Attachment_1_-ZD_Ovhl_Spec_R-245-0532_REV_A_Chg_2__11-03-11_.pdf

REVISION . A . CHANGE NO. 2 .

SPECIFICATION FOR ULSTEIN MODEL 1350-H MARINE

THRUSTER (Z-DRIVE) OVERHAULS, TECHNICAL SUPPORT

& PARTS APPLICABLE TO USCG 175’ WLM VESSELS

R-245-0532

ORGINATOR: E. M. GASKINS (Marine Equipment Specialist) DATE: 12/14/2009

UPDATED BY: E. M. GASKINS (Marine Equipment Specialist) DATE: 05/15/2013

ORIGINATOR’S COMMAND: SURFACE FORCES LOGISTICS CENTER .

PRODUCT LINE: ICE BREAKER/BUOY & CONSTRUCTION TENDER (SES2) .

USCG SFLC

SPECIFICATION R-245-0532

REV A Change 2 DATED 11/03/2011

SPECIFICATION FOR Z-DRIVE OVERHAULS, TECHNICAL SUPPORT

& PARTS APPLICABLE TO USCG 175’ WLM VESSELS

1.0 SCOPE

1.1. This document sets forth the requirements for the receipt, storage, disassembly, inspection, overhaul, reassembly, testing, preservation, packaging, packing, marking and warehousing of Marine Thruster, Z-Drives used on 175’ WLM U.S. Coast Guard Vessels. Additionally, it includes provisions for technical support and purchasing various piece parts.

1.2. Government Furnished Property (GFP)

1.2.1. Marine Thruster, Z-Drive - Ulstein Aquamaster Model 1350H; P/N B8202396-001, (NSN 2010-21-920-0919)

1.2.2. Marine Thruster, Z-Drive - Ulstein Aquamaster Model 1350H, P/N B8202396-002, (NSN 2010-21-920-0899)

1.2.3. Z-Drive Shipping Skid

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.

2.2. Government Documents – The following specifications, standards, 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.

2.2.1. Coast Guard Documents

A USCG Surface Forces Logistics Center (SFLC) – Specification D-000-0100 REV

G, Dated 02/2006, Bar Coding for USCG SFLC Material.

B Commandants Instruction – M9000.6E, Dated 10/21/2004, Naval Engineering Manual, Chapter 505: Flexible Hose and Expansion Joint Program.

REV A Change 2 DATED 11/03/2011

C USCG Drawing – 175-WLM-240-051, Dated 5/4/01, Mechanical Mods for Tractor

Controls.

D USCG Drawing – 175-WLM-245-001 Rev. A, Dated 8/31/1998, Propeller.

E Technical Publication 3613, Dated 9/24/2002, Z-Drive, WLM 175’ Coastal Buoy

Tender.

F Engineering Change 175-A-029, Dated 4/22/2004, Tractor Control Installation.

G USCG Surface Forces Logistics Center (SFLC) – Specification R-245-175WLM

2.2.2. Military Specifications

A MIL-PRF-24647D (SH), Dated 06/12/2006, Performance Specification, Paint

System, Anti-Corrosive and Anti-Fouling, Ship Hull.

B QPL-24647-10, Dated 05/25/2006, Qualified Products List of Products Qualified Under Performance Specification MIL-PRF-24647, Paint System, Anti-Corrosive and Anti-Fouling, Ship Hull.

2.3. Commercial Documents – The Following documents form a part of this specification to the extent specified herein. The documents shall be the version listed by number and date from the referenced industry organization.

2.3.1. National Conference of Standards Laboratories (NCSL) - NCSL Z540-3-2006

Dated 1/01/2006, Calibration Laboratories and Measuring and Test Equipment – General Requirements.

2.3.2. American Society for Quality Control (ASQ) - ASQ Q9001-2008, Dated 2008, Quality Management Systems – Requirements.

2.3.3. American Society for Testing Materials (ASTM) - ASTM D-3951-98, Dated 11/10/1998 (R-2004), Standard Practice for Commercial Packaging.

2.3.4. International Standards Organization (ISO) – ISO 9001, Dated 2008

2.4. 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.

Nothing in this specification, however, supersedes applicable laws and regulations unless a specific exemption has been obtained.

REV A Change 2 DATED 11/03/2011

2.5. Document Availability – To obtain the referenced documents see section 6.0 of this specification.

3.0 REQUIREMENTS

3.1. General – The Contractor shall provide all labor, equipment and materials required to receipt for, store, disassemble, inspect, overhaul, reassemble, test, preserve, package, pack, mark, warehouse, and provide all documentation cited herein for each Ulstein Aquamaster Model 1350H Z-Drive assembly provided by the U.S. Coast Guard. Each Z-Drive overhaul shall be performed in accordance with applicable technical manuals, drawings, specifications and standard commercial practices.

3.1.1. After completing each Z-Drive overhaul, the final packaged Z-Drive system shall consist of all assemblies listed in 3.2.1 and the following additional items:

A New mounting gasket, P/N B8107128; Qty-001 B New hex cap screws Gr. 5, P/N HX1.25C5.00; Qty-076 C New hex nuts Gr. 5, P/N HXN1.25C; Qty-076 D New hex jam nuts, P/N HN1.25NCJMG5; Qty-076

Note: Many of the part numbers cited throughout this specification are generally specific to the currently recognized OEM. However, substitute Z-Drive part(s) assigned different part numbers that could satisfy USCG form, fit, and function requirements will be considered by the Contracting Officer on a case basis.

3.2. Government Furnished Property (GFP) – The Contractor shall provide inside storage for all GFP offering complete protection from the weather elements, stored on the original shipping skid when not in use.

3.2.1. Z-Drive Completeness Assessment - The Contractor shall complete a full equipment inventory of any Z-Drive delivered and receipted for under this contract.

