P-245-0339 160 WLIC.doc

REVISION No. C .

CHANGE No. .

TITLE

PURCHASE SPECIFICATION FOR PROPELLERS

USED ON 160 FT

WLIC CONSTRUCTION TENDER

P-245-0339

ORGINATED BY STEVE HARDSOCK DATE 09/98 .

ORGINATOR’S COMMAND ENGINEERING LOGISTICS CENTER (ELC)

DEPARTMENT / DIVISION EQUIPMENT MANAGEMENT DIVISION (CODE 026).

INTERNAL REVIEWER MIKE GASKINS DATE 11/06 .

SOWRB APPROVAL DATE .

PURCHASE SPECIFICATION FOR PROPELLERS

USED ON 160 FT WLIC CONSTRUCTION TENDERS

1.0 SCOPE

1.1. This document sets forth the requirements for the manufacture, testing, inspection, and packaging of propellers used on U.S. Coast Guard 160 foot WLIC Construction Tender Vessels.

1.2. CLASSIFICATION

1.2.1. Propeller Types

a Type 1 - Left Hand (LH), P/N 160-WLIC-4400-1-LH b Type 2 - Right Hand (RH), P/N 160-WLIC-4400-2-RH

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 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, or 5 of this specification, whether or not they are listed.

2.2. GOVERNMENT DOCUMENTS

2.2.1. SPECIFICATIONS, STANDARDS, PUBLICATIONS, AND HANDBOOKS – The following specifications, standards, publications, and handbooks form a part of this specification 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.

2.2.2. SPECIFICATIONS

a MIL-DTL-2845E(SH) - DATED 18 AUG 1999, Propulsion Systems, Boat and Ship; Main Shafting, Propellers, Bearings, Gauges, Special Tools, and Associated Repair Parts; Preservation, Packaging, Packing and Storage of

2.2.3. STANDARDS

a MIL-STD-167-1A(SHIPS) - DATED 2 NOV 2005, Mechanical Vibrations of Shipboard Equipment b MIL-STD-2035A(SH) - DATED 15 MAY 1995, Nondestructive Testing Acceptance Criteria c DOD-STD-2185(SH) - DATED 28 OCT 1986, Requirements for Repair and Straightening of Bronze Naval Ship Propellers

2.2.4. OTHER GOVERNMENT DOCUMENTS

a USCG Drawing No. 160WLIC-4400-2 REV B, DATED 09/08/06, 48 X 44 (4) BLADE PROPELLER, 5” TAPER BORE b COAST GUARD SPECIFICATION D-000-0100 - DATED 10/91 REV G 02/06, Bar Coding for USCG Surface Forces Logistics Center Procured Material c NAVSEA TECHNICAL MANUAL, NAVSEA S9245-AR-TSM-010/PROP - DATED 31 MARCH 1997, Technical Manual Marine Propeller Inspection, Repair and Certification, NSN 0910-LP-012-5880 d NAVSEA TECHNICAL PUBLICATION T9074-AS-GIB-010/271 - DATED 16 FEB 1999, Requirements for Nondestructive Testing Methods

2.3. COMMERCIAL DOCUMENTS

2.3.1. American Bureau of Shipping (ABS)

a Guide for Bronze and Stainless Steel Propeller Castings - DATED 2007

2.3.2. Society of Automotive Engineers (SAE)

a SAE-J-448A - DATED June 1963, Surface Texture Standard b SAE AMS-T-22085 - DATED 01 June 1999, Tapes, Pressure-Sensitive, Adhesive, Preservation and Sealing–FSC 7510

2.3.3. American National Standards Institute (ANSI)/National Conference of Standards Laboratories (NCSL) a ANSI/NCSL Z540-1-1994 - DATED 1994, General Requirements for Calibration Laboratories and Measuring and Test Equipment

2.3.4. American Society For Quality Control (ASQC)

a ANSI/ASQC Q9003-1994 - DATED 1994, Quality Systems - Model for Quality Assurance in Final Inspection and Test

2.4. DOCUMENT AVAILABILITY - To obtain the referenced documents see section 6.0.

2.5. ORDER OF PRECEDENCE - In the event of a conflict between the text of this specification and the references cited herein, the text of this specification takes precedence. Nothing in this document, however, supersedes applicable laws and regulations unless a specific exemption has been obtained.

