R-245-2009-CW030.doc

USCG - SFLC

DATE – 11/13

REVISION No. .

CHANGE No. .

TITLE:

225 WLB CONTROLLABLE PITCH PROPELLER HUB

OVERHAUL SPECIFICATON

R-245-2009

ORGINATED BY Andrew G Ollerman DATE 11/13

ORGINATOR’S COMMAND SURFACE FORCES LOGISTICS CENTER (SFLC)

PLATFORM / SECTION IBCTPL/Supply

INTERNAL REVIEWER DATE

SOWRB APPROVAL James Happe DATE 12/13

225 WLB CONTROLLABLE PITCH PROPELLER HUB

OVERHAUL SPECIFICATION

1.0 SCOPE

1.1 This Overhaul Specification outlines the general requirements for the receipt, arrival inspection, overhaul, acceptance testing, preservation, packaging, packing, and marking of U.S. Coast Guard controllable pitch propeller (CPP) hubs.

1.2 CLASSIFICATION

1.2.1 Types - CPP Hub Assemblies

a. Type 4 - (OEM - Rolls-Royce) 225 WLB (Hulls 201-216)

1.2.2 Styles - CPP Hub Assemblies

a. Style B - Port, Right Hand (clockwise rotation)

1.3 GOVERNMENT FURNISHED PROPERTY (GFP)

1.3.1 CPP Hubs, controlled by the USCG Surface Forces Logistics Center, Baltimore, MD by NSN's.

a. Type 4, Style B - 2010-01-421-3952

1.4 GOVERNMENT FURNISHED MATERIAL (GFM) – None.

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 or recommended for additional information or as examples. While every effort has been made to insure the completeness of this list, document users are cautioned that they must meet all specified requirements of the documents cited in section 3, 4, or 5 of this specification, whether or not they are listed here.

2.2 DOCUMENT AVAILABILITY - To obtain the referenced documents see section 6.1.

2.3 GOVERNMENT DOCUMENTS - The following specifications and standards form a part of this specification to the extent specified herein. Unless otherwise specified, the documents listed here by number and date shall be those in the Department of Defense Single Stock Point of Specifications and Standards (DODSSP) and supplements thereto.

2.3.1 SPECIFICATIONS

a. MIL-DTL-2845E (SH), Dated 18 August 99, Propulsion Systems, Boat and Ship; Main Shafting, Propellers, Bearings, Gauges, Special Tools, And Associated Repair Parts; Preservation, Packaging, Packing and Storage Of.

b. MIL-PRF-17672E, Dated 14 October 2010, Hydraulic Fluid, Petroleum, Inhibited.

c. DOD-P-24562A (SH), Dated 01 November 1982, Propellers, Ship, Controllable Pitch (Metric).

d. DoD 4140.01-M-1, Dated 07 September 2007; Compliance for Defense Packaging: Phytosanitary Requirements for Wood Packaging Material (WPM).

2.3.2 STANDARDS

a. MIL-STD-167-1A (SHIPS), Dated 02 November 2005, Mechanical Vibrations of Shipboard Equipment.

b. MIL-STD-2035A, Dated 15 May 1995, Nondestructive Testing Acceptance Criteria.

2.4 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.

2.4.1 DRAWINGS

a. USCG Drawing 225-WLB-245-204, REV B, Dated 5/15/96, CPP HUB ASSEMBLY R H

2.4.2 COAST GUARD SPECIFICATIONS

a. USCG-SFLC SPECIFICATION D-000-0100, Dated 10/91 REV G 02/06, Bar Coding for US Coast Guard Procured Material.

2.4.3 TECHNICAL PUBLICATIONS

a. T9074-AS-GIB-010/271, Dated 01 May 1997, Requirements for Nondestructive Testing Methods.

2.5 COMMERCIAL DOCUMENTS - The following documents form a part of this specification to the extent specified herein. The documents shall be the version listed by number and date from the referenced industry organization. Commercial documents may also be listed in Department of Defense Single Stock Point of Specifications and Standards (DODSSP).

