PROPELLERS_SPECIFICATIONS_P-245-0612_MAY_2016.docx

Appendix A REVISION No. . CHANGE No. .

PURCHASE SPECIFICATION FOR PROPELLERS

USED ON 110 FT

WPB PATROL BOATS

P-245-0612

ORGINATED BY Wayne Nickel (PBPL Supply) DATE: 11/2011 .

ORGINATOR’S COMMAND USCG Surface Forces Logistics Center (SFLC) .

DEPARTMENT / DIVISION Patrol Boat Product Line (PBPL) .

UPDATED BY DATE: .

REVIEWED BY Mike Soost (PBPL Engineering) DATE: 11/2011 .

SFLC QA REVIEW Matt Wentzler DATE: 10/2011 .

PLSSR APPROVAL Mike Soost (PBPL Engineering) DATE: 11/2011 .

1.0 SCOPE

1.1. General – This document sets forth the requirements for the manufacture, testing, inspection, preservation, packaging, packing, marking and bar-coding of right hand (RH) and left hand (LH) marine monobloc propellers applicable to the U.S. Coast Guard 110 foot WPB Coastal Patrol Boats. The quantity and type of propellers purchased under this specification will be indicated on each Contract Deliverables List.

1.2. Classification

1.2.1. Propeller Types

a. Type 1 - Left Hand (LH), P/N 110-WPB-245-001-LH

NSN: 2010-01-222-2440

b. Type 2 – Right Hand (RH), P/N 110-WPB-245-001-RH

NSN: 2010-01-222-2441

1.3. Government Furnished Equipment (GFE) - The listed items are property of and managed by the USCG Surface Forces Logistics Center, Baltimore MD and will be released to the Contractor after contract award.

1.3.1. Gauge Set, Type 1 – NSN 2010-01-F92-0222 - Consisting of a plug and ring gauge packaged and packed in a wooden crate.

1.3.2. Test Shaft Kit, ACN 2010-01-F99-1585 - Consisting of test shaft, plug gauge, two pressure gauges, two hydraulic pumps, hydraulic nut, relief valve, brass spacer, two hose assemblies, seals, hydraulic oil, and various fittings packaged and packed in its own box.

2.0 APPLICABLE DOCUMENTS

2.1. General – The documents listed in this section are specified in sections 3, 4, and 5 of this purchase specification. This section does not include documents cited in other sections of this description or 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 description, whether or not they are listed.

2.1.1. Government Documents – The following specifications, standards, publications, and handbooks form a part of this overhaul description 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. Coast Guard Documents – The following documents form a part of this specification to the extent specified herein. The documents listed shall be by title and effective date, unless otherwise documented.

2.2.1. Drawings

a. USCG Drawing No. 110 WPB 245-4 Rev. A, dated 4/9/2009 – Propeller Details

b. USCG Dwg. 110 WPB 245-5 dated July 29, 1996 – Assembly of Oil Injection Equipment

2.2.2. Specifications

a. USCG-SFLC Specification D-000-100 Rev. G, Change 1, dated 02/06, Bar Coding for USCG Surface Forces Logistics Center Material.

b. USCG-SFLC Standard Specification 740, dated January 2009

2.3. Other Government Documents – The following documents form a part of this specification to the extent specified herein. The documents listed shall be by title and effective date, unless otherwise documented.

2.3.1. NAVSEA Technical Publication S9243-A5-MMD-010 dated 11/30/1995 – Gages, Plug and Ring, Propellers and Propulsion Shafting; Repair, Inspection, Certification and Use

2.3.2. MIL-PRF-680C dated 03/25/2010 – Performance Specification, Degreasing Solvent.

2.3.3. MIL-PRF-121G dated 4/30/2001 – Performance Specification, Barrier Materials, Greaseproof, Waterproof, Flexible, Heat Sealable

2.3.4. MIL-PRF-16173 dated 9/7/2006 – Performance Specification, Corrosion Preventative Compound, Solvent Cutback, Cold Application

2.3.5. MIL-DTL-2845E (SH) dated 08 Aug 1999 – Propulsion Systems, Boat and Ship; Main Shafting, Propellers, Bearings, Gauges, Special Tools, and Associated Repair Parts; Preservation, Packaging, Packing and Storage of

2.4. Commercial Documents – The following documents form a part of this specification to the extent specified herein. The documents listed shall be by title and effective date unless otherwise documented.