A complete Z-Drive assembly should consist of the following assemblies:

A Upper Unit Assembly B Pneumatic Clutch Assembly C Clutch Adapter Assembly D Steering Gear Assembly E Intermediate Assembly F Lower Unit Assembly G STBD or PORT Propeller and Nozzle Assembly (as applicable) H STBD or PORT Module Assembly (as applicable) I STBD or PORT Upper Unit Hydraulic Assembly (as applicable) J STBD or PORT Lube Distribution Assembly (as applicable) K STBD or PORT Pneumatic Control Assembly (as applicable) L Feedback Electronic Assembly

REV A Change 2 DATED 11/03/2011

M Feedback Box Assembly N Feedback Box Assembly (For Tractor Control) O Feedback Sensor Assembly (P4) (For Tractor Control) P Junction Box Assembly Q Junction Box Assembly (For Tractor Control)

3.2.2. The Contractor shall immediately contact the Contracting Officer for any Z-Drive

Assembly that is incomplete. Additionally, the Contractor shall complete and submit a Government Furnished Property Discrepancy Report form (see section 6.0) to the Contracting Officer for any missing items/assemblies or incomplete assemblies within (21) calendar days after receipt of the discrepant Z-Drive assembly.

3.3. Z-Drive Inspection Preparation: Once authorized by the Contracting Officer, any Z-

Drive inducted for overhaul shall be prepared for inspection as indicated below.

3.3.1. Uncrate and remove any preservative and all existing protective coverings.

3.3.2. Thoroughly clean the Z-Drive to remove all surface contaminants in preparation for a detailed Pre-Overhaul Inspection.

3.4. Z-Drive Pre-Overhaul Inspection – After cleaning, the Contractor shall completely disassemble the unit and perform a detailed Pre-Overhaul Inspection of components in accordance with applicable technical manuals, drawings and standard commercial practices.

3.4.1. Z-Drive Pre-Overhaul Inspection Report – Results of the inspection shall be fully documented in a Contractor prepared Pre-Overhaul Inspection Report which shall be submitted to the Contracting Officer for review. This report shall be organized and identified by Z-Drive serial number, contract number, delivery order number, and assembly or sub assembly with applicable serial/part numbers. The report shall also include the following information:

A Dimensional data for all measured components

B Propeller condition including a detailed sketch and/or digital photographs showing the location and severity of all defects and irregularities noted in accordance with 2.2.1.h.

C A detailed sketch and/or digital photographs showing the location and severity of all significant defects and irregularities on the Z-Drive assembly and associated parts. A significant defect shall be defined as any part or module assembly whose repair or replacement will substantially impact cost and/or the delivery schedule due to its material condition or replacement lead time. Key components to be

REV A Change 2 DATED 11/03/2011 considered include but are not limited to bearing journals, bearing housings, seal areas, ring and pinion gears, and gear shafts.

D Condition assessment of the beveled gear sets. Note: If renewal of these gear sets is required, correct configuration/orientation gear sets shall be utilized.

E Inspection/validation of Tractor Control mechanical modifications.

F The condition of the shipping container/skid with digital photographs and recommendations for repair or renewal.

G Overhaul recommendations that include a breakdown of all proposed labor, materials, costs, parts, and estimated time necessary to restore each Z-Drive to “like new” visual and mechanical condition configured to current USCG requirements.

3.5. Review of Z-Drive Pre-Overhaul Inspection Report – Upon receipt, the Contracting

Officer’s designated technical representative will review the Z-Drive Pre-Overhaul Inspection Report to determine completeness and reasonableness of proposed overhaul recommendations. No further work shall be performed until directed in writing by the Contracting Officer.

3.6. Authority to proceed with Z-Drive Repair – The Contracting Officer will provide the

Contractor with notification that outlines all overhaul recommendations that are approved and authorized. All original Contractor overhaul recommendations that are not approved shall not be accomplished. All assembly/component overhaul and test procedures shall conform to applicable specifications and commercial standards.

3.7. Z-Drive Assembly Configuration Control – Each overhauled Z-Drive Assembly shall be configured to the sub-assemblies and associated part numbers outlined below.

Additional modifications, upgrades, or changes are not authorized without written consent of the Contracting Officer.

3.7.1. Port Z-Drive Assembly; P/N B8202396-002 (General Arrangement)

A Upper Unit Assembly; P/N D8202397 or D8202430 (as applicable) B Pneumatic Clutch Assembly; P/N D8202364 C Clutch Adapter Assembly; P/N D8202381 D Steering Gear Assembly; P/N B8202388 E Intermediate Assembly; P/N B8202398 F Lower Unit Assembly; P/N D8202369 or D8202431 (as applicable) G Port Prop & Nozzle Assembly; P/N B8202395/PRS24 or B8202432/PRS24

(applicable if option for S/S insert in Nozzle is exercised) or B8202399/PRS124 (applicable if option for steel nozzle with 5 blade propeller is exercised) or

REV A Change 2 DATED 11/03/2011

B8202440/PRS124 (applicable if option for S/S insert in Nozzle with 5 blade propeller is exercised)

H Port Module Assembly Modified; P/N B8202373-2 I Port Upper Unit Hydraulic Assembly; P/N B8107214-2 J Port Lube Distribution Assembly; P/N B8107177-2 K Port Pneumatic Control Assembly; P/N B8202387-2 L Feedback Electronic Assembly; P/N B8107187 M Feedback Box Assembly; P/N B8104751 N Feedback Box Assembly (Tractor Control); P/N B8102328 O Feedback Sensor Assembly (P4) (Tractor Control); P/N B8105064 P Junction Box Assembly; P/N B8107573 Q Junction Box Assembly (Tractor Control); P/N B8109564

3.7.2. Starboard Z-Drive Assembly; P/N B8202396-001 (General Arrangement)

A Upper Unit Assembly; P/N D8202397 B Pneumatic Clutch Assembly; P/N D8202364 C Clutch Adapter Assembly; P/N D8202381 D Steering Gear Assembly; P/N B8202388 E Intermediate Assembly; P/N B8202398 F Lower Unit Assembly; P/N D8202369 G Starboard Prop & Nozzle Assembly; P/N B8202395/PRS21 or B8202432/PRS21

(applicable if option for S/S insert in Nozzle is exercised) or B8202399/PRS123 (applicable if option for steel nozzle with 5 blade propeller is exercised) or B8202440/PRS123 (applicable if option for S/S insert in Nozzle with 5 blade propeller is exercised)

H Starboard Module Assembly Modified; P/N B8202373-1 I Starboard Upper Unit Hydraulic Assembly; P/N B8107214-1 J Starboard Lube Distribution Assembly; P/N B8107177-1 K Starboard Pneumatic Control Assembly; P/N B8202387-1 L Feedback Electronic Assembly; P/N B8107187 M Feedback Box Assembly; P/N B8104751 N Feedback Box Assembly (Tractor Control); P/N B8102328 O Feedback Sensor Assembly (P4) (Tractor Control); P/N B8105064 P Junction Box Assembly; P/N B8107573 Q Junction Box Assembly (Tractor Control); P/N B8109564

Note: Many of the part numbers cited throughout this specification are generally specific to the currently recognized OEM. However, substitute Z-Drive part(s) assigned different part numbers that could satisfy USCG form, fit, and function requirements will be considered by the Contracting Officer on a case basis.