2.5.1 American National Standards Institute (ANSI)/ National Conference of Standards Laboratories (NCSL)

a. NCSL Z540.3 Dated 03 August 2006, Requirements for the Calibration of Measuring and Test Equipment.

2.5.2 American Society For Quality (ASQ)

a. American Society for Quality (ASQ) – ASQ Q9001-2008, Dated 01 January 2008, Quality Management Systems – Requirements

2.6 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. NO EXCLUSIONS WILL BE MADE TO SECTION 4 OF THIS SPECIFICATION.

3.0 REQUIREMENTS

3.1 GENERAL - Overhaul is defined as the labor and materials required to restore all classifications of hubs listed herein to the operational parameters and performance characteristics of new controllable pitch propeller hubs.

3.1.1 This shall include the inspection and testing required confirming the same.

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 the equipment is not in use.

3.3 TEST & INSPECTION PLANS - The Contractor shall submit test and inspection plans to the Contracting Officer for approval. Each 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 OEM's drawings, specifications, and technical publications.

3.3.1 DISASSEMBLY/RECEIVING INSPECTION REPORT - Each hub assembly received by the Contractor shall be disassembled and inspected upon receipt. All parts shall be dimensionally inspected. Appendix “B” (WLB Hub Measurements) shall be filled out completely along with pricing and submitted to the Contracting Officer for approval. No further work is authorized until the submitted report is approved.

a. This report shall include the following items along with all tests and inspections made by the Contractor.

1. Separate cost breakdowns for each CPP hub, broken down by each part therein.

(a)

Each part determined to be beyond economical repair shall be so indicated, and the submitted pricing shall be for new parts.

(c) Any parts beyond economical repair (scrap) shall be set aside for Coast Guard inspection, see section 4.8.

(d) Total cost of overhaul for each hub inspected.

2. Comments, if any, pertaining to unusual observances during inspection and testing.

3. Any recommended upgrades or modifications and their associated costs.

4. Non-destructive testing on all parts tested by the Contractor.

(a) Non-destructive testing shall be performed in accordance with T9074-AS-GIB-010/271.

3.4 OVERHAULS - Overhaul of the CPP hubs shall be performed using criteria set forth in the OEM drawings, specifications, and technical publications.

3.4.1 Reconditioning of Parts - It is acceptable to recondition certain parts provided the final dimensions are within OEM repair standards. (i.e. trunnion OD’s can be ground undersize and match machined to undersize bearings and slide guides can be machine ground oversize and fitted with oversize slide blocks.)

3.4.2 Replacement Parts - All replacement parts shall be new OEM parts.

a. With each delivery order, the Contractor shall submit certification that all replacement parts are new OEM parts.

b. The government reserves the option to supply any replacement parts needed as GFM.

3.5 CLEANING & FINISHING - The Contractor shall clean and polish all machined surfaces as necessary to remove any etching, scoring, or other imperfections that would be detrimental to the operation of the hub.

3.5.1 Each hub body shall be cleaned to remove grease, dirt, and marine growth to aid in any required NDT inspection requirements.

3.6 CLEANLINESS - The area in which hub assembly, testing, and inspections are performed shall be kept free of any accumulation of dust, dirt, metal shavings, or contaminated fluids, and shall be separate from the manufacturing and machining area.

3.7 NDT INSPECTIONS - The Contractor shall perform a dye penetrant inspection of each blade seal port and periphery area in accordance with T9074-AS-GIB-010/271. The acceptance criteria of MIL-STD-2035A, Table IV shall be used for evaluations.

3.8 MASS TOLERANCE - The mass tolerance of all similar internal components arranged axisymmetrically shall be in accordance with DOD-P-24562A, paragraph 3.18.4.

3.8.1 The Government reserves the option to verify the mass tolerance of the internal hub components. The Contractor shall notify the Contracting Officer prior to hub reassembly in accordance with section 3.20.

