

P-562-0100

REVISION

Date: May 12, 2014

TITLE

225B WLB RUDDER BLADE

CONSTRUCTION SPECIFICATION

P-562-0100 ORGINATED BY: J.Happe /A. Ollerman DATE: May 2014 ORGINATOR’S COMMAND: Surface Force Logistic Center (SFLC) IBCT-PL

1.0 Scope: This specification defines the fabrication, inspection, preservation and packaging requirements of a single rudder blade used on 225 and 225B WLB class buoy tenders of the United States Coast Guard.

1.2 Government Furnished Property (GFP): Rudder Blade Mock is available on a loan basis under Activity Control Number (ACN) 2040-01-F04-0192.

2. Applicable Documents:

2.1 USCG Drawings:

a) 225B-WLB-562-002 Rudder Structural A & D, Rev. C, Dated 5/30/2003 (7 sheets).

2.2 Military Specifications:

a) MIL-A-22262B (SH), Abrasive Blasting Media Ship hull Blast Cleaning, Dated. 21 Mar. 96

b) MIL-PRF-16173E INT AMD 1, Corrosion Preventive Compound Solvent Cutback, Cold Application, Dated: 7 Sept 2006.

c) MIL-PRF-24647D INT AMD 1, Paint System, Anticorrosive and Antifouling, Ship Hull Dated: 12 June 2006.

d) NAVSEA S9074-AQ-GIB-010/248, Requirements for welding and brazing procedure and performance qualification, Dated 8/1/95.

2.3 Commercial Documents:

a) American Welding Society (AWS) Specification D1.1 Structural Welding

Code, Steel, 2000 edition.

b) American Welding Society (AWS) Specification B2.1 Specification for Welding Procedure and Performance Qualification.

c) The Society for Protective Coatings, SSPC-SP 10, Near White Blast Cleaning, dated: 1 Jan 2007.

d) The Society for Protective Coatings, NACE NO. 5/SSPC-SP12, Joint Surface

Preparation Standard. dated 1 Jul 2002.

e) National Conference of Standards Labs, ANSI/NCSL Z540-1 Calibration Laboratories and Measuring Equipment, dated Jan, 1994 (R 2002).

2.4 Coast Guard SFLC Bar Coding Specification:

a) Bar Coding, D-000-0100, latest revision.

2.5 Document Sources: See section 6.0 for sources of the above listed documents.

2.6 Precedence: In the event of a conflict between the text of this specification and the references cited herein this specification shall take precedence.

3. Requirements:

3.1 The contractor shall provide all labor and materials to manufacture the rudder blade for use on Coast Guard 225’ WLB Class Cutters. The rudder blade shall be manufactured in accordance with Coast Guard Drawing 225B WLB-562-002 and this specification. Each rudder blade shall include all pieces shown in the bill of material with exception of # 6 pintle casting, #7 ice knife casting and #9 epoxy paste.

3.1.2 225B WLB-562-002 depicts rudder stock, pintle casting, ice knife, and other rudder components. To be clear, the scope of this specification is only the rudder blade.

3.1.3 Be aware the Rudder Blade incorporates two (2) castings #5 “Upper Rudder casting” and #11 “Lower Pintle Casting”.

3.1.3 All patterns and/or molds the Contractor manufacturer’s associated with castings shall be provided to the USCG at conclusion of contract and will become property of the USCG.

3.1.4 Provide material certifications, heat treatment certifications, and NDT certifications for the two castings to USCG prior to use (machining, welding into larger rudder assembly, etc.).

3.1.5 The Taper fit shall be cut per drawing WLB-562-002. Final blue fit will be performed in another contract that fit’s this new blade to an existing rudder stock.

3.2 Government Furnished Tooling:

3.2.1 Rudder Blade Jig: Rudder blade mock is available on a loan basis under ACN 2040-01-F04-0192. Contractor shall inspect the mock and make any repairs as necessary to ensure its suitability for continued use. Contractor shall report any found condition, damage or, otherwise, nonconformity which may render the equipment beyond repair and no longer suitable for continued use. Mock equipment shall be returned to the Coast Guard SFLC at the close of the contract.

3.3 ABS inspections: Materials requiring ABS (American Bureau of Shipping) certifications are waived and shall be perform by Coast Guard Quality Assurance office.

3.4. Material Certs: Contractor shall provide material certifications to the Coast Guard Quality Assurance Representative during the inspection phase of the contract.

3.5 Welding:

3.5.1 Weld Quality: All welds shall be thoroughly fused with base metal. Welds shall be free of craters, undercutting, overlaps, porosity, or cracks. All welding shall conform to AWS D1.1.

3.5.2 Welder Qualification: Welders shall have a current and valid qualification record certified by one or more of the following organizations American Welding Society, American Bureau of Shipping or Department of the Navy.

3.5.2.1 All welders certifications shall be in accordance with AWS B2.1 or NAVSEA S9074-AQ-GIB-010/248.

3.5.3 Contractor shall make welder certifications available to the Contract Administrator prior to contract award. A copy of the welder certifications shall also be available for the Coast Guard Quality Assurance Representative.

3.6 Serial Numbers: A system of serial numbers shall be used for each rudder blade produced under the contract. The serial number shall be stamped in legible ¾” minimum height figures on either side surface of the rudder casting.

3.6.1 Format: The rudder blade serial number shall include the following segments:

a) Class: 225’

b) Year of manufacture: 14 etc.

c) Sequence number: 001, 002 and so on.

Example: “225-14-001”, for the first rudder blade produced depending on the exact year of manufacture and shall continue with succeeding sequence numbers for each rudder blade produced thereafter on this and future job orders.

