Statement_of_Work_(FBO).docx

1.0 ABSTRACT:

1.1 This item describes the fabrication of one (1) propeller shaft assembly for the USS Mount Whitney (LCC20), including one (1) propeller shaft, two (2) propeller shaft sleeves, one (1) propeller key, and one (1) dowel pin for the propeller key.

1.1.1 Forging of one (1) propeller shaft and one (1) propeller shaft key, as well as centrifugal casting two (2) propeller shaft sleeves, for the USS Mount Whitney (LCC20).

1.1.2 Machining to final dimensions of one (1) propeller shaft and one (1) propeller shaft key from forgings, as well as fabrication of one (1) propeller key dowel pin, for the USS Mount Whitney (LCC20). Key and dowel pin to be fit on final machining.

1.1.3 Installation and machining to final dimensions of two (2) propeller shaft sleeves, as well as propeller shaft coating, for the USS Mount Whitney (LCC20).

1.1.4 Blue fitting of a GFM provided propeller and testing of GFM provide Nut with the completed propeller shaft assembly for the USS Mount Whitney.

2.0 REFERENCES:

2.1 References:

2.1.1 Drawing No. 4456205F, Shafting Details

2.1.2 Drawing No. 2492032D, Shafting Forgings

2.1.3 0910-LP-105-8704, Type I Equipment Manual for Pilgrim Hydraulic Propeller Nut

2.1.4 MIL-S-23284A, Steel Forgings, Carbon and Alloy, for Shafts, Sleeves, Couplings, and Stocks (Rudders and Diving Planes)

2.1.5 ASTM B369, Standard Specification for Copper-Nickel Alloy Castings

2.1.6 MIL-S-1222H, Studs, Bolts, Hex Cap Screws, Socket Head Cap Screws and Nuts

2.1.7 MIL-STD-2189, Section 243-1, Design Methods for Naval Shipboard Systems, Part 1 Propulsion Shafting

2.1.8 NAVSEA, S9243-AW-TRS-011/0203-086-501A, Technical Repair Standard for Surface Ships Main Propulsion Shafting Refurbishment Requirements.

2.1.9 MIL-STD-2199A, DOD Standard Practice, Coverings of Waterborne Main Propulsion Shafting on U.S. Naval Surface Ships and Submarines

2.1.10 NAVSEA, T9074-AS-GIB-010/271, Requirements for Nondestructive Testing Methods

2.1.11 MIL-STD-2035, DOD Test Method Nondestructive Testing Acceptance Criteria

2.1.12 MIL-STD-792F, Manufacturing Process Standard Identification Marking Requirements for Special Purpose Components

2.1.13 S9086-HP-STM-010/CH-245R5, NSTM Chapter 245, Propellers

2.1.14 Drawing no. 203-2500352B, Propeller and Details

2.1.15 MIL-DTL-2845E, Preservation, Packaging, Packing and Marking of Main Propulsion Shafting

3.0 ITEM LOCATION / DESCRIPTION: None Additional

4.0 GOVERNMENT FURNISHED EQUIPMENT/ MATERIAL:

4.1 1 EACH, PROPELLER SHAFT TAPER RING GAUGE

4.2 1 EACH, PROPELLER SHAFT NUT

4.3 1 EACH, PROPELLER

No. of blades: 4 Direction of rotation: Right hand Weight, propeller/cap: 59,083 lb./1310 lb. est.

Dia./Pitch.: 20.00 ft./24.82 ft.

5.0 NOTES: None Additional

6.0 QUALITY ASSURANCE REQUIREMENTS:

6.1 Propeller Shaft and Propeller Shaft Key Forgings. Centrifugal Casting of Propeller Shaft Sleeves.

6.1.1 Propeller Shaft and Propeller Shaft Key Forgings.

6.1.1.1 Materials to be forged steel meeting specification Mil-S-23284 Amend 3 Cl 2 as per Ref. 2.1.1, Ref. 2.1.2, Ref. 2.1.4 and Ref. 2.1.7 Table I., including all applicable notes. Material to be certified dimensionally and physical characteristics in presence of ABS.

6.1.1.2 Forging to be manufactured to ensure adequate material for correct dimensions after final machining in Option 1. Ref. 2.1.2 provided for reference.

6.1.1.3 Forging straightness, out of round and concentricity shall be within limits to ensure the finish machined shaft meets all requirements on Ref. 2.1.1.