3.9 BALANCING - If any machining is required to major hub components (i.e. hub body, hub cap, crosshead, and piston) due to erosion or wear, each complete hub assembly, less blades, shall be dynamically balanced on a rotating balancing machine. The maximum allowable out-of-balance force shall be calculated in accordance with MIL-STD-167-lA paragraph 5.2.

3.9.1 The Contractor shall balance the hubs in the presence of the Coast Guard Quality Assurance Representative.

3.10 HUB TESTING, OPERATING, AND PRESERVATION OIL - The following is the required hub type and normal system operating hydraulic fluids combination. Each specified oil type shall be used for the required testing and preservation of each hub type as specified in section 1.2.1.

3.10.1 HUB TYPES AND REQUIRED OIL – See Appendix A

3.11 HUB ACTUATION TESTING - Each hub assembly shall be hydraulically actuated to the full ahead and full astern positions. Observations shall be made and documented to assure smooth movement to each position with no binding or obstruction of movement. The Contractor shall document the size of the hydraulic power unit used to conduct the actuation test along with the elapsed time it took to actuate to each position, flow of hydraulic fluid, system pressure, and hydraulic oil temperature. .

3.12 HUB CAVITY PRESSURE TESTING - The following procedures shall be required to conduct the cavity pressure test of each type of hub.

3.12.1 Prior to any testing, each hub assembly shall be filled completely with the required hydraulic oil as required in section 3.12.1 of this specification. It shall be verified that each hub is full of oil and that no air is present.

3.13 HUB TYPES 4 AND 6 - The Contractor shall conduct a pressure test of the hub cavity by applying and maintaining a constant pressure for the duration of the testing period.

3.13.1 A visual inspection shall be conducted for the duration of the test checking for leaks. Acceptance shall be based on zero leakage for the duration of the testing.

3.14 HUB TYPES 1, 2, 3, AND 5 – The Contractor shall conduct a pressure test of the hub cavity by applying the required pressure, secure the pressure source, then monitor the pressure gauge for any drop in pressure.

3.14.1 Acceptance shall be based on a zero pressure drop for the duration of the testing.

3.15 HUB TYPES AND REQUIRED TESTING – The following listed pressures and duration times shall be the minimum parameters used to conduct the hub cavity testing as required in sections 3.14, 3.15 and 3.16 of this specification.

3.15.1 Type 4 – 60 psi for a duration of 30 minutes.

3.16 FINAL ACCEPTANCE OPERATIONAL INSPECTION/TEST REPORT

a. This report shall include the following items along with any others needed to verify all requirements.

1. Date of inspection.

2. Inspector's name.

3. Identification of units by serial number, part number, and stock number.

4. Complete final measurement report of all critical dimensions and applicable overhaul tolerances for each part to include clearances and thrust measurements.

5. A final operational test of each completely assembled hub using hydraulic pressure to actuate the hub from the full ahead to the full astern position. The measured actuation time and hydraulic supply parameters shall be documented on the report.

6. A cavity pressure test of each completely assembled hub to assure that no leaks occur. The hydraulic pressures and duration times used to conduct this test shall be documented on the report.

7. A complete listing of all test equipment to be used with a current calibration date for each piece of test equipment. The test equipment shall include pressure gauges, hoses, hydraulic power unit, and tools.

8. A complete description of each test and inspection including step by step procedures for all tests and inspections, in chronological order, with pass/fail criteria.

9. Mass tolerance documentation of internal hub components in accordance with DOD-P-24562A.

10. Dynamic balance in accordance with MIL-STD-167-1A, if applicable.

3.16.1 No tests or inspections required herein are intended to supplant any controls, examinations, inspections, or tests normally employed by the Contractor to ensure the quality of the equipment overhauled.

3.16.2 No hub shall be delivered until the final operational acceptance and pressure test results are approved by the Contracting Officer.

3.17 HUB MARKINGS - If the markings on the hub assemblies are unreadable each hub shall be re-stamped. The stampings shall be at least ¼” high of legible printing.