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3.8. Overhaul Parts – Only new parts shall be installed.

3.8.1. Ring and Pinion Gear Sets – All ring and pinion gears shall be hard cut to reduce premature wearing of the gear faces.

3.8.2. Expendable / Consumable Parts – The Contractor shall provide and install all new pressure switches, temperature switches, micro-switches, pressure transducers, potentiometers, gaskets, seals, o-rings, flexible hoses and approved sealant as specified in applicable technical repair manuals and this specification during reassembly.

3.8.3. Mandatory Replacement Parts – The parts listed in APPENDIX A of this specification shall be renewed regardless of age and/or condition.

3.8.4. Contingency Replacement Parts – Individual parts listed in APPENDIX B of this specification shall only be renewed when directed by the Contracting Officer based primarily on the Pre-Overhaul Inspection Report.

3.8.5. Scrap and Discarded Parts – Parts and/or assemblies determined to be beyond economical repair and subsequently scrapped shall be secured in a designated storage area and individually tagged. Each tag shall include the applicable Z-Drive serial number, contract/delivery order number, part description, and associated part number, reason for rejection, inspector and date.

A All scrap parts will be inspected and verified by a Coast Guard Representative.

B After CG inspection, the Contractor shall either return or locally dispose all scrap parts/assemblies as directed by the Contracting Officer.

3.8.6. Long Lead Time Parts/Assemblies – The Contractor shall procure and manage specific high cost/long lead time parts/assemblies as listed in APPENDIX C per the quantities indicated. It is the intent of this requirement to insure there are sufficient long lead time parts/assemblies readily available to support projected Z-Drive overhaul requirements for the duration of the contract. Initial stocking levels for these parts will be funded by the Coast Guard through issuance of a onetime individual delivery order citing the applicable contract line item (CLIN) immediately after the contract is awarded. Planned expenditure of any listed long lead time part(s) or assembly(s) on a given Z-Drive overhaul shall be noted on the applicable inspection report and reordered by the Contractor within 5 calendar days after installation.

3.9. Prop Shaft & Steering Seal Kits – The Contractor shall insure a minimum of two (02) Prop Shaft and Steering Seal Kits are stocked at all times to support 175’ WLM Z-Drive scheduled and emergency dry-dock work for the duration of the contract. Seal kit(s) will be acquired and funded through issuance of an individual delivery order citing the

REV A Change 2 DATED 11/03/2011 applicable contract CLIN on an as needed basis. Each kit shall include all of the parts listed in APPENDIX D and be packaged/packed in accordance with standard commercial practices. Seal Kit(s) shall be shipped no later than 48 hours after receipt of the delivery order.

3.10. Z-Drive Propeller – The propeller provided with each Z-Drive shall be removed, cleaned, inspected, refurbished, and reinstalled in accordance with USCG Drawing 175- WLM-245-001 and specification R-245-175WLM (APPENDIX E). The intent of this requirement is to restore the propeller to its “original” design and performance attributes.

3.10.1. A Coast Guard SFLC Quality Assurance Representative will witness final acceptance inspection/tests of each propeller, regardless of location, to validate conformance to specification requirements.

3.10.2. The Contractor shall also blue fit each refurbished propeller to its assigned Z-drive output shaft to insure acceptable contact. This procedure shall be done in the presence of an SFLC QA Representative.

3.11. Flexible Hoses – All hydraulic and other flexible hoses associated with each Z-Drive overhaul shall be renewed. Each installed hose shall have a minimum service life of eight (08) years and be tested to 150% of normal operating pressure.

3.11.1. Additional Hose Requirements – Each flexible hose shall have a corrosion resistant tag attached using stainless steel locking wire. Each tag shall be neatly and legibly stamped with the following information:

A Serial Number

B Hydrostatic Test Pressure Date [DD/MM/YY]. This may be provided by the assembly manufacturer on a separate tag.

C Service Life Date (Replacement Date) [QTR”Q”/YY]. References to calendar year quarter shall include the letter “Q” after the quarter number to avoid confusion with months. The 1st quarter of 2012 would be represented by “1Q12”.

3.12. Cleaning and Finishing – The Contractor shall clean and polish all machined surfaces as necessary to remove any etching, scoring or other imperfections that might compromise operation of the Z-Drive or the final surface coating system.

3.13. Exterior Paint Specification/Surface Coating – The surface coating shall be applied in accordance with Rolls-Royce Canada Ltd paint specification PS30 or industry equivalent.

3.14. Z-Drive Reassembly Report – The Contractor shall document all measurements/tests indicated in 3.13.1. This data shall be collated into a neat, orderly, and legible Post

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Overhaul Inspection Report and submitted to the Contracting Officer for review and approval. If this report is determined to be acceptable, the Contracting Officer will authorize SFLC Quality Assurance Representative to schedule final acceptance inspections and tests at the Contractor’s facility as outlined in section 4.6 of this

3.14.1. Post Overhaul Inspection Report Criteria – At a minimum, each report shall include the following information:

A Contract Number; Delivery Order Number; Z-Drive Serial Number; Contractor Name, Address and Telephone Number

B All higher assemblies by part number/nomenclature to include a summary of work performed during the overhaul process. Related, a list of all associated piece parts that were renewed or rebuilt.

C All measurements/tests that were taken in accordance with standard commercial practices.

3.15. Z-Drive Performance Tests and Inspections – The Contractor shall perform the following tests/inspections on each overhauled Z-Drive to validate conformance to overhaul requirements and standards.

3.15.1. Spin Test - An approved in-plant spin test procedure shall be performed and documented.

A Any spin test procedure must be submitted to the Contracting Officer for review and approval prior to use.

B Spin tests may be initiated as necessary until the Contractor’s internal QA requirements are satisfied. However, for CG acceptance purposes, a final spin test of each overhauled Z-Drive must be successfully performed in the presence of an SFLC QA representative.

