R-245-0469.doc

REVISION No. A .

CHANGE No. .

EFFECTIVE DATE___12/04/2013

TITLE

PROPELLER REPAIR SPECIFICATION

FOR 175 FT WLM COASTAL BUOY TENDER

VESSELS

R-245-0469

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_______________

PROPELLER REPAIR SPECIFICATION

FOR 175 FT WLM COASTAL BUOY TENDER

VESSELS

1.0 SCOPE

1.1. This document sets forth the requirements for the receipt, storage, inspection, repair, testing, preservation, packaging, packing, and marking of bronze propellers used on U.S. Coast Guard175’ 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 exercise proper care and safe handling whenever working on or handling same.

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 material.

3.4. TEST & INSPECTION DATA REQUIREMENTS, PRE-REPAIR 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-repair 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-repair 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: blade pressure face; blade suction face; 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 USCG SFLC Standard Specification 0740, Welding and Allied Processes.

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 CONSTRUCTION Part 7 Appendix Section 10, paragraph 1.5.5 (b).

3.8.2. Welding repairs of the propellers shall meet the requirements outlined in ABS RULES FOR SURVEY AFTER CONSTRUCTION Part 7 Appendix Section 10.

3.8.3. The Contractor shall document all welding performed on the visual inspection sheets for each propeller. Each weld shall be dimensionally identified by location, length, width, and depth.

3.9. SURFACE FINISH - Surfaces of the propeller blades, fillets, and hub shall be ground fair and polished to the finishes outlined below in accordance with SAE-J-448A.

3.9.1. Propeller blade surfaces - 125 micro inches or better

3.9.2. Propeller fillets and hub - 125 micro inches or better

3.9.3. All high spots, burrs, abrasions, nicks, corrosion, and foreign matter shall be removed from propeller glands, hub bores, flanges, and mating surfaces.

3.9.4. All exposed threaded areas shall be chased and tapped.

3.10. BALANCING - Each propeller shall be single plane balanced as stated herein. All balancing shall be accomplished by means of balancing equipment, which requires rotation of the work piece. The residual unbalance in each plane of correction shall not exceed the value determined by calculating the following formula: U = 4000W/N2 where:

U = Maximum allowable residual unbalance in oz.-inches.

W = Weight of rotating part in pounds.

N = Maximum operating speed of unit. (403 RPM)

Prior to performing any balance tests, the Contractor shall demonstrate the sensitivity of the balance machine using a weight determined from the following formula: Ws = 0.1(U)/r where:

Ws = Sensitivity Weight

U = Propeller residual unbalance tolerance r = Radial location of the weight

The addition of this weight shall be easily detected and discernable to the balance machine operator.

3.10.1. The mandrel or concentric rings used to support the propeller during balancing shall not exceed a total indicated run-out (TIR) of .001 inches.

3.10.2. Material removed to effect balancing shall be taken from the suction face of the heavy blade. Care shall be taken to keep a fair surface.

a. The area from which metal is taken shall not come within 10 percent of the chord length to the leading or trailing edges.

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

3.11. TEST & INSPECTION DATA REQUIREMENTS, FINAL INSPECTION REPORT – After completion of all welding, and repairs, the Contractor shall perform final dimensional, balancing, and visual and dye penetrant surface inspections of each propeller. The Final Inspection Report shall represent the actual final condition of each propeller after all repair work has been completed.

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

3.11.2. The Final 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 finish of blade surfaces, fillets, hub, and bore

h. Surface inspections (Visual and 100 percent dye penetrant examination in accordance with section 3.5 of this specification)

i. Hub bore visual inspection and final dimensions

j. Balancing data as determined in section 3.10 of this specification

3.11.3. Areas of the propeller where dimensions were taken and recorded on the pre-repair inspection report, but were not affected by follow-on repair work, do not have to be re-inspected. However, the Final Dimensional Inspection Report shall include all applicable pre-repair and post repair data and accurately reflect the final dimensional condition of the propeller.

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 (Q.A.)

4.1. GENERAL - The Contractor shall provide and maintain an inspection system which shall ensure each item offered to the Government for acceptance conforms to contract requirements. The system shall be documented and meet the requirements of ANSI/ASQC-Q9003-1994.

4.2. RESPONSIBILITY FOR INSPECTION - The Contractor is responsible for the performance of all inspection requirements as specified herein. The Contractor may use his own or any other facility for the performance of the inspections and tests, unless disapproved by the Government. The Government reserves the right to perform or witness any of the inspections and tests set forth in this specification at any time.

4.3. RESPONSIBILITY FOR COMPLIANCE - All items shall meet the provisions of Sections 3. 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.

4.4. INSPECTIONS/TESTS - The inspections and tests required herein are the minimum necessary and are not intended to replace any controls, examinations or tests normally employed by the Contractor to assure the quality of the product. The following are required and will be monitored by a Government Quality Assurance Representative.

4.4.1. Dimensional attributes a, b, c, d, e, f, g, and i of the Final Inspection Report noted in section 3.11.2 of this specification.