6.1.1.4 Testing is to be carried out to ensure material meets all requirements of Ref. 2.1.1, Ref 2.1.4, and Ref. 2.1.7 Table I, including all applicable notes, as well as testing required for ABS certification. Requirements include all applicable drawing notes and Appendices. Testing to include chemical and mechanical properties, 100% magnetic particle and ultrasonic testing, hardness and impact testing, macro and microscopic inspections.

6.1.1.5 Certificates shall be provided demonstrating conformance with all requirements in Ref. 2.1.1, Ref. 2.1.4, Ref. 2.1.7 Table I and by ABS. Requirements include all applicable drawing notes and Appendices.

6.1.1.6 Three (3) test coupons of material to be delivered to MSC. Coupons to be taken from propeller shaft forging at locations indicated and information provided as per on Ref. 2.1.2. Coupons to be forwarded to MSC POC listed in 7.5.2.

6.1.2 Centrifugal Casting of Propeller Shaft Sleeves.

6.1.2.1 Sleeve materials to be certified dimensionally and for physical characteristics in presence of ABS. Certificates to be issued regarding the same.

6.1.2.2 Sleeves shall be provided with 0.250 inches of excess material on the OD and ID to allow for field fitting. 1.00 inch of excess material shall be left on the length to allow for field fitting. The sleeves shall be provided un-split and applicable drawing notes shall be adhered too. Delivered sleeve dimensions shall be as follows:

13.000 inches

25.375 inches

Tolerance:

+/- 0.032 inches

6.1.2.3 Sleeve material is to be centrifugally cast suitable for seawater service meeting ASTM B369, UNS C96400 and have ABS certifications.

6.1.2.4 Sleeve straightness and out of round dimensions shall be within 0.020 inches. Sleeve concentricity shall be within 0.030 inches.

6.1.2.5 Sleeve finish shall be 250 RMS or better.

6.1.2.6 Sleeve radiographic and pressure testing is to be carried out in accordance with Ref. 2.1.1, as well as testing required for ABS certification. Testing to include all applicable drawing notes.

6.2 Propeller Shaft and Propeller Shaft Key Finish Machined.

6.2.1 All materials to be certified dimensionally and for physical characteristics, including straightness and runout. All physical characteristics, including dimensions, straightness, runout and finish shall be in accordance with Ref. 2.1.1, including all applicable drawing notes.

6.2.2 Note: Shaft threads for hydraulic nut shall be as per applicable drawing notes on Ref. 2.1.1 and Ref. 2.1.3.

6.2.3 Shaft and key material is to be forged steel meeting specification Mil-S-23284 Amend 3 Cl 2. Material to have ABS certifications and meet all requirements outlined in section 6.1.

6.2.4 Non-destructive testing is to be carried out in accordance with Ref. 2.1.1, Ref. 2.1.4, as well as testing required for ABS certification. Requirements include all applicable drawing notes and Appendices. Testing to include hardness testing and 100% magnetic particle testing.

6.2.5 Shaft hardness testing to be conducted before cold rolling, after cold rolling and after machining to final dimension. Testing certificates to be issued.

6.2.6 Certificates for testing shall state conformance with all requirements outlined in Ref. 2.1.1, Ref. 2.1.4, Section 6.2.5 and by ABS. Requirements include all Ref. applicable drawing notes and Appendices.

6.2.7 Static balancing to be carried out as per Ref. 2.1.1.

6.2.8 Final dimensional and runout measurements to be checked in presence of ABS and Government Representative. Taper to be checked using GFE provided taper ring gauge. All dimensions and runouts to meet requirements of Ref. 2.1.1.

6.2.9 Flange bolt holes to be undersized by 0.065 inches on inside diameter to allow for field machining to final dimension.

6.2.10 Dowel pin shall be fabricated using material in accordance with Mil-S-1222H (Ref. 2.1.6).

6.3 Shaft Sleeves Installed and Final Machined. Shaft Coated.

6.3.1 Sleeve to be fitted in accordance with Ref. 2.1.1 and Ref. 2.1.8.

6.3.2 Report of sleeve fitting to be submitted demonstrating correct fit and finish with propeller shaft. Report to include shaft journal ODs, sleeve IDs, surface finishes, surface temperatures, shop temperature, shrink fit specified and shrink fit achieved.