C Prior to the final spin test procedure, all gear contact faces shall be coated with an oil resistant dye.

3.15.2. Hydraulic Steering Test – In conjunction with 3.14.1, the Contractor shall demonstrate that the hydraulic steering system is free of any leaks, unusual noise, or excess vibration by pressurizing and exercising the steering system such that the nozzle is rotated in both directions through several complete cycles.

3.15.3. Gear Contact Pattern Inspection – After the final acceptance spin test procedure has concluded, the Contractor shall perform a joint inspection with

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SFLCs QA Representative of all accessible gear faces to validate acceptable gear contact pattern.

3.16. Warranty General – Each overhauled Z-Drive shall be considered “System Stock”.

Therefore, the Contractor shall ensure long term preservation/storage maintenance requirements are satisfied such that the standard manufacturer’s warranty is preserved.

This warranty shall guarantee that each overhauled Z-Drive System, when installed under the supervision of the Contractor’s Field Service Representative, will be free from defects that could lead to premature failure for a period of one (01) year.

3.16.1. Onsite Warranty Claim Assessment – At the request of the Contracting Officer, the Contractor shall provide onsite technical expertise to evaluate all potential warranty issues wherever the vessel is located. In the event that a warranty claim is substantiated and the Z-Drive must be removed to accomplish repairs through dry-docking or dockside arrangements utilizing ships force and/or shore personnel, the Contractor shall provide a qualified field service representative to oversee all aspects of removal, repair, and installation in accordance with established procedures and specifications.

3.16.2. Warranty Response – The Contractor shall provide a Field Service

Representative to the vessels designated location within 72 hours after notification of a potential warranty claim by the Contracting Officer.

3.16.3. Warranty Parts – The Contractor shall be responsible for obtaining all parts needed to correct a warranty claim.

3.16.4. Warranty Completion Report – The Contractor shall submit a Warranty

Completion Report to the Contracting Officer within seven (07) calendar days of warranty resolution. At a minimum, this report shall contain the following information:

A Contract number and Delivery Order number B Z-Drive serial number C Hours since overhaul D Summary of condition found and corrective action(s) taken E Parts expended to correct failure (if applicable) F Name of the servicing technician G Arrival and departure dates/times

3.17. Overhauled Z-Drive Installation Support – At the request of the Contracting Officer, the Contractor shall dispatch a certified Service Representative to any Coast Guard vessel where installation of any Z-Drive overhauled under this contract is planned. The primary role of the Service Representative shall be to ensure that the installation and subsequent operational tests fully comply with established procedures and standard

REV A Change 2 DATED 11/03/2011 commercial practices and therefore do not in any way void or affect the Contractor’s warranty, if applicable.

3.17.1. The cost of the Service Representative shall be computed using a daily flat rate charge based on a normal eight hour workday that excludes weekends and recognized holidays. Additional charges for installation work performed on weekends and holidays shall be negotiated between the Contracting Officer and the Contractor as required. The flat rate charge shall be a separate contract line item. In addition to the flat rate charge, the contractor will be reimbursed by the Coast Guard for costs incurred for transportation (coach rate for airlines and mid-size for rental cars), lodging and meals as delineated in the Joint Federal Travel Regulation (JFTR) and FAR Part 33.

3.17.2. If a Z-Drive is being shipped directly from the Contractor’s facility to a Coast

Guard vessel for immediate installation, the cost of the Service Representative will be included as a separate line item in the delivery order for that particular unit. If the Z-Drive is issued from SFLC stock, funding for the Service Representative will be provided through issuance of an individual delivery order under the contract.

3.17.3. In each event that mandates the services of a Service Representative, the

Contracting Officer and the Contractor shall mutually agree on the inclusive dates, times, and physical location required. Once established, only the Contracting Officer may authorize changes to this agreement.

3.18. Troubleshooting and Repair Services - In addition to the requirements outlined in section 3.16, the Contractor shall provide a certified Service Technician when requested by the Contracting Officer for onsite Z-Drive technical services that include but are not limited to troubleshooting, system/component repair or replacement, technical oversight for removals/installs, equipment upgrades/ modifications, and vibration analysis. It is the intent of this provision to provide service support for all Z-Drives within the cutter class when required, and therefore may not be linked to a specific Z-drive that was overhauled under this contract.

3.18.1. Each event (service call), when requested, will be funded through issuance of an individual delivery order under the contract. This document will also define the specific requirements, the affected vessel and its current location, and the inclusive dates/times by Contractor/Contracting Officer mutual agreement for the service to be rendered. Note: Once established, only the Contracting Officer may authorize changes to this agreement.

3.18.2. The cost of the Service Technician shall be computed using a daily flat rate charge based on a normal eight hour workday that excludes weekends and recognized holidays. Additional charges for troubleshooting and repair service performed over weekends and holidays shall be negotiated between the

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Contracting Officer and the Contractor as required. In addition to the flat rate charge, the contractor will be reimbursed by the Coast Guard for costs incurred for transportation (coach rate for airlines and mid-size for rental cars), lodging and meals as delineated in the Joint Federal Travel Regulation (JFTR) and FAR Part 33.

3.18.3. Service Completion Report – The Contractor shall submit a Service Completion

Report to the Contracting Officer within seven (07) calendar days after all tasks have been satisfied for each delivery order. At a minimum, this report shall contain the following information:

A Contract number and Delivery Order number B Name and physical location of U.S. Coast Guard vessel C Z-Drive serial number D Summary of work performed with attachments (if applicable) and any follow-on recommendations E Parts expended (if applicable) F Name of Service Technician G Arrival and departure dates/times

3.19. Warehousing, Maintenance & Distribution – The Contractor shall provide warehousing, maintenance and distribution services for all spare Z-Drives (3 Port & 3 Starboard) managed in SFLCs rotatable pool for the duration of this contract.

Requirements specific to this section are outlined in APPENDIX F.

3.20. Notifications & Inspections – The Contractor shall be responsible for notifying the

Contracting Officer at least seven (07) working days prior to any inspections or testing that require the presence of an SFLC QA Representative.

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 in accordance with ISO 9001, documented and available for review by the Coast Guard.

4.2. Records – The Contractor shall maintain records of all inspections and tests. At a minimum, these records shall indicate the nature and number of observations made, the number and type of deficiencies found, and any corrective action(s) taken.