4.4.2. Surface inspections in accordance with section 3.5 of this specification. Surface inspections shall be performed upon arrival of the Government Quality Assurance Representative prior to any other inspections/tests required herein.

4.4.3. Balancing inspection in accordance with section 3.10 of this specification.

4.5. TEST AND INSPECTION REPORTS - One copy of any required inspection, test or tolerance check report shall be sent to the Contracting Officer.

4.5.1. A copy of any test, inspection or tolerance check report shall also be provided to the Coast Guard Quality Assurance Representative upon arrival at the Contractor’s facility.

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

4.5.3. All out of tolerance dimensions must be accompanied by an approved Request for Deviation/Waiver or other documentation endorsed by the Contracting Officer.

4.6. CALIBRATION SYSTEM - The Contractor as well as any subcontractors shall be required to maintain a test equipment calibration program in compliance with ANSI/NCSL Z540-1. The program shall be documented and traceable to the National Institute of Standards (NIST).

4.6.1. The calibration system records shall be maintained for inspection for the duration of any contract referencing this specification.

5.0 PRESERVATION, PACKAGING, PACKING, & MARKING

5.1. PRESERVATION & PACKAGING

5.1.1. Prior to preservation, each propeller shall be cleaned by any process or combination of processes, which will accomplish thorough cleaning without damage to the propeller.

a. After cleaning, tape conforming to SAE AMS-T-22085 and strippable compound preservative shall be applied to each propeller in accordance with MIL-DTL-2845E, paragraph 3.14.1.3.

b. After the application of strippable compound, galvanized sheet metal blade edge protectors, utilizing corrosion resistant hardware, shall be installed in accordance with MIL-DTL-2845E paragraph 3.14.1.4.

5.2. PACKING - Each propeller shall be individually packed in accordance with MIL-DTL-2845E paragraph 3.14.2.2.2.

5.2.1. If the original shipping container received by the Contractor is in good material condition and complies with 5.2 of this specification, the container shall be reused.

5.2.2. If a new shipping container is required, the Contractor shall notify the Contracting Officer within fifteen days after receipt of the GFP.

5.3. MARKING - Each packaged, and packed propeller shall be marked in the upper left-hand side of the two longest sides, (two opposite sides if square) of each container. The lettering shall be black painted stencil and permanently affixed to each container. The lettering shall be at least 1” high, and be applied on a highly contrasting painted background. NOTE: ALL PREVIOUS MARKINGS AND/OR QUALITY ASSURANCE DECALS SHALL BE COMLETELY REMOVED FROM A REUSABLE SHIPPING CONTAINER PRIOR TO THE APPLICATION OF ANY NEW MARKINGS.

5.3.1. This marking shall consist of the STOCK NUMBER, ITEM NAME, PART NUMBER, SERIAL NUMBER, CONTRACT NUMBER, SHIPPING WEIGHT (in lbs.,), condition code i.e. CONDITION A, QUANTITY with UNIT OF ISSUE (1) EA, and the words COAST GUARD SFLC MATERIAL.

5.3.2. See below for marking layout.

a. Type 1 - PROPELLER, LEFT HAND (LH)

STOCK NUMBER: 2010-01-413-8557

ITEM NAME: PROPELLER, LH

PART NUMBER: 551209

SERIAL NUMBER: As stamped on hub CONTRACT NUMBER: As indicated on contract

DELIVERY ORDER NUMBER: As indicated on contract

SHIPPING WEIGHT: As determined by Contractor

CONDITION CODE: CONDITION A

QUANTITY & UNIT OF ISSUE:

1- EA

COAST GUARD SFLC MATERIAL

REUSABLE CONTAINER DO NOT DESTROY

b. Type 2 - PROPELLER, RIGHT HAND (RH)

STOCK NUMBER: 2010-01-413-7146

ITEM NAME: PROPELLER, RH

PART NUMBER: 551210

SERIAL NUMBER: As stamped on hub

CONTRACT NUMBER: As indicated on contract

DELIVERY ORDER NUMBER: As indicated on contract SHIPPING WEIGHT: As determined by Contractor

CONDITION CODE: CONDITION A

QUANTITY & UNIT OF ISSUE: 1- EA

COAST GUARD SFLC MATERIAL

REUSABLE CONTAINER DO NOT DESTROY

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

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

a. The actual labels shall be Type “V”, Grade “A”, Style “2”, Composition “b” with plastic laminate.