3.0 REQUIREMENTS

3.1. GENERAL – The contractor shall provide all equipment, labor and materials to manufacture, test, inspect, preserve, package, pack and mark propellers in accordance with the referenced drawing and data provided within this specification.

3.2. MATERIAL - Each propeller blade shall be manufactured from ABS Type 4 Nickel Aluminum Bronze, consisting of the chemical composition and tensile properties listed in ABS Part 7 Section 10 entitled Guide for Bronze and Stainless Steel Propeller Castings (dated 2007).

3.2.1. The Contractor shall perform a material chemical composition analysis and tensile properties test for each propeller casting. The documented results shall be submitted to the Coast Guard Contracting Officer for review/approval.

3.2.2. All material chemical composition analysis and tensile property tests shall be made by a laboratory meeting the calibration requirements in section 4.6 of this specification.

3.3. TEST AND INSPECTION PLAN - The Contractor shall submit a test and inspection plan to the Contracting Officer 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. CONSTRUCTION OF PROPELLER CASTINGS – Each propeller casting shall be constructed in accordance with ABS Part 7 Section 10 entitled Guide for Bronze and Stainless Steel Propeller Castings (dated 2007), and USCG DWG. NO. 160WLIC-4400-2 REV B, 48 x 44 (4) Blade Propeller 5” Taper Bore.

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

3.4.2. Each casting shall include a provision to allow for an integrally cast coupon. This coupon shall be tested for its chemical composition and tensile properties referenced in 3.2.1.of this specification.

3.5. 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.

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

3.5.2. The Contractor shall demonstrate a manufacturing or inspection process that ensures tolerances for all hydrodynamic surfaces are met.

3.5.3. Dimensional Inspection shall be in accordance with this specification and USCG DWG. NO. 160WLIC-4400-2 REV B, 48 x 44 (4) Blade Propeller 5” Taper Bore.

3.6. DIMENSIONAL TOLERANCES

3.6.1. Propeller tolerances shall be in accordance with USCG DWG. NO. 160WLIC-4400-2 REV B, 48 x 44 (4) Blade Propeller 5” Taper Bore and this specification.

3.6.2. Blade thickness at each 10 percent station shall be within plus or minus 1.25 percent of the maximum thickness of the blade section.

3.6.3. Blade section half widths at each design radius shall be within a tolerance of plus or minus 0.20 percent of maximum section width.

3.6.4. Clearance under the fairing rod shall not exceed .060 inches and shall not vary at a rate greater than .010 inches per inch.

3.7. WELD REPAIRS - If the castings require any weld repairs, welding procedures, welders, and welding operations shall be qualified in accordance with S9074-AQ-GIB-010/248 or approved in accordance with the procedures outlined in ABS Guide for Bronze and Stainless Steel Castings (dated 2007), paragraph 1.7.2.

3.7.1. No weld repair is authorized unless prior approval is received from the Contracting Officer.

3.7.2. Welding on the pressure face of any propeller casting in the critical area shall not be undertaken without prior approval of the Contracting Officer.

a The critical area is described as the pressure face of the blade between the fillet and the .4 radius and starting at the leading edge encompassing 80% of the chord length taken at the 0.4 radius. (Reference Figure 1 of DOD-STD-2185(SH).

b Welding repairs of propeller castings shall meet the requirements of DOD-STD-2185(SH) or ABS Guide for Bronze and Stainless Steel Propeller Castings (dated 2007).