4.3. Calibration System – The Contractor, and any subcontractors, shall be required to maintain a test equipment calibration program in compliance with ISO 9001. The program shall be documented and traceable to the National Institute of Standards

(NIST).

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4.4. Responsibility for Inspection – The Contractor shall be responsible for the performance of all inspection requirements specified herein and shall provide adequate space, personnel, and calibrated test equipment to satisfy inspection/test criteria. All inspections/tests shall be performed at the Contractor’s facility unless other locations are requested by the Contractor in advance and approved by the Contracting Officer. The Coast Guard reserves the right to verify or have performed any of the inspections that are deemed necessary to assure each overhauled Z-Drive conforms to contract requirements.

4.5. 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.

4.6. Tests & Inspections – The inspections/tests required herein shall be witnessed by an

SFLC Quality Assurance Representative and are the minimum required. They are not intended to supplant any controls, examination, or in-process inspections/tests normally employed by the Contractor to assure the quality of the item in question. Note: The Contractor shall have the latest versions of the drawings, specifications, tolerances and approved test procedures readily available for any of the inspections listed.

4.6.1. Post Overhaul Tests and Inspections

A. Z-Drive spin test (refer to section 3.14.1 B.)

B. Hydraulic Steering Test (refer to section 3.14.2)

C. Gear tooth contact impression inspection (refer to section 3.14.3)

D. Propeller to Z-drive output shaft blue fit (refer to section 3.9.2)

E. Accessory inspection/validation (refer to section 3.8.5 A)

F. Preservation, Packaging, Packing and Marking Inspection (refer to section 5.5)

G. Propeller Post Repair Inspections/Tests as outlined in reference 2.2.1.G.

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

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4.7.1. A copy of any test/ inspection report shall be provided to the Quality Assurance Representative upon his/her arrival at the Contractors’ facility.

4.7.2. A copy of the approved in-plant Spin Test shall be placed in the box of loose parts in waterproof packaging.

4.8. Packing Inspection – The Contracting Officer shall be notified prior to the packaging and marking of the completed Z-Drive in accordance with section 3.19 of this

5.0 PRESERVATION, PACKAGING, PACKING, & MARKING

5.1. Preservation – Each Z-Drive assembly shall be preserved/packaged in accordance with ASTM-D-3951 and prepared for storage or shipment within five (5) calendar days after the completion of all final acceptance test(s) and inspection(s). To prevent internal corrosion and deterioration, each Z-Drive shall be treated with an internal anti-corrosion compound (VSI Circulating Oil 32 or equivalent) in accordance with the manufacturers’ instructions. Additionally, the Contractor shall ensure all openings are blanked off or plugged with suitable materials that are attached in a manner that will prevent accidental dislodging during transit or handling. Preservation treatment shall be sufficient to provide protection against corrosion and seal hardening for a period of at least two (02) years.

5.2. Packaging and Packing – Refer to APPENDIX F

5.3. Marking – Refer to APPENDIX F

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 SFLC specification D-000-0100.

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.

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6.0 NOTES

6.1. Coast Guard & Commercial Document Sources

6.1.1. Coast Guard Documents

A. USCG Surface Forces Logistics Center 2401 Hawkins Point Road Baltimore, MD. 21226-5000 410-762-6474 (K.A.)

ATTN: CPD/IBCT PL

www.uscg.mil/hq/SFLCbalt/

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 St. 4th Floor New York, NY 10036 212-642-4900

FAX 212-398-0023

www.ansi.org

D. American Society for Quality (ASQ)

600 N. Plankinton Ave Milwaukee Wisconsin 53202

PH 414-272-8575 FAX 414-272-1734

www.asq.org

APPENDIX A

UPPER UNIT ASSEMBLY

Item Number Description Qty

Item Number Description Qty

1004 Key 1 1053 O-Ring 1 1006 Shim Set 1 1054 O-Ring 1 1008 Shim Set 1 1060 Hex Capscrew 16 1013 Shim Set 1 1061 Hex Capscrew 14 1015 Shim Set 1 1062 Hex Capscrew 24 1017 Key 1 1063 Hex Capscrew 12 1019 Gasket 1 1064 Hex Capscrew 12 1027 Hex Plug 1 1065 Hex Capscrew 12 1030 Bearing Cone 1 1067 Hex Capscrew 10 1031 Bearing Cup 1 1072 Key 2 1032 Bearing Cone 3 1077 Seal 1 1033 Bearing Cup 3 1078 Locking Nut 1 1034 Bearing 1 1079 Socket Countersunk Screw 4 1035 Bearing 1 1083 Proximity Sensor 1 1036 Lockwasher 1 1086 Hex Capscrew 2 1037 Lockwasher 1 1087 Locknut 1 1038 Lockwasher 1 1088 Lockwasher 1 1039 Locknut 1 1089 Socket Capscrew 8 1040 Locknut 1 1093 Micro Switch 4 1041 Locknut 1 1094 Machine Screw 4 1045 Filler Breather 1 1095 Hex Bolt 1 1047 Quick Exhaust Valve/Kit 1096 Spacer 1 1050 Seal (VITON) 2 1097 Proximity Sensor 1 1052 O-Ring 1 1098 Connector 1

STEERING GEAR ASSEMBLY

Item Number Description Qty Item

Number Description Qty

2002 Shim set 1 2021 Shim Set 2 2003 Hex Capscrew 24 2025 Gasket 2 2005 O-Ring 2 2026 Hex Capscrew 24 2009 Bearing Cone 4 2027.1 Male ORB/JIC Connector 1 2010 Bearing Cup 4 2027.2 O-Ring 1 2011 Lockwasher 2 2029 X-Over Relief Valve 2 2012 Locknut 2 2029.1 O-Ring 4 2013 Shim Set 2 2030.1 O-Ring 4 2014 Hex Capscrew 32 2034 Socket Capscrew 12 2016 O-ring 2 2035 Spring Lockwasher 12 2018 Socket Capcsrew 14