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

6.0 NOTES

6.1. GOVERNMENT & COMMERCIAL DOCUMENT SOURCES

6.1.1. GOVERNMENT DOCUMENTS

a. Department of Defense Single Stock Point (DODSSP)

Building 4, Section D

700 Robbins Avenue

Philadelphia, PA 19111-5094

PH 215-697-2664

FAX 215-697-9398

b. DOD & Navy Publications and Forms (Other Than

DODSSP)

Naval Publication and Forms Center

5801 Tabor Ave.

Philadelphia, PA 19120

PH 215-697-2000

6.1.2. COMMERCIAL DOCUMENTS

a. American Bureau of Shipping (ABS)

ABS Plaza

16855 Northchase Drive

Houston, TX 77060

281-877-6000, FAX 281-877-6001

www.eagle.org

b. Society of Automotive Engineers, Inc. (SAE)

400 Commonwealth Drive

Warrendale, PA 15096

724-776-4841

FAX 724-776-0790

www.sae.org

c. American Society For Quality (ASQ)

600 North Plankinton Avenue

Milwaukee, Wisconsin 53203

414-272-8575, FAX 414-272-1734

d. American National Standards Institute (ANSI)

25 West 43rd Street

(Between 5th and 6th Avenues)4th Floor

New York, NY 10036

212—642-4900

FAX 212-398-0023

www.ansi.org

6.1.3. OTHER GOVERNMENT DOCUMENTS

a. USCG Surface Forces Logistics Center

705 E. Ordnance Road Baltimore, MD. 21226-5000

Attn: TIMB

TABLE IV. ACCEPTANCE STANDARDS FOR INSPECTION OF BRONZE PROPELLERS 9

Location of discontinuities Type of discontinuities2 Maximum acceptable discontinuity size (inches)1'3 Discontinuity acceptance standards Allowable areas of concentration

6 x 6 Area of concentration6.7

Maximum No.8.9 Maximum spacing between aligned discontinuities."

CASTINGS

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

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

radius, but not to exceed

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

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

The remaining surfaces of the blades.

D

whichever is less

WELDMENTS

area.

See footnotes on following page.

APPENDIX I (Page 1 of 2)

TABLE IV FOOTNOTES

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

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

3. Any linear discontinuity over 1/16 inch in length located within a peripheral band 1 inch wide; and whose major dimension is oriented normal to the blade edge shall be repaired.

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

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

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

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

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

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

APPENDIX I (Page 2 of 2)

175’WLM PROPELLER

ISO 484/2 CLASS II REPAIR TOLERANCES

NOTE: ALL DIMENSIONS ARE IN MILLIMETERS (mm) UNLESS OTHERWISE SPECIFIED

MEAN PITCH EACH RADIUS = +/- 2% OF DESIGN WITH MINIMUM OF 20mm

DESIGN

MAX

MIN

0.3R

0.4R

0.5R

0.6R

0.7R

0.8R

0.9R

0.95R

MEAN PITCH EACH BLADE = +/- 1.5% OF DESIGN WITH MINIMUM OF 10mm

MIN

1689 1714

MEAN PITCH OF PROPELLER = +/- 1.0% OF DESIGN WITH MIN OF 7.5mm

MIN

BLADE WIDTH = +/- 3.0% OF DIA DIVIDED BY NO. OF BLADES or +/-

10mm whichever tolerance is greater

HIGH

LOW

0.3R 408.9

419.8

398.0

0.4R 495.2 506.1

484.3

0.5R 571.7 582.6

560.8

0.6R 635.5 646.4 624.6

0.7R 671.4 682.3 660.5

0.8R 681.5 692.4

670.6

0.9R 648.0 658.9

637.1

0.95R 582.0

592.9

571.1

APPENDIX II (Page 1 of 3)

175’WLM PROPELLER

ISO 484/2 CLASS II REPAIR TOLERANCES (cont.)

MAX BLADE THICKNESS = +4% WITH MIN 2mm/-2% WITH MIN OF 1.5mm

MAX

DES

MIN

85.5

82.2

80.6 73.2

70.4

68.9 61.8

59.4

57.9 52.0

50.0

48.5 43.8

41.8

40.3 37.0

35.0

33.5 31.3

29.3

27.8 29.0

27.0

25.5

PROPELLER RADIUS = +/- 0.4% OF DESIGN RADIUS WITH A MIN OF 2mm

MIN

727.9 722.1

TRACK (MEASURED AT BLADE CENTERLINE AT 0.95R) = +/- 1.5% OF

DIAMETER

MIN

BALANCE TOLERANCE = See specification

SURFACE FINISH

BLADES = Not to exceed 125 micro-inches

EXTERIOR HUB = Not to exceed 125 micro-inches

APPENDIX II (Page 2 of 3)

175’WLM PROPELLER

ISO 484/2 CLASS II REPAIR TOLERANCES (cont.)

HUB DIMENSIONS

BORE LARGE END DIAMETER = 215.87mm - 215.93mm

BORE SMALL END DIAMETER = 185.04mm - 185.10mm

COUNTERBORE DIAMETER = 330.20mm - 330.25mm

COUNTERBORE DEPTH = 32mm +/-1mm

HUB LENGTH = 377mm +/-1mm

HUB FWD END DIAMETER = 420mm +/-1mm

HUB AFT END DIAMETER = 323mm +/-1mm

KEYWAY WIDTH = 44.42mm - 44.45mm

KEYWAY DEPTH = 13.25mm +/-0.25mm

APPENDIX II (Page 3 of 3)