2.4.1. Society of Automotive Engineers (SAE)

a. SAE J448A - dated June 1963 – Surface Texture Standard

b. SAE AMS-T-22085 - dated 6/1/1999 – Tapes, Pressure-Sensitive, Adhesive, Preservation and Sealing–FSC 7510

2.4.2. National Conference of Standards Laboratories (NCSL)

a. NCSL Z540-3 dated 1/1/2006 – Requirements for the Calibration of Measuring and Test Equipment

2.4.3. American Society For Quality Control (ASQC)

a. ASQC Q9003-1994 - dated 1/1/1994 – Quality Systems - Model for Quality Assurance in Final Inspection and Test

2.4.4. International Organization For Standardization (ISO)

a. ISO 484/2-1981(E), dated 8/15/1981 – Shipbuilding-Ship Screw Propellers-Manufacturing Tolerances - Part 2: Propellers of Diameter Between 0.80 and 2.50 m Inclusive

2.4.5. American Bureau of Shipping (ABS)

a. ABS Rules for Survey After Construction 2011 - Guide for Bronze and Stainless Steel Propeller Castings, Part 7 Appendix Section 10

2.4.6. Acoustical Society of America (ASA)

a. ASA S2.26 dated, 01/01/2001, Vibration Testing Requirements and Acceptance Criteria for Shipboard Equipment

2.4.7. British Standards Institute (BSI)

a. BSI BS EN 1982, dated 30 May 2008 – Copper and copper alloys — Ingots and castings

2.5. Document Availability – To obtain the referenced documents see section 6.1.

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

3.0 REQUREMENTS

3.1. General – The Contractor shall provide all equipment, labor and materials to manufacture, test, inspect, preserve, package, pack and mark Left Hand (LH) and Right Hand (RH) propellers in accordance with the referenced drawing(s) and data provided within this specification.

3.2. Government Furnished Equipment (GFE) – The Contractor shall provide protective storage for the GFE 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.

3.2.2. The Contractor shall conduct a visual inspection of the GFE Ring and Plug Gauge Set and Test Shaft Kit upon receipt to verify condition and usability. The CG Contract Administrator shall be notified immediately of any damage or missing parts including dents, dings, scratches, corrosion, or distortion of the critical test surfaces of the Ring and Plug Gage that could affect accuracy related to intended purpose.

a. The Contractor shall contact the CG Contract Administrator prior to inspection to schedule CG Quality Assurance personnel or COTR to be present during inspection of all GFE.

b. The Contractor shall submit a GFE inspection report to the CG Contract Administrator.

c. No repairs shall be conducted to GFE without prior authorization from the CG Contract Administrator.

3.3. Test and Inspection Plan – The Contractor shall submit a test and inspection plan to the CG Contract Administrator for approval. This plan shall include the specific inspections and tests specified herein, and all tests and inspections made by the Contractor to verify conformance to every requirement and tolerance as specified in the cited drawings, technical publications, and this specification.

3.4. Propeller Manufacture – Contractor shall manufacture each propeller in accordance with USCG Drawing No. 110 WPB 245-4, ref: 2.2.1.a. Propeller manufacturing tolerances shall meet ISO class 1 per ISO 484/2-1981(E) ref: 2.4.4.a.

3.5. Material – Each propeller shall be ABS Type 4 manufactured from N.A.B. Spec BSI BS EN 1982, lead content not to exceed 0.01%.

3.5.1. The Contractor shall perform a material chemical composition analysis and a tensile properties test for each propeller casting. The documented results shall consist of a comparison to the required specification and shall be submitted to the Coast Guard CG Contract Administrator for review/approval.

3.5.2. All material chemical composition analysis and tensile property tests shall be made by a laboratory meeting the calibration requirements in section 4.3 of this specification.

3.6. Construction of Propeller Castings – Each monobloc propeller casting shall be constructed in accordance with ABS Part 7 Section 10 titled Guide for Bronze and Stainless Steel Propeller Castings (Dated 2011), and USCG DWG. NO. 110 WPB-245-4.

