Attachment_1_Specification_Propulsion_Shaft_Purchase_and_Repair.docx

REVISIONS

Revision: A Date: 8/6/2014

USCG WPB-87

SPECIFICATION PROPULSION SHAFT

PURCHASE & REPAIR

P-243-0618

ORGINATED BY: P.R. Mulrooney DATE: 05/2011 .

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

DEPARTMENT / DIVISION: Patrol Boat Product Line (PBPL) .

UPDATED BY: Wayne Nickel (Rev. A) DATE 8/6/2014 .

REVIEWED BY: Mike Soost, Jeff Wong (PBPL Engineering) DATE 7/15/2014 ___.

SFLC QA REVIEW: Brad Clemons (SFLC QA) DATE _8/6/2014___ _.

PLSSR REVIEW: DATE: .

1. SCOPE

1.1 General - New Shafts: The Contractor shall provide all equipment, labor and materials to manufacture, test/ inspect, preserve, package, pack, mark, bar-code and deliver 87 WPB propulsion shafts in accordance with the referenced drawing(s) and data provided within this specification.

1.2 General - Repaired Shafts: The Contractor shall provide all equipment, labor and materials to receive, inspect/report, repair, test/ inspect, preserve, package, pack, mark, bar-code and deliver propulsion shafts in accordance with the referenced drawing(s) and data provided within this specification to return the propulsion shaft(s) to a serviceable “A” condition.

NOTE

Serviceable “A” condition is defined as a reconditioned propulsion shaft meeting all required design specifications and design dimensions in accordance with Coast Guard drawing 87WPB 243-050 and being capable of functioning and performing in the same manner as an identical new propulsion shaft although it may not have the appearance of a new propulsion Shaft.

1.3 Government-Furnished Property:

($/UNIT)

1.4 GFP storage. All GFP must be stored in a locked location at the Contractors facility.

a. New crates fabricated per this specification shall be safe guarded and stored in the same place as other GFP.

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

U.S. Coast Guard Surface Forces Logistics Center 2401 Hawkins Point Rd, Bldg. 88 Baltimore, MD 21226

2.0 APPLICABLE DOCUMENTS

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

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

a. MIL/DOD/CID Specifications: http://www.assistdocs.com/search/search_basic.cfm

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

c. Public Laws, Code of Federal Regulations, U.S Codes, and other Federal Government laws: www.gpoaccess.gov

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

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

b. ANSI, ASTM, IEEEE, NFPA, ASME, SAE Standards: http://www.techstreet.com/

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

d. SSPC Standards and pictorial guides: http://shopping.netsuite.com/sspcmarketplace

2.3 Coast Guard Drawings:

a. USCG DWG. 87 WPB 243-050 Rev. - Propulsion Shaft: Single Sheet Detail.

b. USCG DWG. 87 WPB 243-001 - Propulsion Shaft Details.

2.4 Coast Guard Publications:

a. Surface Forces Logistics Center Specification D-000-0100, Rev. G, Change 1, Bar Coding for SFLC Stocked Material

b. Surface Forces Logistics Center Standard Specification 0740 (SFLC Std Spec 0740), 2012, Welding and Allied Processes

2.5 Other Government Documents:

a. MIL-DTL-2845E (SH) DATED Aug 18, 1999, Packaging of Main propulsion Shafting, Bearings, Boat & Ship Propellers and associated Repair Parts.

b. MIL-STD-2191 (SH) DATED Nov 5, 1992 DOD Standard Practice, Repair Welding, Weld Cladding, Straightening, And Cold Rolling Of Main Propulsion Shafting.

2.6 Commercial Documents:

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

b. ASTM A 276 Rev. A, Dated 11/1/2013, Standard Specification for Stainless Steel Bars and Shapes.

c. ASME B17.1 dated 1/1/1967, Rev. (Reaffirmed 2013), Keys and Keyseats

2.7 Order of Precedence: In the event of a conflict between the text of this specification and the references cited herein, this specification shall take precedence, unless otherwise specified herein. Nothing in this specification, however, supersedes applicable laws and regulations unless a specific exemption has been obtained.

