75F_Rudder_Construction.pdf

Construction Specification for 75 F Class Rudders

REVISION _______ Date: _______

TITLE

Specification

For Both 75’ F Class Steering Rudder and Stock Construction

And 75’ F Class Flanking Rudder and Stock Construction

ORGINATED BY: A. Ollerman DATE: Dec, 2015.

ORGINATOR’S COMMAND: SFLC, IBCTender Product Line, Supply Branch

REVIEWED BY: J. Happe DATE Jan, 2016.

REVIEWERS COMMAND: SFLC, IBCTender Product Line, Engineering Branch DATE .

1.0 Scope: This specification describes the requirements for the fabrication, testing and packaging requirements for:

(a) Steering Rudder and Rudder Stock Assembly , including associated components, for US Coast Guard 75 ‘F’ Class WLR River Tenders.

And

(b) Flanking Rudder and Rudder Stock Assembly , including associated components, for US Coast Guard 75 ‘F’ Class WLR River Tenders.

1.1 Government Furnished Property (GFP): None

2.0 Applicable Documents:

2.1 USCG Drawings:

75F-WLR-562-003, Steering Rudders and Stocks, Rev 4, Dated 9/89

75F-WLR-562-004, Steering Rudder Tiller, Rev 5, Dated 4/89

75F-WLR-562-005, Flanking Rudders and Stocks, Rev 6, Dated 4/90

75F-WLR-562-006, Flanking Rudder Tiller, Rev 5, Dated 4/89

2.2 Military Specifications:

MIL-PRF-16173E w/ Int. Amendment 1, Sep 2006, Corrosion Prevention Compound, Solvent Cutback, Cold-Application

MIL-S-45180, 1998; Sealing Compound, Gasket, Hydrocarbon Fluid and Water Resistant

2.3 Coast Guard Publications:

Surface Forces Logistics Center Standard Specification 0740 (SFLC Std Spec 0740), 2014, Welding and Allied Processes

Surface Forces Logistics Center Standard Specification 6310 (SFLC Std Spec 6310), 2014, Requirements for Preservation of Ship Structures

2.4 Technical Manual:

Naval Sea Systems Command (NAVSEA) S9243-A5-MMD-010 Technical Manual for Gages, Plug and Ring, Propellers and Propulsion Shafting; Repair, Inspection, Certification and use. (Stock Number: 0910-LP-587-9500)

2.5 Commercial Documents:

The Society for Protective Coatings (SSPC)/NACE International (NACE), Joint Surface Preparation Standard SSPC-SP 10/NACE No. 2, 2007, Near-White Blast Cleaning

ANSI/NCSL Z540-3, 2006, Requirements for the Calibration of Measuring and Test Equipment

ASTM International (ASTM) D5363, 2008, Standard Specification for Anaerobic Single Component Adhesives (An)

2.6 Coast Guard SFLC Bar Coding Specification: D-000-0100, latest revision

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

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

2.9 SFLC Furnished Tooling: None

3.0 Requirements:

3.1 General. The Contractor shall provide all labor and materials to accomplish the work specified in this specification, for each rudder assembly. Ensure that all materials shall be in accordance with the specified drawing and applicable piece numbers.

3.2 Rudder Blade (both Steering and Flanking) and Rudder Stock fabrication particulars.

Fabricate each rudder assembly, as shown on Coast Guard Drawings 75F-WLR-562-003 and 75F-WLR-562-005. Ensure that each rudder assembly includes the following associated pieces:

(a) Palm keys. 1 ea required for every Rudder-Rudder stock assembly.

(b) Tiller keys. 1 ea required for every Rudder-Rudder stock assembly.

(c) Palm bolts and nuts. 6 ea required for every Rudder-Rudder stock assembly.

(d) Lower stock (integral with rudder blade). 1 ea required for every Rudder- Rudder stock assembly.

(e) Upper stock. 1 ea required for every Rudder-Rudder stock assembly.

(f) Stock Upper nut. 1 ea required for every Rudder-Rudder stock assembly.

3.2.1 Submit all material certifications to the COR, during the inspection phase of the contract. In the event any clarification on materials cited on referenced drawing is required, Contractor shall contact the Contracting Officer.

3.2.2 Keys: Keys shall be manufactured of steel in accordance with Coast Guard Drawings 75F-WLR-562-003 and 75F-WLR-562-005. All keys shall be fitted to their prospective keyways to allow for a “tap fit” using a wood block or soft mallet.

3.2.3 Palm bolts: Bolts shall be fitted and holes between lower and upper stocks reamed to provide proper fit and ready for field installation with no additional fitting required.

Fit shall be FN1 (Light Drive Fit).

3.3 Welding Requirements: Perform all welding and allied processes, and nondestructive inspection (NDI), in accordance with SFLC Std Spec 0740

3.4 Void Plugs: Ensure that the rudder void is provided with a drain and fill plug, made of 316 Stainless Steel or Monel. Chase insert threads and coat new plugs prior to installation with a sealing and locking compound conforming to ASTM D5363-AN0123 or a flexible joint compound conforming to MIL-S-45180, Type II.

3.5 Air Test. Air test new rudder blade by applying a pressure of 10 psig to the void, in accordance with SFLC Std Spec 0740, Appendix C. Submit a condition-found report (CFR) to the COR, within 24 hours after completion of air test, to include air test result.