3.6.1. Each propeller casting shall be formed with one continuous pour.

3.6.2. A separate test coupon shall be provided for every casting poured. This coupon shall be tested for its chemical composition and tensile properties. A copy of the results of the testing shall be given to the CG Contract Administrator.

3.7. Weld Repairs - If the castings require any weld repairs, welding procedures, welders, and welding operations shall be qualified in accordance with American Society of Mechanical Engineers (ASME), Section IX, 2008, Qualifications Standard for Welding and Brazing, and Welding and Brazing Operators per SFLC STD Spec 0740. Certification documentation shall be maintained and available to the CG Contract Administrator for review at any time during the contract period.

3.7.1. No weld repair is authorized unless prior approval is received from the CG Contract Administrator.

3.8. Propeller Finishing – Each propeller may be finished using Computer Numerical Controlled (CNC) machining using equipment that can be programmed for automatic contouring of hydrodynamic surfaces or in the conventional casting manner that employs hand grinding and finishing for obtaining required blade contour and profile dimensions.

3.8.1. The tolerances specified at the design sections shall apply to all hydrodynamic surfaces.

3.8.2. The Contractor shall demonstrate a manufacturing or inspection process that ensures tolerances for all hydrodynamic surfaces are met. The use of marine propeller inspection systems such as Prop Scan or Hale Measurement Recording Instrument (MRI) or a combination of such systems will be acceptable.

3.8.3. Dimensional Inspection shall be in accordance with this specification and USCG DWG. NO. 110 WPB-245-4.

3.9. Hub Bore Inspection – The Contractor shall demonstrate that the finished hub bore for each propeller meets dimensional requirements by utilizing the government furnished plug gage referenced in 1.3.1 to perform the inspections outlined below. These inspections shall be conducted in accordance with Chapter 3 of NAVSEA Technical Manual S9243-A5-MMD-010 titled Gages, Plug and Ring, Propellers and Propulsion Shafting; Repair, Inspection, Certification and Use.

a. Position the propeller with its bore axis vertical and the large taper uppermost. The propeller must be supported on the bottom of its boss by a soft washer (wood, alloy, etc) with 3/4 inch minimum clearance for the plug gauge small end to pass through.

b. The plug gauge shall be rigged so that it can be suspended over the bore of the propeller and dropped when required.

c. Prior to dropping the plug gauge it shall be spotlessly clean and free of oil. The plug gauge shall then be coated with a very light trace of marking blue evenly on the entire taper.

d. The plug gauge shall be suspended centrally in the bore of the propeller with a drop distance of 4 inches. Too much blue will result in an evident hydraulic bounce leaving the plug gauge free. If this happens the procedure must be repeated with a lighter smear of blue until positive seating is achieved.

1. Contractor shall not thin marking blue to achieve blue fit.

e. The plug gauge must be withdrawn carefully to ensure that the blue marking is not touched or otherwise marked. The hydraulic nut will be needed to break out the plug gauge.

f. Ideal contact is with blue removal contact witness markings throughout the plug gauge length. The limits of acceptability are as follows:

1. 95% between the forward end of the propeller hub and the first oil groove with no breaks extending across the band.

2. 95% between the aft end of the propeller hub and the first oil groove with no breaks extending across the band.

3. At least 80% of the remaining surface area.

3.10. Hub bore fit – Using GFP Test Shaft, USCG DWG. 110 WPB 245-5 and the following procedure.

3.10.1. Cover the exposed threads at shaft end with nylon or P.V.C. tube and assemble propeller to dummy shaft and ensure complete contact between the conical surfaces by a light, but positive, axial force. Measure the distance between the propeller hub face to the small end of the shaft taper. The acceptable distance shall be 0.177 inches, plus 0.080 inches, minus .020 inches.

3.10.2. Check that the hydraulic nut is fully assembled, (i.e., gland fully compressed home into nut body). Secure by screwing the hydraulic nut to the shaft end and screw until the gland face of the nut abuts the face of the propeller.

3.10.3. With each pump relief valve tap closed and the respective pipe to securing nut slackened; operate each pump handle in turn to vent the respective system.

NOTE: Propeller draw can be determined by measuring the distance between the propeller hub face and the fixed hydraulic nut body. “Draw” is defined as the axial distance the propeller must travel up the taper in order to affect the interference between the propeller and the shaft necessary to transmit the designed torque. Required draw is 0.182 - 0.192 inches.