3.0 REQUIREMENTS

3.1 Manufacture – The propulsion shaft(s) shall be manufactured in accordance with Coast Guard drawing 87 WPB 243-050. Contractor shall provide all manufacturing, assembly, and testing as required herein.

a. Contractor shall provide a propeller end and coupling end key as part of each manufactured propulsion shaft.

1. The key to keyway fit shall be Class 1 per ASME B17.1

3.1.1 All new shafts shall be marked on the coupling end face with a stamped-in serial number at least 1/8” high on the coupling end face. The Contracting Officer (KO) will provide propulsion shaft serial numbers as required.

3.1.2. Materials – The shaft material shall be Aquamet 22HS or Aqualoy 22HS which is similar in content to XM19 alloy of ASTM A 276.

a. Prior to item manufacture the Contractor shall provide certifications of material conformance within 20 days of delivery order date to the KO for approval. This is a requirement for each delivery order.

3.1.3 Dimensions – All dimensions and dimensional tolerances shall be as indicated on the specified drawing.

a. If not specified, tolerances shall be as listed below:

3.1.4 Drawing Deviations, Manufacture – The following drawing deviation is authorized for propulsion shaft manufacture only:

a. Propulsion Shaft diameter shall be 4” +0.005” / -0.005”.

b. Taper TIR maximum shall be .004”.

c. Shaft body TIR maximum in areas other than the tapers shall be .006”.

d. Runout readings using a dial indicator shall be taken by supporting the shaft on precision rollers (two total) 48 inches from the ends of the shaft, or between lathe centers.

3.2 Repair – The Contractor shall carefully remove the propulsion shaft(s) from the GFP crate and conduct a thorough inspection to determine all the necessary repairs to return the propulsion Shaft to a serviceable “A” condition. A Condition Found Report (CFR) shall be submitted to the KO within ten (10) days of receipt of GFP. The CFR shall include all inspection findings and test results as specified below including any recommended repairs to return the propulsion shaft to a serviceable “A” condition. The CFR shall also include a breakdown of estimated cost of labor and materials for any repair work including repair or replacement of the shipping crate. The CFR shall contain the following information as a minimum:

a. Contractor name, address and telephone number.

b. Contract number and delivery order number as applicable.

c. Propulsion Shaft serial number(s).

d. Inspection sheets showing dimensional data and test results.

e. Total Indicated Runout (TIR) in accordance with the drawing as amended by the allowable deviations herein.

f. Liquid dye penetrant testing in way of the keyways, tapers, threads, and bearing and seal areas.

g. Name of the person conducting the testing.

h. Test equipment used, nomenclature, serial number, and calibration date.

3.2.1 No further work shall proceed until authorized by the KO in writing.

3.2.2 The Coast Guard will evaluate if shaft(s) will be repaired or scrapped due to the extent of necessary repairs and determine disposition. Disposition options are as follows:

a. Contractor to scrap on site and provide credit to the Coast Guard based on current U.S. stainless steel scrap prices.

b. Shafts to be re-packaged in original shipping container, properly marked per section 5.5 and returned to SFLC Baltimore, MD.

3.2.3 Deviations: The following drawing deviations are authorized for propulsion shaft repair only:

a. Areas of the shaft body not in way of the bearing or seal areas may be reduced to a minimum diameter of 3.960. These areas must be pit free, smooth to 63 micro inches in accordance with SAE-J-448A “Surface Texture”, with tapers no steeper than 4:1 from the original diameter and concentric within the TIR Requirements below.

b. Local out of roundness conditions in the way of pits, nicks, dents, scratches or weld repairs that have been stoned out are limited to 0.010”.

