R-245-0503.doc

REVISION No._____________

CHANGE No. 1______ REVISION Date_____________

CHANGE Date __09/13/2011__

TITLE

PROPELLER REPAIR SPECIFICATION

87 FT COASTAL PATROL BOATS

R-245-0503

ORIGINATED BY E. M. GASKINS DATE 02/01/2007 .

UPDATED BY ____DATE ____ .

ORIGINATOR’S COMMAND SURFACE FORCES LOGISTICS CENTER (SFLC)

DEPARTMENT / DIVISION PATROL BOAT PRODUCT LINE.

INTERNAL REVIEWER WAYNE NICKEL DATE 12/2013.

SOWRB APPROVAL DATE____________.

PROPELLER REPAIR SPECIFICATION

For

USCG 87’ COASTAL PATROL BOATS (CPB)

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 87’ CPB vessels.

1.2. CLASSIFICATION

1.2.1. Types

a. Type 1, - Left Hand (LH), P/N 706-3350.00 LH

b. Type 2, - Right Hand (RH), P/N 706-3351.00 RH

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

1.3.1. Propeller(s), Type 1, NSN 2010-01-459-0421, Left Hand.

1.3.2. Propeller(s), Type 2, NSN 2010-01-457-0573, Right Hand.

2.0 APPLICABLE DOCUMENTS

2.1. GENERAL – The documents listed in this section are specified in sections 3, 4, or 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, or 5 of this specification, whether or not they are listed.

2.2. GOVERNMENT DOCUMENTS

2.2.1. SPECIFICATIONS, STANDARDS, PUBLICATIONS, AND HANDBOOKS – The following specifications, standards, publications, and handbooks form a part of this specification to the extent specified herein. Unless otherwise specified, the versions in effect are those listed in the GSA Index of Federal Specifications, Standards And Commercial Item Descriptions or the current Department of Defense Single Stock Point of Specifications And Standards, (DODSSP), and supplements thereto, cited in the solicitation or contract.

2.2.2. SPECIFICATIONS

a. MIL-DTL-2845E(SH) - DATED 18 AUG 1999, Propulsion Systems, Boat and Ship; Main Shafting, Propellers, Bearings, Gauges, Special Tools, and Associated Repair Parts; Preservation, Packaging, Packing and Storage of

2.2.3. STANDARDS

a. MIL-STD-167-1A(SHIPS) - DATED 2 NOV 2005, Mechanical Vibrations of Shipboard Equipment

b. MIL-STD-2035A(SH) - DATED 15 MAY 1995, Nondestructive Testing Acceptance Criteria

c. DOD-STD-2185(SH) – DATED 28 OCT 1986, Requirements for Repair and Straightening of Bronze Naval Ship Propellers

d. USCG SFLC Standard Specification 0740, Welding and Allied Processes

2.2.4. OTHER GOVERNMENT DOCUMENTS

a. USCG Drawing No. 87-WPB-245-003 REV A - DATED 5/5/06, 87FT COASTAL PATROL BOAT PROPELLER DETAILS

b. COAST GUARD SPECIFICATION D-000-0100 - DATED 10/91 REV G 02/06, Bar Coding for USCG Engineering Logistics Center Procured Material

c. NAVSEA TECHNICAL MANUAL, NAVSEA S9245-AR-TSM-010/PROP - DATED 31 MARCH 1997, Technical Manual Marine Propeller Inspection, Repair and Certification, NSN 0910-LP-012-5880

d. T9074-AS-GIB-010/271 - DATED 16 FEB 1999, Requirements for Nondestructive Testing Methods

2.3. COMMERCIAL DOCUMENTS

2.3.1. International Standards Organization

a. ISO 484/2-1981(E): Shipbuilding-Ship screw propellers-Manufacturing tolerances-Part 2: Propellers of diameter between 0.80 and 2.50m inclusive

2.3.2. American Bureau of Shipping (ABS)

a. Guide for Bronze and Stainless Steel Propeller Castings - DATED 2007

2.3.3. Society of Automotive Engineers (SAE)

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

b. SAE AMS-T-22085 - DATED 01 June 1999, Tapes, Pressure-Sensitive, Adhesive, Preservation and Sealing–FSC 7510

2.3.4. 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

2.3.5. American Society For Quality Control (ASQC)

a. ANSI/ASQC 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 MIL-STD-2185.