3.10.4. The hydraulic nut pump should now be operated to register in the order of 1,450 – 2,900 psi. This should discourage oil from the expansion pump from leaking past the taper ends to atmosphere on initial pressurization.

3.10.5. The expansion pressure pump should now be increased gradually to 12,000 - 16,000 lbs. in a manner such that the rate of pressure on the nut is increased at the same time to 6,000 - 8,000 lbs. or until satisfactory depth is reached.

a. With a propeller that has been manufactured to the relevant plug gauge and shaft to the relevant ring gauge, i.e., a well executed pressure joint, both the designed pressures should be reached at the time that the “draw” is attained.

b. In the event that either pump leads with a pressure rate more rapid than is necessary, it is always advisable that:

1. The hydraulic nut pressure rate should never exceed the relative expansion pressure rate.

2. It should be that the expansion pressures are in advance of the nut relative pressure.

3. Pressure required between shaft and propeller when fitting propeller is 11,600 psi (minimum).

4. Pressure required at hydraulic nut when propeller has taken up full draw (0.182 - 0.192 inches) to be approximately 4,440 -7,500 psi.

3.10.6. The expansion pressure should now be released gradually to zero by careful control of the pressure pump relief valve tap. The above control will protect the gauge indicator pointer.

a. At the precise time that the pressure is released from the nut, a final check on the draw must be made and compared to the initial readings obtained with the nut in place and pressured.

b. Should no movement be observed after ten minutes, it will only remain for the equipment to be dismantled and plugs fitted to the propeller body together with other thread protection gear.

3.10.7. For the removal of the propeller, assuming that all preparatory work has been carried out up to the point of connecting hydraulic pipes all that is necessary is as follows:

a. Assemble hydraulic nut to shaft.

b. Commence pumping oil into the propeller body until oil issues between boss and shaft at forward end of propeller boss. Do not exceed 25,000 psi.

c. Following removal, all hydraulic connections shall have plugs refitted to prevent entry of dirt.

3.11. Ring and Plug Gauge, Test Shaft Kit– After completion of all planned testing the Contractor shall conduct a visual inspection of the GFE Ring and Plug Gauge Set and Test Shaft Kit to verify condition. The CG Contract Administrator shall be notified immediately of any damage or missing parts including dents, dings, scratches, corrosion, or distortion of the critical test surfaces that could affect accuracy related to intended purpose.

a. If a short term storage period of less than 30 days is anticipated, the Contractor shall clean the applicable Ring or Plug Gauge with a petroleum based solvent meeting the requirements of MIL-PRF-680 Type II, coat with a preservative in accordance with MIL-PRF-16173, grade 2, and re-stow the ring or plug gage in its designated position within the shipping container. A neutral barrier material conforming to MIL-PRF-121G, type 1, shall be applied to all wood surfaces that come in direct contact with either gauge.

b. If the contract is at its conclusion or during long term storage periods exceeding 30 days, the Ring and Plug Gauge set shall be thoroughly inspected and cleaned with a petroleum based solvent in accordance with MIL-PRF-680 Type II, and then completely coated with a preservative that conforms to MIL-PRF-16173, grade 4 and re-stow the ring or plug gage in its designated position within the shipping container. A neutral barrier material conforming to MIL-PRF-121G, type 1, shall be applied to all wood surfaces that come in direct contact with either gauge.

3.11.2. The Test Shaft Kit shall be packaged and packed as it was received by the Contractor.

3.11.3. No repairs shall be conducted to GFE Ring and Plug Gauge Set without prior authorization from the CG Contract Administrator.

3.11.4. Coast Guard SFLC Quality Assurance personnel will inspect all GFE prior to return to the Coast Guard.

3.12. Surface Finish – Surfaces of the propeller blades and hub shall be ground fair and polished in accordance with SAE J448 to meet the following requirements:

a. The propeller blade surface roughness from R 0.2 to tip shall not exceed 63 micro-inches Ra.

b. Propeller hub exterior surface shall not exceed 125 micro-inches Ra.