1. This 0.010” out of round deviation is not authorized in way of bearing or seal areas.

c. The outside diameter of each shaft section shall be concentric with the axis of rotation to a maximum of 0.008” T.I.R.

d. Taper shall be concentric with the axis of rotation to a maximum of 0.005” T.I.R.

e. Keyways on shafts manufactured in accordance with drawing 87WPB 243-050.

d. Runout readings using a dial indicator shall be taken by supporting the shaft on precision rollers (two total) 48 inches from the ends of the shaft, or between lathe centers.

3.2.4 Weld Repairs: Recommended weld repairs shall be documented on the CFR during initial inspection.

a. Welder qualifications and welding procedures shall be completed in accordance with Surface Forces Logistics Center Standard Specification 0740 (SFLC Std Spec 0740), 2012, Welding and Allied Processes.

b. Weld repairs shall be made using a filler material compatible with ASTM A276, type XM19, alloy S20910. Submit a CFR indicating the filler used for all weld repairs.

c. Weld repair increments are listed in section 6.1.

3.2.5 Shaft Keys: The Contractor may receive older propulsion shafts that were manufactured to USCG drawing 87WPB 243-001. These shafts have smaller keys. Contractor shall provide a propeller end and coupling end key for these repaired propulsion shafts. The keys shall be manufactured in accordance with drawing 87WPB 243-001.

3.3 RUNOUT, CONCENTRICITY, ECCENTRICITY & TAPER INSPECTION - The runout, concentricity, and eccentricity shall be as specified below.

3.3.1 Measurement Procedures – Runout readings using a dial indicator shall be taken by supporting the shaft on precision rollers (two total) 48 inches from the ends of the shaft, or between lathe centers. The rollers shall be at least two inches wide. The jig holding the rollers shall be adjustable to follow the bow in the shaft. (No additional supports shall be used).

a. Runout readings shall be determined as follows:

1. Roll the shaft slowly for two hours prior to measuring to relieve temporary shaft sagging.

2. Conduct complete propulsion shaft run-out readings via dial indicator survey at the small and large ends of each taper, the fore and aft ends of each bearing area position, three equally spaced locations between the bearing areas, and three equally spaced locations between the intermediate bearing area and coupling taper. .

3. Each station shall be marked at the position of the maximum run-out on the periphery of the shaft.

3.3.2 Non-Destructive Inspection – Liquid dye penetrant testing per SFLC Std Spec 0740 shall be completed in all areas in way of the keyways, tapers, threads, bearing and seal areas, and welds from weld repairs. Results, any repair recommendations and estimated repair cost shall be documented on the CFR.

3.4 Blue-fit – Both propeller shaft tapers shall be blue fit to a certified 0.750”/ft ring gage with a tolerance of +0.002” – 0.000” per foot on diameter.

a. The certified ring-gage shall be furnished by the Contractor.

b. The blue fit shall be a minimum of 80% contact.

3.5 Straightening – Shaft straightening shall be accomplished by the “cold press” method only. No heat will be used to straighten shafts manufactured or repaired in accordance with this specification.

3.6 Polishing: Each shaft shall be polished to the surface textures as shown on CG Drawing 243-050 except the 70 micro-inch. Use 63 micro-inches instead of 70.

3.7 Final Inspection and Test Report, all shafts: A detailed Final Inspection and Test Report shall be submitted to the Contracting Officer for approval prior to scheduling Coast Guard SFLC Quality Assurance personnel. The report shall specify the final condition of each propulsion shaft after all work has been completed. A copy of the inspection and test report shall be turned over to the Coast Guard Quality Assurance representative upon arrival for final inspecting and testing. The inspection and test report shall contain the following information as a minimum:

a. Contractor name, address and telephone number.

b. Contract number and delivery order number as applicable.

c. Propulsion Shaft serial number(s).

d. Inspection sheets showing dimensional data and test results.

e. Total Indicated Runout (TIR) in accordance with the drawing as amended by the allowable deviations herein.

f. Final taper blue-fit impression test results.

g. Liquid dye penetrant testing in way of the keyways, tapers, threads, and bearing, seal areas.

h. Thread functionality.

i. Name of the person conducting the testing.

j. Test equipment used, nomenclature, serial number, and calibration date.