3.8. SURFACE FINISH - Surfaces of the propeller blades and hub shall be ground fair and polished in accordance with SAE-J-448 to meet the following requirements:

3.8.1. Propeller blade surfaces - 125 micro inches or better.

3.8.2. Propeller Hub - 125 micro inches or better.

3.9. BALANCING - Each propeller shall be single plane balanced in accordance with MIL-STD-167-1A, paragraph 5.2.2 as stated herein. All balancing shall be accomplished by means of balancing equipment, which requires rotation of the work piece. The minimum detectable unbalance of the balancing machine used shall be below the residual unbalance specified herein. The residual unbalance in each plane of correction shall not exceed the value determined by calculating the following formula:

U = 4000W/N2

U = Maximum allowable residual unbalance in oz.-inches

W = Weight of rotating part in pounds

N = Maximum operating speed of unit. (475 RPM)

3.9.1. Material removed to effect balancing shall be taken from the suction face of the heavy blade. Care shall be taken to keep a fair surface.

a The area from which metal is taken shall not come within 10 percent of the chord length to the leading or trailing edges.

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

3.10. SURFACE INSPECTIONS

3.0 A visual inspection shall be performed on all exterior blade surfaces in accordance with MIL-STD-2035(SH), section 4.

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

3.0 The Contractor shall perform a dye penetrant inspection over 100 percent of the blade surfaces including the hub in accordance with T9074-AS-GIB-010/271. The acceptance criteria of MIL-STD-2035(SH) Table IV shall be used for evaluations.

3.0 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.

3.0 TEST AND INSPECTION DATA REQUIREMENTS, FINAL 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.

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

a. Propeller blade radius

b. Pitch at the 0.3 through 0.95 radii

c. Average pitch of each blade at the 0.3 through 0.95 radii

d. Blade section width at the 0.3 through 0.95 radii

e. Thickness at every 10 percent station for each blade section from the 0.3 through 0.95 radii

f. Leading and trailing edge profiles at the 0.3 through 0.95 radii

g. Rake

h. Track

i. Angular spacing of blade center axes

j. Fairing rod clearances

k. All propeller hub dimensions including taper and keyway

l. Surface finish of blade and hub areas

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

n. Material composition

o. Balancing Data

3.0 The final inspection report shall be submitted to the Contracting Officer for review. If this report is determined to be acceptable, the Contracting Officer will authorize SFLC’s Quality Assurance Branch to schedule final inspections/tests outlined in section 4.4 of this specification.

3.0 PROPELLER STAMPING - Each propeller shall be stamped in accordance with the marking data provided on USCG DWG. NO. 160WLIC-4400-2 REV B, 48 x 44 (4) Blade Propeller 5” Taper Bore.

3.0 The stampings shall be at least 1/4" high, neat and legible.

3.0 NOTIFICATIONS & INSPECTIONS - The Contractor shall be responsible for notifying the Contracting Officer at least seven (7) calendar days prior to inspections or monitored testing required herein.

4.0 QUALITY ASSURANCE (Q.A.)

4.0 GENERAL - The Contractor shall provide and maintain an inspection system which shall ensure each item offered to the Government for acceptance conforms to contract requirements. The system shall be documented and meet the requirements of ANSI/ASQC-Q9003.

4.0 RESPONSIBILITY FOR INSPECTION - The Contractor shall be 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 any of the inspections and tests set forth in this specification at any time.

4.0 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.

4.0 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.

4.0 Dimensional inspections in accordance with section 3.6 of this specification.

4.0 Surface inspections in accordance with section 3.10 of this specification.

4.0 Balancing inspection in accordance with section 3.9 of this specification.

4.0 Stamping inspection in accordance with section 3.12 of this specification.

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

4.0 TEST AND INSPECTION REPORTS - One copy of any inspection, test or tolerance check report shall be sent to the Contracting Officer.

4.0 A copy of any test, inspection or tolerance check report shall also be provided to the Coast Guard Quality Assurance Representative upon arrival at the Contractor's plant.

4.0 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.