3.13. Balancing – After completion of all required manufacturing processes, each propeller shall be single plane balanced in accordance with ASA S2.26 (Imbalance shall not exceed 7.1 oz-in). The residual unbalance in each plane of correction shall not exceed the value determined by calculating the following formula: U = 62.3W/N2 where:

U = Maximum allowable residual unbalance in N-m W = Weight of rotating part in Kg (340 kg estimated) N = Maximum operating speed of unit (800 RPM) U = 0.25 N-m (25.8 kg-mm)

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.

3.13.1. The mandrel or concentric rings used to support the propeller during balancing shall not exceed a total indicated run-out (TIR) of 0.025 mm (.001”).

3.13.2. Material removed to affect balance shall be taken from the suction face on as large an area as practicable and shall not approach the leading or trailing edges within (10) ten percent of the blade width.

3.13.3. Care shall be taken to assure that removal of material shall not cause the tolerances for thickness, surface contour, edge contour, width or pitch to be exceeded.

3.13.4. There shall be no machining, welding or material addition or removal to the propeller after final balance check.

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

3.14. Surface Inspections - A visual inspection shall be performed on all exterior blade surfaces in accordance with USCG-SFLC Standard Specification 740.

3.14.1. The Contractor shall perform a dye penetrant inspection over 100 percent of the blade surfaces including the hub in accordance with ASTM E1417, 2005, Standard Practice for Liquid Penetrant Testing per SFLC STD Spec 0740.

3.14.2. The Contractor shall document all propeller defects resulting from the visual and dye penetrant inspections. These defects shall be indicated by type and size on visual inspection sheets. Each propeller will require individual inspection sheets for the pressure face of the blades, suction face of the blades, the fillet, and the hub.

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

3.15. Final Test and Inspection Report – The Contractor shall perform final dimensional, balancing, visual, and dye penetrant surface inspections for each propeller manufactured and record this data on a final inspection report. This report shall accurately reflect the final condition of each propeller.

3.15.1. The final inspection report shall contain, at a minimum, the following data:

a. Propeller blade radius.

b. Pitch at the 0.5 through 0.95 radii.

c. Average pitch of each blade at the 0.5 through 0.95 radii.

d. Blade section widths at the 0.4 through 0.95 radii.

e. Thickness at every 10 percent station for each blade section from the 0.4 through 0.95 radii.

f. Track

g. Edges smooth, no sharp edges.

h. Angular spacing of blade center axis.

i. Surface finish of blade, hub and bore areas

j. Surface inspection (visual and 100 percent dye penetrant)

k. Hub bore visual inspection

l. Hub bore inspection in accordance with 3.9

m. Hub bore fit in accordance with 3.10

n. Material composition

o. Balancing Data

p. Fairing Rod Clearences

3.15.2. The Final Inspection Report shall be submitted to the CG Contract Administrator for review. If this report is determined to be acceptable, the CG Contract Administrator will authorize SFLC’s Quality Assurance Branch to schedule final inspections/tests outlined in section 4.6 of this specification.

3.16. Propeller Identification Markings – Each propeller shall have the following information stamped in accordance with the marking data provided on USCG Drawing No. 110 WPB-245-4 Rev. A, dated 4/9/2009.

a. Serial Number provided by the CG Contract Administrator

b. Ship’s Class – 110 WPB

c. Starboard or Port

d. Direction of rotation (RH or LH) when viewing aft looking forward.

e. National Stock Number (NSN) provided by applicable specification.

f. Design diameter – 1260mm

g. Design pitch at 0.7R – 1560mm

h. Name of manufacturer and date of manufacture

i. Actual propeller weight in lbs

j. ABS Grade 4

3.17.1. The characters shall be ¼” to ½” high, on the hub outside diameter near the aft end, clear of the fillets.

NOTE: THE SERIAL NUMBER FOR EACH NEW PROPELLER MANUFACTURED IN ACCORDANCE WITH THIS SPECIFICATION WILL BE PROVIDED BY THE CG CONTRACT ADMINISTRATOR.

3.18. Photo Documentation – The Contractor shall provide Photo Documentation to the CG Contract Administrator during in-process welding repairs of the casting (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 CG Contract Administrator during the manufacturing phases outlined below.

3.18.1. Photo Documentation Phases:

a. During the dye penetrant inspection showing any linear/non-linear discontinuities of the propeller casting.

b. During repair of the propeller casting whenever welding is required.

c. 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.

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

e. Prior to shipment, showing container markings.