6.3.3 Sleeve final dimensions and measurements on propeller shaft to be in accordance with Ref. 2.1.1 including all applicable drawing notes.

6.3.4 Report to be issued with all shaft dimensions and measurements.

6.3.5 Upon completion of sleeve installation and outside diameter final machining, 100 % of sleeves to be checked using liquid penetrant. Liquid penetrant tests to be conducted before shaft coating.

6.3.6 The shaft coating system shall be applied, meeting the two-coat system of polysulfide fairing compound and fiberglass wrap in Mil-S-2199A.

6.3.7 Material manufacturer information, ABS approval certificates and lot numbers shall be provided for all coating system components.

6.3.8 Shaft coating system shall be proven using a spark test to the satisfaction of ABS and Government Representative.

6.3.9 Shaft assembly shall be protected and crated as per 2.1.15. See Section 7 for packaging requirements. Government representative to be present for final inspection and packaging.

6.4 Blue Fitting of GFM Propeller and test fitting of GFM Nut.

6.4.1 Crated propeller to be delivered to contractor facility at Government expense.

6.4.2 On uncrating, propeller inspection to be carried out as per Ref. 2.1.13. Government Representative to be present for uncrating and inspection of propeller.

6.4.3 Clean the entire propeller (both sides) to clean bright metal. Minimize metal loss. Upon completion of mechanical cleaning, conduct 100% dye penetrant check of the propeller including both edges and tapered cone. Submit typewritten as found report to MSC and ABS. Wash the propeller when all inspections are complete.

6.4.4 Propeller to be blue fit to shaft, ensuring a minimum of 80% contact with shaft. Blue fit to be to satisfaction of ABS and Government Representative. Ref. 2.1.14 included as reference.

6.4.5 Nut to be test fit to threads to ensure good fit.

6.4.6 Hydraulic function of nut to be tested to ensure no leakage and proper operation.

6.4.7 Propeller and Nut to protected and crated as per 2.1.15. See Section 7 for packaging requirements. Government representative to be present for final inspection and packaging.

6.5 General Requirements.

6.5.1 All testing is to be carried out in accordance with Ref. 2.1.9, Ref. 2.1.10, as well as outlined in Sections 6.1, 6.2, 6.3, and 6.4.

6.5.2 All materials used in propeller shaft assembly to be permanently marked with a traceable serial number, heat number, manufacturer ID, ABS approval number, ASTM/MIL-SPEC material specification, NDT tests/information, and date of approval.

6.5.3 All permanent markings to be made in accordance with Ref. 2.1.12. Shaft markings to be placed in recessed area of flange face inside diameter of mating flange mating surface.

6.5.4 Sleeve markings to be recorded prior to machining of sleeve ends.

6.5.5 Key markings to be recorded prior to installation.

6.5.6 All materials and propeller shaft assembly to be shipped with 2 copies of certifying documents in the box and 2 copies affixed to the outside of the container. An additional copy of all certifications shall be e-mailed to MSC.

6.5.7 ABS and Government Representative shall witness testing, inspection and measurement. ABS documents and certification to be issued for all items included in the assembly. Documents shall include ABS certification statement regarding material physical/chemical characteristics, testing and dimensional measurements. Documentation shall show results of all testing and certification requirements.

6.5.8 Final inspection shall be performed prior to shipping all materials.

6.5.9 Shafting assembly, propeller and nut to be protected and crated as per Ref. 2.1.15

7.0 STATEMENT OF WORK REQUIRED:

7.1 Propeller Shaft and Propeller Shaft Key Forgings. Centrifugal Casting of Propeller Shaft Sleeves.

7.1.1 Propeller Shaft and Propeller Shaft Key Forgings.

7.1.1.1 The contractor shall provide all materials and fabricate one (each) of piece 100, listed on Ref 2.1.1.

7.1.1.2 The contractor shall provide all materials and fabricate one (each) of piece 109, listed on Ref 2.1.1.

7.1.1.3 The pieces shall be provided with dimensions to ensure sufficient material exists for machining to final dimensions.

7.1.1.4 The chemical and mechanical characteristics of the material shall be in accordance with ABS and Mil-S-23284 (Ref. 2.1.4) Amend 3 Cl 2.