4.0 CALIBRATION SYSTEM - The Contractor as well as any subcontractors shall be required to maintain a test equipment calibration program in compliance with ANSI/NCSL Z540-1. The program shall be documented and traceable to the National Institute of Standards (NIST).

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

4.0 PACKING INSPECTION - The Contracting Officer shall be notified prior to the preservation, packaging, packing, and marking of the completed units in accordance with section 3.13.

5.0 PRESERVATION, PACKAGING & PACKING, & MARKING

5.0 PRESERVATION & PACKAGING

5.0 PROPELLERS Type 1 and Type 2

5.0 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.

5.0 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-2845(SH), paragraph 3.14.1.3.

5.0 After the application of strippable compound, galvanized sheet metal blade edge protectors shall be installed in accordance with MIL-DTL-2845(SH), paragraph 3.14.1.4.

5.0 PACKING

5.0 PROPELLERS Type 1 and Type 2

5.0 Each propeller shall be individually packed in a new Contractor furnished multiple trip wooden container in accordance with MIL-DTL-2845(SH), paragraph 3.14.2.2.2.

5.0 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 painted stencil and permanently affixed. The lettering shall be at least 1” high, and be applied on a highly contrasting, painted background.

5.0 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

5.0 MARKING LAYOUT

5.0 TYPE 1 - PROPELLER, RIGHT HAND (LH)

STOCK NUMBER 2010-01-036-7597

ITEM NAME PROPELLER, LH

PART NUMBER 160-WLIC-4400-2LH

SERIAL NUMBER As provided by Contracting Officer

SHIPPING WEIGHT As Determined by Contractor

CONTRACT NUMBER As indicated on the contract

CONDITION CODE CONDITION A

QUANTITY & UNIT OF ISSUE 1- EA

COAST GUARD SFLC MATERIAL

REUSABLE CONTAINER DO NOT DESTROY

b TYPE 2 - PROPELLER, RIGHT HAND (RH)

STOCK NUMBER 2010-01-037-7295

ITEM NAME PROPELLER, RH

PART NUMBER 160-WLIC-4400-2RH

SERIAL NUMBER As provided by Contracting Officer

SHIPPING WEIGHT As Determined by Contractor

CONTRACT NUMBER As indicated on the contract

CONDITION CODE CONDITION A

QUANTITY & UNIT OF ISSUE 1- EA

COAST GUARD SFLC MATERIAL

REUSABLE CONTAINER DO NOT DESTROY

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

1.1.1. All bar coded labels shall be in accordance with SFLC specification D-000-0100 REV G, dated 02/06.

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.

2.0 NOTES

2.1. GOVERNMENT & COMMERCIAL DOCUMENT SOURCES

2.1.1. GOVERNMENT DOCUMENTS

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

PH 215-697-2667/2179

FAX 215-697-1462

b DOD & Navy Publications & Forms (Other Than DODSSP)

Naval Publication and Forms Center

5801 Tabor Ave.

Philadelphia PA. 19120

215-697-2000

2.1.2. COMMERCIAL DOCUMENTS

a American Bureau of Shipping (ABS) ABS Plaza 16855 Northchase Drive Houston, TX 77060

PH 281-877-6000

FAX 281-877-6001

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

PH 412-776-4841

FAX 412-776-5760

E-MAIL www.sae.org c American Society For Quality Control (ASQC) 611 East Wisconsin Avenue Milwaukee, Wisconsin 53202

PH 414-272-8575

FAX 414-272-1734

d American National Standards Institute (ANSI) 25 West 43rd Street (Between 5th and 6th Avenues)4th Floor New York, NY 10036

PH 212-642-4900

FAX 212-398-0023

www.ansi.org

2.1.3. OTHER GOVERNMENT DOCUMENTS

a USCG Engineering Logistics Center MAIL STOP #026 BLDG 31 2nd FL.

2401 Hawkins Point Road Baltimore, MD. 21226-5000 410-762-6503 Attn: Code 046