3.18.2. In addition to providing electronic photographs at the various manufacturing phases indicated, the Contractor shall provide a final Compact Disc (CD) to the CG Contract Administrator that includes all of the pictures referenced in 3.18.1. The pictures on this CD shall be organized in “jpg format” within folders labeled as follows: NDT Inspection (photos referenced in 3.18.1.a); Welding Repair (photos referenced in 3.18.1.b); Surface Finish/Hub Stamping(photos referenced in 3.18.1.c); and Preservation, Packaging, and Markings (photos referenced in 3.18.1.d and e).

3.19. Notifications and Inspections – The Contractor shall be responsible for notifying the CG Contract Administrator at least seven (10) calendar days prior to inspections or monitored testing required herein.

4.0 QUALITY ASSURANCE (Q.A.)

4.1. General – Contractor shall maintain an inspection system which shall insure each item offered to the Coast Guard for acceptance or approval conforms to the contract requirements. The inspection system shall be documented, meet the requirements of ASQ Q9003 and be available for review by the Coast Guard.

4.1.1. Contractor shall submit a Quality Assurance Plan for approval to the CG Contract Administrator.

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

4.3. Calibration System – Contractor, as well as any subcontractors, shall maintain a test equipment calibration program in compliance with NCSL Z540-3. The program shall be documented and traceable to the National Institute of Standards and Technology (NIST).

4.3.1. The calibration system records shall be maintained for inspection for the duration of any contract referencing this overhaul description.

4.4. Responsibility for Inspection – Contractor shall be responsible for the performance of all inspection requirements specified herein. Contractor shall provide space, personnel and test equipment for the conduct of all inspection requirements. All inspection and testing shall be performed at the Contractor’s 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. Contractor shall notify the CG Contract Administrator prior to the scheduled commencement of any inspections required by this overhaul description.

4.5. Responsibility For Compliance – All items shall meet the provisions of Sections 3 & 5. The inspections set forth in this description shall become part of the Contractor’s overall inspection system or quality program. The absence of any inspection requirement in this description 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. Inspections / Tests – PITCHOMETER: All inspections MUST be achieved with a high accuracy Propeller Scan Pitchometer. (Drop Type Pitchometers will not be an accepted method of performing the below tests on the Coast Guard propellers. The inspections/tests required in section 3.0 are the minimum required and are not intended to supplant any controls, examination, inspections or tests normally employed by the Contractor to assure the quality of the item in question.

4.6.1. Contractor shall have the latest versions of the drawings, specifications, tolerances and approved test procedures available for inspection, if necessary.

4.6.2. The following are required and will be observed / inspected by a USCG-SFLC Quality Assurance Representative.

a. Dimensional inspections, including the hub bore, in accordance with section 3.4, 3.9 and 3.10 of this specification.

b. Surface inspections in accordance with section 3.12 of this specification.

c. Balancing inspection in accordance with section 3.13 of this specification.

d. Propeller identification markings in accordance with section 3.16 of this specification.

e. GFE inspection in accordance with section 3.11 of this specification.

f. Preservation, packaging and marking in accordance with 5.0 of this specification.

4.7. Failure Responsibility – If a propeller fails to pass any inspection or test, the Contractor shall report the failure and the recommended fix to the CG Contract Administrator. If approved, the corrective action on the materials or processes shall be taken in accordance with this section.

a. The CG Contract Administrator reserves the right to totally reject any failed item without considering any suggested corrective action.

4.7.1. The inspection/testing shall be discontinued until all corrective action has been taken.

4.7.2. After all corrective actions have been taken the inspection/tests shall be continued or repeated at the option of the CG Contract Administrator.

4.7.3. Acceptance shall be withheld until re-inspection has shown the corrective action was successful and the item satisfactorily passed all inspections and tests.

4.7.4. All corrective actions shall be documented as part of the Contractor's inspection system and submitted for approval to the CG Contract Administrator.

a. Each corrective action report shall include, but not be limited to the cause of each defect, corrective action suggested, and the steps taken to prevent a recurrence of each defect.

4.8. Test & Inspection Reports – A copy of any standard Contractor test or inspection report shall be turned over to the CG Contract Administrator upon his/her request.