3.6 Surface Preparation And Coating:

3.6.1 Rudder Blade External Surfaces. Prepare and coat all rudder blade exterior surfaces, using the system specified for “U/W Body and Boot-Top, Icebreaker <235', in Salt Water” in SFLC Std Spec 6310, Appendix A (Cutter & Boat Exterior Painting Systems).

Omit application of the ablative copper top coating.

3.6.1.2 Other external surfaces. Prepare and coat the un-machine surfaces using the system specified for “Inaccessible Areas, Steel”, in SFLC Std Spec 6310, Appendix A (Cutter & Boat Exterior Painting Systems).

3.6.1.2.1 Ensure that all machine finished surfaces at risk of damage from sand blast and paint operations are blanked off or otherwise protected.

3.6.2 Internal surfaces.

Fill all void interior surfaces with a rust preventive compound conforming to

MIL-PRF-16173, Class II, Grade 3, to coat all surfaces.

Drain, collect, and dispose of remaining compound in accordance with all applicable Federal, state, and local regulations.

Ensure that the coated surfaces are left exposed to the atmosphere for 24 hours to allow for adequate drying.

3.7 Notifications & Inspections: The contractor shall be responsible for notifying the Contracting Officer no less then seven (7) calendar days prior to the contractor being ready for any Quality Assurance (Q.A.) inspections or testing required herein. Foreign contractors are required to notify the Contracting Officer no less then thirty (30) calendar days prior.

4.0 Quality Assurance (QA):

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

4.2 Responsibility for Inspection: The Contractor shall be responsible for the performance of all inspection requirements specified herein. The Contractor shall provide space, personnel and test equipment for the conduct of all inspection requirements. All inspection and testing shall be performed at the Contractors facility prior to the Coast Guards acceptance of the contracted items. The Coast Guard reserves the right to verify or have performed any of the inspections set forth herein where such inspections are deemed necessary to assure that supplies and services conform to prescribed requirements. The contractor shall notify the Contracting Officer of the scheduled commencement of any inspections required by this specification.

4.3 Responsibility for Compliance: All items shall meet the provisions of Sections 3 & 5.

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

4.4 Inspection System: The Contractor shall maintain an inspection system, which shall ensure that each item offered to the Coast Guard for acceptance or approval conforms to the contract requirements. The inspection system shall be in accordance with Federal Acquisition Regulation (FAR) clause 52.246-2. The system shall be documented and available for review by the Coast Guard inspector.

4.5 Inspections & Tests: The inspections & tests required herein are the minimum necessary and are not intended to replace any controls, examinations, or tests normally employed by the contractor to assure the quality of the product. The following are required:

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

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

c) Welding requirements and welder certifications conform to paragraph 3.3 (Welding Requirements).

d) Verify all coating requirements conformance with paragraph 3.6 (Surface Preparation and Coating).

e) Inspection of Preservation, Packaging and Marking (PP&M) as required by part 5.0 of this specification.

4.6 Calibration System: The Contractor shall be required to maintain a test equipment calibration program in compliance with ANSI/NCSL Z540-3. The program shall be documented and traceable to the National Institute of Standards (NIST). The calibration system records shall be maintained for inspection for the duration of any contract referencing this specification

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

5.0 Preservation, Packaging & Marking (PP&M), Rudder Assembly (Preliminary):

Packed rudder assembly shall be preserved, packed and marked to withstand outdoor storage with only the cover of a tarp or shrink wrap for protection from the elements.

5.1 Preservation: All unpainted pieces or surfaces subject to corrosion if left unprotected shall be coated with corrosion preventative compound, Grade 3 in accordance with MIL- PRF-16173. Preservation is further defined in the following packaging requirements.

5.2 Packaging, Rudder Blade: The Rudder Assembly shall be packed in a skid mounted wood shipping container that is suitable for repeated use. The container shall have a lid that is attached with self-tapping wood screws for easy removal and reattachment. As a general requirement, the container shall be capable of supporting the rudder assembly in order to maintain stability and protection during shipping by commercial carrier. Interior blocking and cradles shall be used.

5.3 Marking: Mark each shipping container with the following corresponding information:

NSN: 2040-01-501-9601

Name: 75F-WLR Rudder, Marine Contract Number: “see contract” Part Number: 75-WLR-F-562-003 Condition Code: “A” Quantity and Unit: 1 “EA” Weight: 1,500 lbs

NSN: 2040-01-503-0291

Name: 75F-WLR Rudder, Marine Contract Number: “see contract” Part Number: 75-WLR-F-562-005 Condition Code: “A” Quantity and Unit: 1 “EA” Weight: 1,500 lbs

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

5.4 Loose Parts: After QA and acceptance all loose parts shall be packaged unattached to rudder blade in separate box inside main container.

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

a) All bar coded labels shall be in accordance with SFLC Bar Coding specification number D-000-0100.

1) The actual labels shall be Type “V”, Grade “C”, Style 2”, Composition “a”.

2) The Bar Code Label can be applied separately or as part of the marking required in 5.3.

6.0 Notes:

6.1 Document Sources:

Specification and Standards (DODISS Documents) Standardizations Document Order Desk 700 Robbins Avenue Building #4, Section D Philadelphia, PA 19111-5094 215-697-1187 305-443-9353

National Conference of Standards Labs (ANSI/NCSL) 1800 30th St., Suite 305B Boulder, CO 80301 303-440-3339