3.8 First Article Test: A first article test shall be performed on the first manufactured propulsion shaft produced under this contract.

a. Contractor shall notify the Contracting Officer when the first article propulsion shaft is ready for inspection and testing. Notification shall be in accordance with section 3.9.

b. First Article shall include all tests and inspections listed in section 4.1.2.

c. No further production shall be authorized until the first article test unit has passed all inspections and testing.

3.8.1 Waiver of First Article Test – The First Article Test may be waived, at the Coast Guard’s discretion, depending on Contractor’s past performance and experience in the manufacture of similar propulsion shafting.

3.9 Notifications and Inspections: The Contractor shall be responsible for notifying the KO at least ten (10) calendar days prior the contractor being ready for any Quality Assurance (Q.A.) inspections or testing as required herein. The Propulsion Shaft(s) require a one hundred percent Coast Guard Quality Assurance inspection.

4.0 QUALITY ASSURANCE

4.1 Inspections & Tests (Completed Units): The inspections & tests required herein are the minimum necessary and are not intended to replace any controls, examinations, or tests normally employed by the Contractor to assure the quality of the product.

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

4.1.2 The following are required and will be monitored by a Coast Guard SFLC Quality Assurance Representative:

a. Material certifications and properties

b. Dimensional readings, 100%

c. Liquid dye penetrant testing shall be completed in all areas in way of the keyways, tapers, threads, and bearing and sea areas. (Repaired shafts only)

g. Shaft Stampings

h. Thread functionality

5.0 PACKING, PACKAGING, MARKING AND DELIVERY

5.1 New Reusable Shipping Container: Contractor shall furnish labor and material to fabricate each new shipping container as follows:

a. Each completed shaft shall be packed in accordance with MIL-DTL-2845 section 3.15.6 Level A, except Figure 15 shall be used for the box as modified herein.

b. The sides, bottom, and ends shall be made from 2” thick construction grade lumber sized so that one piece covers the height or width of the area, doubled on the ends. The top shall be made from 1” thick construction grade lumber.

c. Cradles – Shall be made from doubled 2” thick construction grade lumber.

d. Skids shall be made from 4” x 4” construction grade lumber. Skids shall be placed on both ends and every 4’ thereafter.

e. The top shall be attached with screws for easy removal, and marked in 2” high red lettering “TOP – REMOVAL WITH SCREW DRIVER” in three places evenly distributed across the top.

f. Place PVC tubing over all threads and tapers and secure in place.

5.2 Packing: Each propulsion shaft shall be individually packaged in its own or a new reusable shipping container.

5.3 Preservation: All shafts shall be cleaned and dried in accordance with MIL-DTL-2845 section 3.7.1. No further preservation shall be done.

5.4 Common Carrier Preparation: All packaged shafts shall be loaded on a flatbed steel trailer with minimal camber and wooden floor only. No aluminum trailers are authorized. Shafts are very sensitive and shall be shimmed to lay as flat and straight as possible.

5.4.1 This shimming shall be attached to the cross skidding to prevent the shims from dislodging from the cross skids during transport.

5.4.2 Carrier shall re-adjust shims as necessary if other shipped items are loaded and offloaded changing the camber of the trailer.

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

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

Required marking for (scrap) “H” Condition Propulsion Shafts:

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

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, serial number, and the Contract Number.

6.0 NOTES

6.1 Weld Repair Increments: The Coast Guard has derived three possibilities for propulsion shaft weld repair increments. They are as follows:

a. General (non-bearing areas) - 3 cubic inch increment (based on 1/8" deep areas to repair, 1" length, 360° undercut as required by MILSPEC).

b. Aft bearing area repair (entire area) - 18 cubic inch increment (based on 1/16" deep area to repair, full bearing area length, 360° around).

c. Intermediate bearing area repair (entire area) - 12 cubic inch increment (based on 1/16" deep area to repair, full bearing area length, 360° around).

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

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

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

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