REV A Change 2 DATED 11/03/2011

INTERMEDIATE ASSEMBLY

Item Number Description Qty Item

Number Description Qty

3003 Spacer 1 3017 Hex Capscrew (SS) 16 3005 Shim Set 1 3020 Retaining Ring 2 3006 Seal Ring 1 3021 Gasket 1 3008 Seal 2 3022 Hardened Flat Washer 24 3009 Coupling 2 3023 Hex Plug SS 1 3010 Bearing 1 3024 Male Pipe/JIC 90 Elbow 2 3011 Adapter 1 3025 Sleeve 2 3012 Bearing 1 3026 Nut 2 3013 Socket Head Pipe Plug 2 3027 Tubing 622 3014 Hexhead Plug 1 3028 Nipple 1 3015 Hex Capscrew 24 3029 Socket Head Pipe Plug 2 3016 Hex Capscrew 16

LOWER UNIT ASSEMBLY

Item Number Description Qty Item

Number Description Qty

4006 O-Ring 1 4050 Spacer 2 4007 Shim Set 1 4051 Spacer 1 4009 Sleeve 1 4052 Spring 6 4010 Spacer 1 4053 Spring Pin 1 4011 Spring 4 4054 O-Ring 2 4012 O-Ring 1 4060 Bearing 2 4013 Spring Pin 2 4061 Bearing 1 4014 Shroud Mods-Rope Cutter 1 4062 Bearing 1 4020 Bearing 2 4064 Lockwasher 1 4021 Bearing 1 4066 Locknut 1 4022 Bearing 1 4067 Retaining Ring 1 4023 Lockwasher 1 4068 O-Ring 2 4024 Locknut 1 4069 O-Ring 1 4025 Hollow Hex Plug SS 1 4070 O-Ring 1

4026 Prop Shaft Seal Assembly

(240) 1

4071 O-Ring 1

4030 Hex Capscrew 24 4072 O-Ring 1 4031 Hex Capscrew 16 4076 Socket Capscrew 12 4032 Socket Capscrew 16 4077 Socket Capscrew 19 4033 Socket Capscrew 16 4078 Socket Capscrew 14 4036 Socket Capscrew (SS) 16 4079 Socket Capscrew 4 4044 Anti Rollover Plate 1 4084 O-Ring 2 4046 Shim Set 1 4093 O-Ring 2 4048 Key 1 4095 Hollow Hex Plug SS 3 4049 Thrust Button 1 4096 O-Ring 1

REV A Change 2 DATED 11/03/2011

MODULE ASSEMBLY

Item Number Description Qty Item

Number Description Qty

6001 Module Mod 1 6007 Hex Capscrew (Gr. 5) 76 6002 O-Ring 1 6008 Hex Nut (Gr. 5) 76 6003 Hex Capscrew 24 6009 O-Ring 1 6004 Hex Nut 24 6010 Hex Nut (Jam GR5) 76 6006 Gasket 1

PROPELLER & NOZZLE ASSEMBLY

Item Number Description Qty Item

Number Description Qty

4802 Gasket 1 4810.01 Anode Assy 1 4804 Propeller Key 1 4812 Socket Capscrew 13 4805 Socket Capscrew 2 4813 Shoulder Screw 4 4807 O-Ring 1 4815 Line Reels 1 4808 Socker Capscrew SS 1 P+N 4801 Prop Mods 1 4809 Hollow Hex Plug SS 1

UPPER UNIT HYDRAULICS ASSEMBLY

Item Number Description Qty Item

Number Description Qty

1704 Flat Washer 4 1715 Hose-Hyd 1701 1705 Hex Capscrew 4 1720 Flow Divider Assembly 1 1706 Male Pipe/JIC 90 Deg Elbow 2 1721 Hose Assembly 1 1707 Female JIC Swivel Straight 2 1722 Hose Assembly 1 1708 Female JIC Swivel Straight 4 1723 Hex Capscrew 2

1710 Fem. JIC Swivel 90 Deg Short 6 1724 Hex Locknut 2

1713 Hose-Hyd No Skive 787 Female JIC Cap 7 1714 Hose-Hyd No Skive 2769 Female JIC Cap 4

LUBE DISTRIBUTION ASSEMBLY

Item Number Description Qty Item

Number Description Qty

1802 Relief Valve Cartridge 1 1815 Temperature Switch (SS) 1 1803 Relief Valve Block 1 1816 Thermometer 1

1804.1 Filter 6 1817 Thermowell 1

1804.2 O-Ring 1 1818 RTD 1

1804.3 Filter Element Connector 2 1821 Pressure Transmitter 1

1805 Press Gage (0-160 PSI/KPA) 1 1822 Pipe Street Tee 1

1806 Pressure Switch 2 1823 Pipe Street Tee 1 1807 Cover 2 1824 Test Point 2 1808 Male Pipe Hex Nipple 2 1825 Male Straight 2 1809 Male Pipe/JIC Connector 1 1826 Valve 1 1810 Male Pipe/JIC Connector 5 1827 Hollow Hex Pipe Plug 1 1811 Male Pipe/JIC 90 Deg Elbow 1 1828 Pipe Street Tee 1 1812 Hollow Hex Pipe Plug 1 1829 Reducer Bushing 1

REV A Change 2 DATED 11/03/2011

LUBE DISTRIBUTION ASSEMBLY (cont.)

Item Number Description Qty Item

Number Description Qty

1813 Hollow Hex Pipe Plug 3 1830 Strain Relief 2 1814 Male Pipe Hex Nipple 2

PNEUMATIC CONTROL ASSEMBLY

Item Number Description Qty Item

Number Description Qty

9401 Valve 1 9416 Pressure Transmitter 1 9403 Hex Capscrew 4 9417 Male Straight 1 9404 Hex Capscrew 2 9418 Snubber/Shutoff Valve 2 9405 Flat Washer 4 9419 Hollow Hex Pipe Plug 1 9406 Flat Washer 4 9420 Hollow Hex Pipe Plug 1 9408 Male Pipe/JIC 45 Deg Elbow 2 9422 Male Pipe/JIC Connector 1 9409 Hose - Hyd No Skive 902 9423 Sensor Block 1 9410 Male JIC/Female Pipe Conn 1 9427 Pipe Street Tee 1 9411 Male Pipe Hex Nipple 1 9428 Minicheck Test Point 1 9412 Male Pipe Nipple 1 9429 Hex Capscrew 2 9413 Male Pipe Hex Nipple 1 9430 Female JIC Swivel Straight 2 9414 Pressure Switch 4 9431 Female JIC Swivel 45 Short 1 9415 Cover 4 9432 Female JIC Swivel 90 Short 1