3.17.1 The stampings shall include, at the minimum, the following information.

a. STOCK NUMBER - See section 5.4.2.

b. PART NUMBER – See section 5.4.2.

c. SERIAL NUMBER – See section 5.4.2.

d. STARBOARD, L.H. (OR PORT. R.H.)

e. TYPE OF MATERIAL

3.18 NOTIFICATIONS & INSPECTIONS - The Contractor shall be responsible for notifying the Contracting Officer at least ten (10) calendar days prior to said Contractor being ready for any inspections testing, or balancing required herein.

4.0 QUALITY ASSURANCE (QA)

4.1 GENERAL - The Contractor shall provide and maintain an inspection system, which shall ensure each item offered to the Government for acceptance conforms to the contract requirements. The inspection system shall be documented and meet the requirements of ASQ Q9001-2008.

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 facilities 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 requirements of this specification. 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 NONCOMPLIANCE - Shall mean any single failure of any individual part or subsystem during final inspection/testing.

4.4.1 The Contractor shall replace the failed part(s) with new and restart the testing from the beginning.

4.5 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.

4.5.1 As determined by the Contracting Officer, prior to any testing, verify that the blade trunnions / crank discs are installed in the proper locations and configuration and match the design of the hub being overhauled. This inspection will verify the trunnions / crank discs are the correct part number and installed in accordance with the OEM drawing.

4.5.2 Mass tolerance inspection in accordance with section 3.10 of this specification.

4.5.3 Balancing inspection in accordance with section 3.11 of this specification, if applicable.

4.5.4 Hub actuation testing inspection in accordance with section 3.13 of this specification.

4.5.5 Hub cavity pressure testing in accordance with sections 3.14, 3.15, 3.16, and 3.17 of this specification.

4.5.6 Hub marking inspection in accordance with section 3.19 of this specification.

4.5.7 Preservation, Packing, and Marking in accordance with section 5.0 of this specification.

4.6 TEST AND INSPECTION REPORTS - One copy of any inspection/test report approved for use from submittals in 3.3 shall be sent to the Contracting Officer for approval.

4.6.1 A copy of all test and inspection reports shall be given to the Coast Guard Quality Assurance Representative upon arrival at the Contractor’s Plant.

4.6.2 A copy of all test and inspection reports generated while the Coast Guard Quality Assurance Representative is in plant shall be provided to the Quality Assurance Representative prior to exiting.

4.6.3 Any inspection, test or tolerance check report submitted shall have all out of tolerance readings circled or indicated.

4.6.4 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.

4.7 CALIBRATION SYSTEM - The Contractor as well as any subcontractors shall be required to maintain a test equipment calibration program in compliance with NCSL Z540.3-2006. The Contractor shall have a copy of the calibration program on hand during the term of this contract for review by any Coast Guard representative when requested.

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

4.8 DISCARDED/SCRAP PARTS - Any scrap parts identified during the arrival inspection and or later testing shall be segregated for inspection by a Coast Guard Representative for condition verification.

4.8.1 Scrap parts shall be returned to the Coast Guard by the Contractor or disposed of at the Contractor’s facility as directed by the Contacting Officer.

4.9 PACKING INSPECTION - The Contracting Officer shall be notified prior to the preservation, packaging, and marking of the completed units in accordance with section 3.20.

5.0 PRESERVATION, PACKING, AND MARKING

5.1 PRESERVATION - All Hub Assemblies shall be preserved in accordance with MIL-DTL-2845E Level A, paragraphs 3.8.1 and 3.16.1.

5.1.1 The hose attached to the hub assembly and oil expansion tank shall be connected to barbed fittings. The hose shall be secured to each barbed fitting with two hose clamps. Each hose clamp shall be tightened to prevent oil from escaping from the hub assembly or expansion tank during shipment and storage.

5.2 PACKING - All Hub Assemblies shall be packed and crated in accordance with MIL-DTL-2845E paragraph 3.16.3, Figure 17.