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 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-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. Shipping container condition (see 5.2 of this specification)

b. Propeller blade radius

c. Pitch at the following sections - (0.5 thru 0.95, 0.97, and 0.99 radiuses)

d. Average pitch of each blade at the following sections - (0.5 thru 0.95, 0.97, and 0.99 radiuses)

e. Blade section width at the 0.4 thru 0.95, 0.97, and 0.99 radiuses

f. Thickness at point of maximum thickness (PMT), at the 0.4 thru 0.95, 0.97, and 0.99 radius

g. Track

h. Fairing rod clearances

i. Surface finish of blade surfaces, fillets, and bore

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

k. Hub bore visual and dimensional inspections

l. Estimated time required for repairs

m. Estimated total labor and material cost of repairs

n. Photo documentation in accordance with 3.14. and 3.14.1.a, b., and c. of this specification.

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. A visual inspection shall be performed on all exterior surfaces in accordance with MIL-STD-2035 section 4.

a. All visual defects, even though deemed acceptable, shall be documented on the inspection report.

b. The Contractor shall perform a dye penetrant inspection over 100 percent of the blade surfaces including the fillets and hub in accordance with Section 5 of T9074-AS-GIB-010/271. The acceptance criteria of MIL-STD-2035, Table IV shall be used for evaluations.

c. The Contractor shall document all defects resulting from the visual and dye penetrant inspections. All defects or indications shall be indicated by type and size on visual inspection sheets. A separate visual inspection sheet shall be submitted for each of the following: the blade pressure face, the blade suction face, the fillet surfaces, and the hub.

d. Photo documentation shall be provided in accordance with 3.14. and 3.14.1.c. of this specification.

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 to satisfy Class I tolerances outlined in International Standard ISO 484/2-1981(E). Applicable dimensions shall be obtained from USCG Drawing No. 87-WPB-245-003 - DATED 5/14/03, 87FT COASTAL PATROL BOAT PROPELLER DETAILS.

3.8. QUALIFICATION OF WELDING PROCEDURES - Welding procedures, welding procedure qualifications, and welder performance qualifications shall be certified in accordance with USCG SFLC Standard Welding and Allied Processes or approved in accordance with the American Bureau of Shipping. The welding procedures and qualification documents shall be submitted for approval with the solicitation.

3.8.1. ABS certification to perform weld repairs in Severity Zone “A” shall be submitted for approval with the solicitation.

3.8.2. 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. (Reference Figure 1 of DOD-STD-2185)

b. SEVERITY ZONES – The severity zones are described in ABS Guide for Bronze and Stainless Steel Propeller Castings dated 2007, Part 7, Section 10, paragraph 1.5.5(b). (Reference Figures 2 and 3 of 7-A-10)

3.8.3. Welding repairs of the propellers shall meet the requirements of USCG SFLC Standard Specification 0740, Welding and Allied Processes.

3.8.4. 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.

a. Photo documentation shall be provided in accordance with 3.14.and 3.14.1.d. of this specification when applicable.

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 - 63 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 holes shall be chased and tapped to ensure full functionality.

3.10. BALANCING - Each propeller shall be single plane balanced in accordance with MIL-STD-167-1A, paragraph 5.2.2 as stated herein. All balancing shall be accomplished by means of balancing equipment, which requires rotation of the work piece. The minimum detectable unbalance of the balancing machine used shall be below the residual unbalance specified herein. The residual unbalance in each plane of correction shall not exceed the value determined by calculating the following formula:

U = 4000W/N2

N = Maximum operating speed of unit. (854 RPM)

U = Maximum allowable residual unbalance in oz.-inches

W = Weight of rotating part in pounds.

3.10.1. 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.

3.10.2. 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 depict the 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 ELC’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, 0.97, and 0.99 radiuses)

c. Average pitch of each blade at the following sections (0.5 thru 0.95, 0.97, and 0.99 radiuses)

d. Blade section width at the 0.4 thru 0.95, 0.97, and 0.99 radiuses

e. Thickness at point of maximum thickness (PMT), at the 0.4 thru 0.95, 0.97, and 0.99 radius

f. Track

g. Fairing rod clearances

h. Surface finish of blade surfaces, fillets, hub, and bore

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

j. Hub bore visual inspection and final dimensions

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

l. Visual inspection data for all weld repairs in accordance with section 3.8.4 of this specification

m. Photo documentation in accordance with section 3.14. and 3.14.1.e. of this specification.

3.11.3. Areas of the propeller that have not been affected by the repair work do not have to be re-inspected for the Final Inspection Report. However, inspection data for the entire propeller shall be included in the final dimensional inspection report.

3.12. STAMPING - Each propeller shall be stamped with the listed information, or the presently stamped information shall be changed if incorrect.

3.12.1. The stampings shall be at least 1/4” high legible printing, or the same height of the existing stamping if only corrected.