FEEDBACK BOX ASSEMBLY – B8104751

Item Number Description Qty Item

Number Description Qty

Feedback Box Assembly 1

STEERING FEEDBACK ELECTRONIC ASSEMBLY

Item Number Description Qty Item

Number Description Qty

2001 Potentiometer 1 2218 Coupling 1 2202 Synchro 1 2219 Coupling 1 2203 Cam 1 2220 Strain Relief 2 2204 Mounting Bracket 2 2221 Socket Setscrew #8-32 2 2205 Micro Switch 2 2222 Selsen Housing 1 2206 Gasket 2 2224 O-Ring 1 2207 Socket Capscrew 10 2225 Threaded Rod (SS) 85 2208 Socket Capscrew 10 2226 Terminal Strip 1 2209 Socket Capscrew 6 2227 Machine Screw - Pan HD 4 2210 Gasket 1 2228 Flat Washer 8 2211 Cover 1 2230 Hex Locknut (SS) 2 2213 Socket Setscrew 1 2231 Ring Terminal 22 2214 Strain Relief 2 2232 Flat Washer 4 2215 Cover Assembly 1 2233 Flat Washer (Fibre) 2 2216 Cam Housing 1 2234 Cable Clamp 2 2217 Cam Housing Plate 1 2235 Machine Screw - Round HD 2

REV A Change 2 DATED 11/03/2011

FEEDBACK BOX ASSEMBLY (for tractor control)

Item Number Description Qty Item

Number Description Qty

Feedback Box Assembly 1

FEEDBACK SENSOR ASSEMBLY (P4)( for tractor controls)

Number Description Qty Item

Number Description Qty

1 Feedback Sensor Cover Assy 1 13 Socket Setscrew 5

2 Synchro (Indication) 1 14 Gasket 1 3 Synchro (Feedback) 1 15 Terminal Strip 1 4 Coupling 1 16 Wire Ferrule 10 5 Coupling 1 17 Wire Ferrule 20 6 Strain Relief 1 19 Cable 2500 7 Socket Set Screw #8-32 2 20 Cable Clamp 2 8 Selsyn Housing 1 21 Machine Screw-Round Head 2

10 O-ring 1 22 Flat Washer (Fibre) 2 11 Threaded Rod (SS) 85 23 Hex Locknut (SS) 2 12 Socket Capscrew 2 24 Ring Terminal 20

REV A Change 2 DATED 11/03/2011

APPENDIX B

CONTINGENCY PARTS LIST

Number Description U/I Item

Number Description U/I

UPPER

1003 Upper Gear Set Set INTER

3018 Torque Tube Ea

UPPER

1007 Input Bearing Retainer Ea INTER

3019 Plate Ea

UPPER

1016 Coupling Hub Ea LOWER

4001 Pod Ea

UPPER

1046 Roto Coupling Ea LOWER

4003 Lower Gear Set Set

UPPER

1070 Clutch Adapter Ea LOWER

4004 Thrust Plate Ea

UPPER

1075 Clutch Ea LOWER

4005 Nose Cone Ea

UPPER

1091 Shaft Lock Pin EA LOWER

4008 Bearing Housing Ea

UPPER

1092 Shaft Lock Pin Holder Ea LOWER

4014.1 Half Shroud Ea

STEER

2001 Steering Gear Set Set LOWER

4040 Leg Ea

STEER

2004 Steering Gear Housing Ea LOWER

4045 Bearing Housing Ea

STEER

2007 Bearing Housing Ea LOWER

4047 Coupling Hub Ea

STEER

2015 Modified Hydraulic Motor Ea

PROP &

NOZZLE

Nozzle Ea

INTER

3001 Intermediate Housing Ea

PROP &

NOZZLE

Strut Ea

INTER

3002 Steering Tube Ea

PROP &

NOZZLE

Nozzle Pad Ea

INTER

3004 Pre-load Ring Ea

APPENDIX C

Z-DRIVE LONG LEAD TIME PARTS LIST

(GREATER THAN 4 MONTHS TO ACQUIRE)

ITEM

NUMBER

CURRENT PART

DESCRIPTION QUANTITY

Upper 1001 B8107028 & B8107027 Upper Housing 1

Upper 1002 D8107156 Input Shaft 1 Upper 1003 D8107078 Upper Gear Set 2 Upper 1005 D8107079 Bearing Housing 1 Upper 1010 D8107059 Upper Vertical Shaft 1 Upper 1012 D8102566-ST Bearing Housing 1 Upper 1016 B8106341 Coupling Hub 1 Upper 1030 HH923649 Bearing Cone 1 Upper 1031 HH923610 Bearing Cup 1 Upper 1032 HM926740 Bearing Cone 3 Upper1033 HM926710 Bearing Cup 3 Upper 1046 B8202382 Roto Coupling 1 Upper 1047 B8202428 Qk Exhaust Valve/Silencer Kit 1 Upper 1070 D8202381 Clutch Adapter 2 Upper 1075 D8202364 Clutch 2 Upper 1077 B8202429 Seal 1 Steer 2001 C8102339/c8102364 Steering Gear Set 2 Steer 2004 D8102652 Steering Gear Housing 1 Steer 2009 HM926747 Bearing Cone 4 Steer 2010 HM926710 Bearing Cup 4 Inter 3002 D8107101 Steering Tube 2 Inter 3018 C8107099 Torque Tube 2 Lower 4001 D8107090 Pod 1 Lower 4002 D8102670 Prop Shaft 1 Lower 4003 D8107065/B8107109 Lower Gear Set 2 Lower 4005 D8107070 Nose Cone 1 Lower 4014 D8106784-ST Half Shroud 2 Lower 4040 D8107954-ST Leg 1 P+N 4811 D8106988 Strut 1

APPENDIX D

Z-DRIVE PROP SHAFT AND STEERING SEAL KIT

CURRENT PART

DESCRIPTION QUANTITY

B8106487 Seal Ring 001 B7802062 Lantern Ring 001 HD-092823 Seal 002 SCS3/8NCX1-1/4SS Socket Capscrew (SS) 016 B8104941 Gasket 001 SS4-HPST Hex Plug (SS) 001 395 O-Ring 001 SCS1/2NCX2-1/2 Socket Capscrew 016 D8202363 Prop Shaft Seal 001 SCS3/8NCX1SS Socket Capscrew (SS) 016 325 O-Ring 001 456 O-Ring 001 SCS1NCX3-1/2 Socket Capscrew 014 SCS1-1/8NCX4 Socket Capscrew 004 214 O-Ring 001 B7807133 Gasket 001 B7807158 Seal Ring 001 377 O-Ring 001 SCS1/2NCX1-1/2SS Socket Capscrew (SS) 001

NOTE: Part numbers and quantities indicated above are for one (01) complete kit. The Contractor shall insure sufficient quantities of these piece parts are readily available at any time to assemble up to two (02) kits for immediate shipment (48 hours) on a given delivery order.