5.3 WPM Requirements – All packing and packaging material shall meet the Phytosanitary Requirements for Wood Packaging Material (WPM) IAW DoD 4140.01-M-1, Compliance for Defense Packaging Ref. 2.3.1.d. paragraph C2.1. WPM is defined as wood pallets, skids, load boards, pallet collars, wooden boxes, reels, dunnage, crates, frames and cleats.

5.3.1 All new purchases of WPM shall be constructed from heat treated (treated to 56° C. core temperature for 30 minutes) lumber and certified by an accredited agency recognized by the American Lumber Standard Committee (ALSC) in accordance with Ref. 2.3.1.d.

5.3.2 For existing crating and / or skid, the Contractor shall determine if the requirements listed in 5.3 are met. If the requirements are not met, the Contractor shall determine if the crating and / or skid can be brought to meet the requirements or needs to be replaced.

5.3.3 All crating and /or skids shall have the appropriate markings in accordance with Ref. 2.3.1.d.

5.4 MARKING - Each preserved, packed, and packaged item shall be marked in the upper left-hand side of the two longest sides, (two opposite sides if square) of each box, carton, package, etc. 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 white painted background.

5.4.1 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, UNIT OF ISSUE with QUANTITY (1-EA) and the words COAST GUARD SFLC MATERIAL CONDITION "A" REUSABLE CONTAINER, DO NOT DESTROY, REMOVE BOLTS, LIFT CRATE FROM SKID.

5.4.2 See below for marking layout.

STOCK NUMBER

2010-01-421-3952

ITEM NAME

Hub Assembly, Propeller, RH

PART NUMBER

110252110

SERIAL NUMBER

As recorded from Hub Assembly

CONTRACT NUMBER

(See Contract)

SHIPPING WEIGHT

As Determined by Contractor

QUANTITY & UNIT OF ISSUE

1 - EA

CONDITION CODE

CONDITION A

OTHER DATA AS

DIRECTED

COAST GUARD SFLC

MATERIAL

REUSABLE CONTAINER, DO NOT

DESTROY, REMOVE BOLTS, LIFT

CRATE FROM SKID.

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

5.5.1 All bar coded labels shall be in accordance with SFLC specification D-000-100.

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

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

6.0 NOTES

6.1 DOCUMENT SOURCES

6.1.1 GOVERNMENT DOCUMENT SOURCES

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

a. DOD & Navy Publications & Forms (Other Than DODSSP)

Naval Publication and Forms Center

5801 Tabor Ave.

Philadelphia, PA 19120

215-697-2000

6.1.2 COMMERICAL DOCUMNET SOURCES

a. American National Standards Institute (ANSI)

25 West 43rd Street

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

New York, New York 10036

FAX 212-398-0023

www.ansi.org

b. American Society For Quality Control (ASQC)

611 East Wisconsin Avenue

Milwaukee, Wisconsin 53202

414-272-8575

Fax 414-272-1734

6.1.3 OTHER GOVERNMENT DOCUMENTS

a. USCG Surface Forces Logistics Center

Mail Stop #026 BLDG 3 2nd Floor

2401 Hawkins Point Road

Baltimore, MD 21226-5000

Attn: Jennifer Blount 410-762-6123

APPENDIX – A

For the testing, preservation, and storage purposes only, either 2110 TH, 2135 TH oils can be used interchangeably. SAE 10W, SAE 10W-30, and any ISO VG 46 may be used also, if it can be certified that the particular oil to be used meets the following characteristics:

TABLE 1

Emulsion Test IAW ASTM D1401, after 30 minutes

The above table applies to only 10W, 10W-30, and ISO VG46 oils and should be readily available from the manufacturer. Table 2 is a list on known oils that meet the requirements of Table 1. With the use of any of these oils, there should not be any compatibility issues when mixed in small amounts (i.e the hub is drained prior in installation on a ship).

TABLE 2

Appendix –B