3.7 Painting, Rudder Blade Exterior:

3.7.1 Surface Preparation: In preparation for painting, the rudder exterior surface shall be sand blasted to near white metal in accordance with SSPC-SP10/NACE No. 2 using grit conforming to MIL-A-22262. Blasting shall result in an anchor profile of 1.5 to 3.5 mils. All machine finished surfaces at risk of damage from sand blast and paint operations shall be plugged, blanked off or otherwise protected while this work is being performed.

a) Alternative Method: To NACE NO. 5/SSPC-SP12 to WJ-2 and SC-1.

3.7.2 Paint Coating: Paint coating shall be two coats, 5 to 6 mils dry film thickness of anti-corrosive epoxy in accordance with MIL-PRF-24647C.

3.7.2.1 Access plate: The exterior side of the rudder access plate shall be painted as above while the interior side shall have one coat, 3 to 4 mils dry film thickness of inorganic zinc paint to DOD-P-24648, color green or grey applied.

3.7.3 Paint application: The contractor shall maintain a quality control system to document and maintain records of the surface preparation and paint application process. A copy of these documents shall be placed in a waterproof protective package and placed in the rudder shipping container.

3.8 Flow Coating, Rudder Interior: The rudder internal cavity shall be thoroughly coated with corrosion preventative compound that conforms to MIL-C-16173 Grade 3. Install monel pipe plugs using a suitable non-hardening thread sealer after completion of flow coating.

3.10 Notifications & Inspections: The contractor shall be responsible for notifying the Contracting Officer no less then seven (7) calendar days prior to the contractor being ready for any Quality Assurance (Q.A.) inspections or testing required herein. Foreign contractors are required to notify the Contracting Officer no less then thirty (30) calendar days prior. Due to the processes involved there will be a need to coordinate multiple inspection points and site visits.

4. Quality Assurance (QA):

4.1 General: The Contractor is responsible for the conformance and overall quality of each item offered to the Coast Guard for acceptance or approval.

4.2 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 Contractors facility prior to the Coast Guards 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. The contractor shall notify the Contracting Officer of the scheduled commencement of any inspections required by this specification.

4.3 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 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 Inspection System: The Contractor shall maintain an inspection system, which shall ensure that each item offered to the Coast Guard for acceptance or approval conforms to the contract requirements. The inspection system shall be in accordance with ANSI/ASQC-A9003-1994. The system shall be documented and available for review by the Coast Guard inspector.

4.5 Inspections & Tests: 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. The following are required:

a) Verification of all dimensional tolerances, lengths, diameters etc. and thickness checks.

b) Provide certificates of material conformance to verify that materials used conform to the material requirements of the applicable drawings and this specification.

c) Welding requirements and welder certifications.

d) Casting Non-destructive test results.

e) Verify paint requirements.

f) Ensure serial numbering is clearly stamped.

g) Inspection of preservation, packaging and marking.

4.6 Calibration System: The Contractor 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). The calibration system records shall be maintained for inspection for the duration of any contract referencing this specification

4.7 Test & Inspection Reports: A copy of any standard contractor test or inspection report shall be turned over to the Coast Guard Q.A. Representative upon his/her arrival at the contractor's plant.

5. Preservation, Packaging & Marking: The rudder shall be preserved, packed and marked to withstand outdoor storage for two years.

5.1 Preservation: All machined or unpainted surfaces subject to corrosion shall be coated with corrosion preventative compound, Grade 3 in accordance with MIL-C-16173. The taper bore shall be covered with plywood blanks held together with threaded rod.

5.2 Packaging, Rudder Blade: The rudder blade shall mount horizontally onto a wooden skid slightly larger than the rudder blade dimensions. The skid shall be built to support the entire weight of the rudder blade and be able to be lifted by use of a fork truck or crane. The rudder shall be secured to the skid by the use of blocks, braces ,straps and fasteners sufficient to prevent movement of the rudder during transport.

5.2.1 The rudder access plate shall be secured to the skid.

5.2.2 The rudder blade shall be entirely covered with commercial ultra-violet resistance shrink-wrap 7-12 mils thick. The wrap shall be secured along the outer edges of the skid by the use of batten wood strips to prevent lifting and tearing of the wrap during transport. Sharp or protruding surfaces shall be securely wrapped or covered prior to applying the shrink wrap.

5.3 Marking: A wooded placard shall be attached to opposite ends of the skid marked with the following information. The placard shall be painted with a white enamel paint background and 1/2” -3/4” size text using black enamel paint. Only the enlarged bold text shown shall be applied to the container.

NSN : 2040-01-F96-0866

Name :RUDDER, BLADE Drawing Number: 225B-WLB-562-003

Serial Number (part 3.5): S/N (fill in) .

Weight: (fill in) LBS.

The following statement: Coast Guard SFLC Material, Condition Code A.

5.4 Bar Coding: The stock number shall also be bar coded in addition to the above marking.

a) All bar coded labels shall be in accordance with SFLC Bar Coding specification number D-000-0100. The actual labels shall be Type “V”, Grade “C”, Style 2”, Composition “a”. The Label can be applied separately or as part of the marking required in 5.3.

6. Notes:

6.1 Document Sources:

Specification and Standards (DODISS Documents)

Standardizations Document Order Desk

700 Robbins Avenue

Building #4, Section D

Philadelphia, PA 19111-5094

215-697-1187

The Society for Protective Coatings (SSPC)

40 24TH St., Sixth Floor

Pittsburgh, PA 15222

1-412/281-2331

American Welding Society (AWS)

550 NW. LeJeune Road

P.O. Box 351040

Miami, FL 33135

305-443-9353

National Conference of Standards Labs (ANSI/NCSL)

1800 30th St., Suite 305B

Boulder, CO 80301

303-440-3339

PAGE