4.9. Packing Inspection - The CG Contract Administrator shall be notified prior to the packaging, packing, marking and bar-coding of the finished propellers in accordance with section 3.19 of this overhaul description.

5.0 PRESERVATION, PACKAGING, PACKING, MARKING AND BAR-CODING

5.1. Preservation and Packaging – Each propeller, GFE Ring and Plug Gauge Set and Test Shaft Kit shall be cleaned, preserved, packaged, packed, marked and bar-coded as specified herein.

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(s).

a. After cleaning, tape conforming to SAE-AMS-T-22085, TYPE II and strippable compound preservative shall be applied to each propeller in accordance with MIL-DTL-2845E (SH) section 3.14.1.3.1.

b. After the application of strippable compound, galvanized sheet metal blade edge protectors shall be installed in accordance with MIL-DTL-2845E (SH) section 3.14.1.4. The edge guards shall be held in place with all stainless steel grade hardware.

c. The Contractor shall construct a skid type shipping container in accordance with Appendix A.

d. Under the observation of the CG Quality Assurance representative the propeller shall be secured to the wooden skid. Once secured the cover of the shipping container shall carefully be placed over the propeller and secured using the lag bolts.

5.1.2. The GFE supplied Test Shaft Kit and Gage Set shall be preserved, packaged and packed as they were received for return to the Coast Guard in accordance with section 3.11 of this specification.

5.2. Packing – Each propeller shall be mounted in the shipping crate in accordance with Appendix A. After packaging and packing is completed, the contractor shall enclose a copy of the prop scan or MRI results on each propeller. The results shall be placed into an envelope and marked for the “PE or EPO”.

5.2.1. The GFE supplied Test Shaft Kit and Gage Set shall be packaged and packed in the original shipping containers.

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 wooden container. The container lettering shall be black waterproof painted stencil and permanently affixed. The lettering shall be at least 1” high, and be applied on a highly contrasting, painted white background. The lag bolts shall be highlighted in red with a stencil saying “Remove cover by removing lag bolts in Red”. The lid shall also have heavy duty lifting eyes in two corners of the lid.

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

5.3.2. The shipping containers for the GFP supplied Test Shaft Kit and Gage Set shall be marked as indicated in section 5.3.3.c and d.

5.3.3. See below for proper marking layout.

a. Type 1- Propeller, Left hand (LH)

b. Type 2 – Propeller, Right Hand (RH)

c. Test Shaft Kit

d. Ring and Plug Gauge Set

5.4. Bar Coding – The National Stock Number (NSN) shall be bar-coded in addition to the markings required above. Bar coded labels shall be in accordance with SFLC specification D-000-100 Rev. G. The bar-code label can be applied separately or as part of the marking required in 5.3 of this description.

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

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

5.5. Coast Guard Acceptance – Acceptance will be made at destination by a government representative. Acceptance will be contingent upon representative's verification of no damage in transit, correctness and completeness of order and Contractor’s conformance to preservation, packaging, packing, marking and bar-coding requirements.

6.0 NOTES

6.1. Government & Commercial Document Sources

6.1.1. Coast Guard Documents

a. USCG Surface Forces Logistics Center 2401 Hawkins Point Road Baltimore, MD. 21226-5000

(410) 762-6434 Fax: (410) 762-6226 Attn: Scott Wood www.uscg.mil/hq/elcbalt

6.1.2. Other Government Documents

a. Department of Defense Single Stock Point (DODSSP) Building 4, Section D 700 Robins Avenue Philadelphia, PA 19111-5094

(215) 697-6396/6257 Fax: (215) 697-9398 www.assist.daps.dla.mil/quicksearch

b. DOD & Navy Publications & Forms (Other Than DODSSP) Naval Publication and Forms Center 5801 Tabor Ave.

Philadelphia PA. 19120

(215) 697-2000

6.1.3. 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.com

b. Society of Automotive Engineers, Inc. (SAE) 400 Commonwealth Drive Warrendale, PA 15096

(412) 776-4841 Fax: (412) 776-5760 www.sae.org

c. National Conference of Standards Laboratories (NCSL) 2995 Wilderness Place Suite 107 Boulder, CO 80301-5404

(303) 440-3339 Fax: (303) 440-3384 www.ncsli.org

d. American Society of Quality Control (ASQC) 600 N. Plankinton Ave.