3.12.2. The stamping shall include, at a minimum, the following information:

a. Company Name

b. Date of Repair Completion

c. Serial Number (supplied by the Contracting Officer if none exists)

d. Direction of Rotation (LH or RH)

e. Type of Material.

f. Weight

3.13. 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.

3.14. PHOTO DOCUMENTATION – The Contractor shall provide Photo Documentation to the Contracting Officer as part of the Pre-repair Inspection Report, during in-process welding repairs (if applicable), after final inspection, and during preservation, packaging, and packing. Each photograph shall include the propeller serial number and date the photograph was taken. The color photographs shall be taken with a digital camera and the images provided electronically in “jpg format” to the Contracting Officer during the overhaul phases outlined below.

3.14.1. PHOTO DOCUMENTATION PHASES:

a. During initial receipt of the propeller with photographs showing the suction face, pressure face, hub markings and two photographs of the shipping crate taken at 90 degrees apart.

b. Prior to the repair of the propeller with close-up views showing any damage, erosion, corrosion that will affect cost or repair cycle time.

c. During the pre-repair dye penetrant inspection showing any porosity or cracks.

d. During repair of the propeller whenever significant cropping or welding is required.

e. After final inspection prior to preservation showing surface texture/finish of the suction face, pressure face, fillet and hub. Stamped markings shall also be photographed.

f. Prior to inserting the propeller in the shipping container, showing strippable compound application and sheet metal blade edge protectors installed.

g. Prior to shipment, showing container markings.

3.14.2. In addition to providing electronic photographs at the various overhaul phases indicated, the Contractor shall provide a final Compact Disc (CD) to the Contracting Officer that includes all of the pictures referenced in 3.14.1. The pictures on this CD shall be organized in “jpg format” within folders labeled as follows: Receiving Inspection (photos referenced in 3.14.1.a.); Pre-repair Inspection (photos referenced in 3.14.1.b. and c.); In Process Repair (photos referenced in 3.14.1.d; Post Final Inspection (photos referenced in 3.14.1.e.; and Preservation, Packaging, and Markings (photos referenced in 3.14.1.f. and g.).

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 with 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 & 5. The inspections set forth in this specification shall become part of the Contractor’s overall inspection system or quality program. The absence of any inspection requirement in the specification shall not relieve the Contractor of the responsibility of assuring that all products or supplies submitted to the Government for acceptance comply with all requirements of the contract. Sampling for quality conformance does not authorize submission of known defective material (either indicated or actual) nor does it commit the Government to acceptance of defective material.

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 shall be monitored by a Government Quality Assurance Representative.

4.4.1. Dimensional inspection in accordance with sections 3.7 and 3.11.2.a, b, c, d, e, f, g, h, and j of this specification.

4.4.2. Surface inspections in accordance with section 3.11.2.i.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.

4.4.4. Stamping inspection in accordance with section 3.12 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 turned over 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.

4.6. 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.

4.7. PACKING INSPECTION - The Contracting Officer shall be notified prior to the preservation, packaging, packing, and marking of the completed units.

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.

c. Photo documentation shall be provided in accordance with 3.14. and 3.14.1.f. of this specification.

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.

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 ELC MATERIAL.

5.3.2. See below for marking layout.

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

STOCK NUMBER: 2010-01-459-0421

ITEM NAME: PROPELLER, LH

PART NUMBER: 706-3350.00 LH

SERIAL NUMBER: As stamped on hub CONTRACT NUMBER: As indicated on contract DELIVERY ORDER NUMBER: As indicated on the delivery order 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: 2010-01-457-0573

ITEM NAME: PROPELLER, RH

PART NUMBER: 706-3351.00 RH

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

DELIVERY ORDER NUMBER: As indicated on the delivery order 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

5.3.3. Photo documentation shall be provided in accordance with 3.14. and 3.14.1.g. of this specification.

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 ELC 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

215-697-2667/2179 FAX 215-697-1462

b. DOD & Navy Publications and Forms (Other Than DODSSP)

Naval Publication and Forms Center

5801 Tabor Ave.

Philadelphia, PA 19120

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

412-776-4841

FAX 412-776-5760

www.sae.org

c. American Society For Quality Control (ASQC)

611 East Wisconsin Avenue

Milwaukee, Wisconsin 53202 414-272-8575, FAX 414-272-1734

d. American National Standards Institute (ANSI)

25 West 42nd Street

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

New York, NY 10018

212—642-4900

FAX 212-398-0023

www.ansi.org

6.1.3. OTHER GOVERNMENT DOCUMENTS

a. USCG Surface Forces Logistics Center

707 E. Ordnance Road

Baltimore, MD. 21226-5000

Attn: TIMB