APPENDIX E

REVISION No. . CHANGE No. .

EFFECTIVE DATE___06/03/2009

TITLE

PROPELLER REPAIR SPECIFICATION

FOR 175 FT WLM COASTAL BUOY TENDER

VESSELS

R-245-175WLM

ORIGINATED BY E. M. GASKINS DATE ___06/2009____

UPDATED BY DATE______________

ORIGINATOR’S COMMAND SURFACE FORCES LOGISTICS CENTER (SFLC)

PRODUCT LINE ICE BREAKER/BUOY & CONSTRUCTION TENDER (SES2).

SOWRB APPROVAL DATE_______________

SPECIFICATION R-245-175WLM

Rev - Dated 06/2009

PROPELLER REPAIR SPECIFICATION

FOR 175 FT WLM COASTAL BUOY TENDER

VESSELS

1.0 SCOPE

1.1. This document sets forth the requirements for the inspection, repair, and testing of bronze propellers used on 175 FT. WLM COASTAL BUOY TENDER VESSELS.

1.2. CLASSIFICATION

1.2.1. Types

a. Type 1, - Left Hand (LH), P/N 551209

b. Type 2, - Right Hand (RH), P/N 551210

1.3. GOVERNMENT FURNISHED PROPERTY (GFP) - The listed items are property of and managed by the USCG Surface Forces Logistics Center (SFLC), Baltimore MD.

1.3.1. Propeller(s), Type 1, NSN 2010-01-413-8557, LH

1.3.2. Propeller(s), Type 2, NSN 2010-01-413-7146, RH

2.0 APPLICABLE DOCUMENTS

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

2.2. GOVERNMENT DOCUMENTS

2.2.1. USCG Drawing No. 175-WLM-245-001 REV A, Dated 2-16-95, entitled COASTAL

BUOY TENDER (WLM) PROPELLER.

2.3. COMMERCIAL DOCUMENTS

2.3.1. American Bureau of Shipping (ABS)

a. Guide for Bronze and Stainless Steel Propeller Castings - DATED 2009

2.3.2. Society of Automotive Engineers (SAE)

a. SAE-J-448A - DATED June 1963, Surface Texture Standard

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 (ASQ)

a. ANSI/ASQ 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 labor, equipment and material required to refurbish the GFP propeller(s) to a serviceable condition in accordance with American Bureau of Shipping (ABS) RULES FOR SURVEY AFTER CONSTRUCTION, Part 7 Appendix Section 10 entitled GUIDE FOR BRONZE AND STAINLESS STEEL PROPELLER CASTINGS and the specific requirements within this specification.

3.1.1. Serviceable condition is defined as being capable of functioning and performing in the same manner as an identical new propeller although it may not have the appearance of newness.

3.2. GOVERNMENT FURNISHED PROPERTY (GFP) - The Contractor shall provide protective storage for the GFP listed in section 1.3 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. MATERIAL - Each propeller is constructed of ABS Type 4.

3.4. TEST & INSPECTION DATA REQUIREMENTS, PRE-OVERHAUL INSPECTION

REPORT - Each propeller received by the Contractor shall be inspected upon receipt and a report outlining the required repairs and pricing submitted to the Contracting Officer for approval. No further work will be authorized until the submitted report is reviewed and approved.

3.4.1. The Pre-Overhaul Inspection Report shall contain, at a minimum, the following data:

a. Propeller blade radius

b. Pitch at the following sections - (0.5 thru 0.95 radii)

c. Average pitch of each blade at the following sections - (0.5 thru 0.95 radii)

d. Blade section width at the 0.4 thru 0.95 radii

e. Thickness at point of maximum thickness (PMT), at the 0.4 thru 0.95 radii

f. Track

g. Surface inspections (Visual and 100 percent dye penetrant examination in accordance with section 3.5.1 of this specification)

h. Hub bore visual and dimensional inspections

i. Estimated time required for repairs

j. Estimated total labor and material cost of repairs

3.4.2. If at any time while performing the Pre-Overhaul inspection or during authorized repairs that the Contractor believes the propeller may be beyond economical repair, the Contracting Officer shall be notified immediately and provided a description of the propeller’s condition to support this assessment.

3.5. SURFACE INSPECTIONS

3.5.1. Visual Inspection – The Contractor shall perform a visual inspection of all exterior surfaces. All defects, even though deemed acceptable, shall be documented by individual type and size. A separate visual inspection sheet shall be required for each of the following: the blade pressure face, the blade suction face, the fillet surfaces, and the hub.

a. Liquid Penetrant Test – In conjunction with the visual inspection, the Contractor shall perform a liquid penetrant test over 100 percent of the blade surfaces including the fillets and hub. The acceptance standards of Table IV (Appendix I of this specification) shall be used for all evaluations.

3.6. PROPELLER REPAIRS - Repair shall be made utilizing the following methods in declining order of preference:

3.6.1. Straightening

3.6.2. Material removal (grinding)

a. Material removal shall be limited to the minimum required to achieve the repair.

3.6.3. Clad welding

3.7. REPAIR TOLERANCES - Each Propeller shall be repaired within the repair tolerances listed in Appendix II of this specification.

3.8. QUALIFICATION OF WELDING PROCEDURES - Welding procedures, welding procedure qualifications, and welder performance qualifications shall be in accordance with ABS RULES FOR SURVEY AFTER CONSTRUCTION, Part 7 Appendix Section 10.

3.8.1. Welding on the pressure face critical areas or severity zones shall not be undertaken without prior approval of the Contracting Officer.

a. CRITICAL AREA - The critical area is described as the pressure face of the blade 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.

b. SEVERITY ZONES – The severity zones are described in ABS RULES FOR

SURVEY AFTER…