Milwaukee, WI 53203

(800) 248-1946 Fax: 414-272-1734 www.asq.org

e. Acoustical Society of America (ASA) Suite 1NO1 2 Huntington Quadrangle Melville, NY 11747-4502

(516) 576-2360 Fax: (516) 576-2377 asa@aip.org

USCG - SFLC

DATE – 11/2011

P-245-0612

f. British Standards Institute (BSI) 389 Chiswick High Rd London W4 4AL United Kingdom +44 (0)20 8996 9001 cservices@bsigroup.com

SKID TYPE SHIPPING CONTAINER

GENERAL DESCRIPTION

The Skid Type Shipping Container is an internally reinforced wooden box consisting of two parts; a skidded base and one piece cover (hood). It is usually specified for contents up to 1000 pounds in weight and is designed to meet the following requirements: allow attachment of the item(s) directly to the skid base; provide protective shrouding of the container contents, facilitate fork lift handling, promote durability and protection through maximum reinforcement, and permit reusability for multiple shipments. The side, end, and top panels are assembled to become a one piece cover (hood) which is then lowered over the secured load and bolted to the skid base.

HOOD REQUIREMENTS

The one piece hood , consisting of the two sides, two ends, and top, shall be fabricated using nominal 2”x10” pressure treated lumber. All built-up pieces used for fabricating the sides, ends, and top shall be connected using stainless steel corrugated fasteners (3/4”x1”) spaced every 6 inches. Internal dimensions shall be calculated to allow a minimum of 2” clearance at any point between the contents and the container. The hood sides shall be reinforced on the interior with battens and diagonals using nominal 2”x6” pressure treated lumber. The hood ends shall be reinforced on the exterior using cleats. The hood shall be assembled using 12D hot dipped galvanized nails spaced approximately 3-4 inches apart. All nails that pass through battens, diagonals, cleats or other areas shall be clinched. Four lifting eyes shall be fabricated from galvanized flat bar to facilitate removal/installation of the hood. One lifting eye shall be bolted to each top corner using appropriate galvanized fasteners. Refer to Figure 1 to view general appearance of hood.

SKID BASE REQUIREMENTS

The one piece skid base, consisting of 3 skids, 2 headers, and a load bearing floorboard shall be fabricated using pressure treated lumber. The 3 skids shall be fabricated using nominal 4”x4” lumber cut to length, beveled 45 degrees on each end to facilitate sliding when necessary. The load bearing floor board shall be fabricated using 3/4'” pressure treated plywood and two 4”x4” floor joists. The plywood shall be nailed (10-12D hot dipped galvanized nails) or screwed (2” stainless steel flathead screws) to the skids. The two floor joists shall be placed at 90 degrees to the skids and positioned as necessary at the center point of the base to accommodate the propeller load. These joists shall be through bolted to the skids using galvanized ½” carriage bolts/washers/nuts. The end headers shall be fabricated using nominal 2”x 4” pressure treated lumber cut to length. The end headers shall also be through bolted to the skids using galvanized ½” carriage bolts/washers/nuts. Refer to Figure 1 to view general appearance of skid base.

FINAL ASSEMBLY REQUIREMENTS

The propeller shall be bolted to the skid base. The Contractor and the Contracting Officer shall mutually agree on the best method to satisfy this requirement given available securing points and the criticality/protection of the hub bore finish. The cover (hood) shall be fastened to the skid base using stainless steel hex head 3/8”x 5” lag screws spaced evenly around the cover perimeter with a minimum of four lag screws provided for each side.

STRAPPING

Prior to shipment, the box shall be banded with 2 metal straps, each encircling the shipping container passing between the skids. Each strap shall be galvanized or stainless steel, ¾” wide with a minimum thickness of .023”. Each strap shall be positioned and secured within 9” of the box end.

MOUNTING PLATE WITH GASKET TO MOUNT PROPELLER TO SKID.

PROPELLER MOUNTED TO ½” STEEL PLATE AND CRATE BOTTOM

PROPELLER WITH PROTECTIVE COATING, EDGE GUARDS AND MRI REPORT MOUNTED TO CRATE BOTTOM.

PROPELLER CRATE TOP WITH MARKINGS (LAG BOLT HOLES IN BOTTOM)

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