7.1.2 Centrifugal Casting of Propeller Shaft Sleeves.

7.1.2.1 The contractor shall provide all materials and fabricate one (each) of piece 1, listed on Ref 2.1.1.

7.1.2.2 The contractor shall provide all materials and fabricate one (each) of piece 2, listed on Ref 2.1.1.

7.1.2.3 The pieces in 7.3.1 and 7.3.2 shall be machined to the dimensions and tolerances listed in Section 6.1.2

7.1.2.4 The material shall be centrifugally cast and physical characteristics shall be in accordance with ABS and ASTM B369, UNS C96400.

7.2 Propeller Shaft and Propeller Shaft Key Finish Machined.

7.2.1 The contractor shall provide all materials and machine one (each) of piece 100, listed on Ref 2.1.1. The piece shall be machined to the dimensions and tolerances shown on Ref. 2.1.1 and listed in Section 6.1.

7.2.2 The contractor shall provide all materials and machine to final dimension one (each) of piece 109, listed on Ref 2.1.1. The piece shall be machined to the dimensions and tolerances shown on Ref. 2.1.1 and listed in Section 6.1.

7.2.3 The contractor shall provide all materials and fabricate one (each) of dowel pin, piece 116, listed on Ref 2.1.1.

7.2.4 The chemical and mechanical characteristics of the material in 7.2.1 and 7.2.2 shall be in accordance with ABS and Mil-S-23284 (Ref. 2.1.4) Amend 3 Cl 2.

7.2.5 The material for item 7.2.3 shall be in accordance with Mil-S-1222H (Ref. 2.1.6).

7.3 Shaft Sleeves Installed and Final Machined. Shaft Coated.

7.3.1 Sleeves shall be fitted to shaft, ensuring correct fit and finish as per Ref. 2.1.1 and Ref. 2.1.8.

7.3.2 Sleeves to be machined to final dimensions and surface finish shown on Ref. 2.1.1.

7.3.3 Note: The forward sleeve, forward edge to be finished using detail 3-E. Shaft to be coated from forward edge of sleeve to radius of flange.

7.3.4 The shaft OD outside of the sleeve area and taper, and fillet area up the radius of the shaft flange shall be coated in accordance with the two-layer application in Mil-Std-2199A. Note: Do not coat or paint the area aft of the propeller sleeve, the flange mating surface, bolt holes, flange OD, or aft side of the flange face above the radius.

7.4 Blue Fitting of GFM Propeller and Nut.

7.4.1 Propeller to be uncrated and inspections performed as per Section 6.4.

7.4.2 Propeller to be blue fit to shaft, ensuring a minimum of 80% blue fit.

7.4.3 Nut to be test fit to threads to ensure good fit.

7.4.4 Nut to be tested hydraulically to ensure no leakage and proper operation.

7.4.5 On completion of work, propeller and nut to be protected and crated as per Section 6.4.

7.5 General Requirements.

7.5.1 All tests and inspections shall be in accordance with Quality Assurance Requirements in Para 6.1 through 6.5.

7.5.2 The contractor shall notify the MSC technical representative when ABS inspections will be performed.

7.6 Packing/Shipment.

7.6.1 Propeller and shaft to be packaged to ensure no damage during transportation and preservation during storage. Items to be packaged for shipment as per Ref. 2.1.15.

7.6.2 Tie down and lift points to be of adequate capacity and number. Tie down and lift points to be clearly marked on all shipments.

7.6.3 All packaging to be fabricated using materials certified for international shipment in accordance with ISPM 15 and marked in accordance with Annex 2 of the same Packing material certification documents to be attached to shipments. An additional copy to be e-mailed to MSC.

7.6.4 All materials and propeller shaft assembly to be shipped with 2 copies of certifying documents in the box and 2 copies affixed to the outside of the container. An additional copy of all certifications shall be e-mailed to MSC.

7.6.5 Packing shall be fabricated so it is re-usable.

7.6.6 Government representative to be present for final inspection and packaging.

7.6.7 The contractor shall provide delivery of the shaft assembly, propeller and nut to:

MSC, Norfolk Attn: USS Mount Whitney (LCC20) Contractor shall clearly mark the shipment with the following information:

Mark for: USS Mount Whitney (LCC20) Propulsion Shaft/Propeller Crate # of #

REQN NR: N#############

8.0 GENERAL REQUIREMENTS: None