Propeller Repair _240WLBB.doc

JPH_0421

WORK ITEM 1: 2010-01-518-9869 and 2010-01-519-0135, Propeller Repair

1. SCOPE

1.1 Intent. This supply item describes the requirements for the Contractor to the receipt, storage, inspection, repair, testing, preservation, packaging, packing and marking of CA-6NM Stainless Azipod’s propellers used on 240 FT WLBB GREAT LAKES ICEBREAKER.

1.2 Government-furnished property.

P/N

CAGE

($/UNIT)

ABB Azipod

ABB Azipod

*Government-loaned property, which shall be returned to the Coast Guard upon completion of the contract.

**New or refurbished equipment that the Government may provide for installation in place of existing equipment.

***Government-furnished property, which is to be supplied by the Coast Guard.

2. REFERENCES

Coast Guard Drawings

Coast Guard Drawing 240 WLBB 245-003, Rev A, Propeller Drawing DATED 06-20-2007 Coast Guard Publications

Surface Forces Logistics Center Standard Specification 0740 (SFLC Std Spec 0740), 2020, Welding and Allied Processes

Surface Forces Logistics Center Standard Specification 6310 (SFLC Std Spec 6310), 2020, Requirements for Preservation of Ship Structures

Surface Forces Logistics Center Standard Specification 0000 (SFLC Std Spec 0000), 2020, General Requirements Other References

MIL-STD-167-1A(SHIPS) - DATED 1 MAY 1974, Mechanical Vibrations of Shipboard Equipment

MIL-STD-2035A(SH) - DATED 15 MAY 1995, Nondestructive Testing Acceptance Criteria

DOD-STD-2185(SH) - DATED 28 OCT 1986, Requirements for Repair and Straightening of Bronze Naval Ship Propellers

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

COAST GUARD SPECIFICATION D-000-0100 - DATED 10/91 REV G 02/06, Bar Coding for USCG Engineering Logistics Center Procured Material

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

NAVSEA T9074-AS-GIB-010/271 - DATED 16 FEB 1999, Requirements for Nondestructive Testing Methods

ISO 484/1-1981: Shipbuilding-Ship screw propellers-Manufacturing tolerances-Part 1: Propellers of diameter greater than 2.50m

American Bureau of Shipping (ABS) Guide for Bronze and Stainless Steel Propeller Castings - DATED 2007

Society of Automotive Engineers (SAE) SAE-J-448A - DATED June 1963, Surface Texture Standard

Society of Automotive Engineers SAE AMS-T-22085 - DATED 01 June 1999, Tapes, Pressure-Sensitive, Adhesive, Preservation and Sealing–FSC 7510

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

ANSI/NCSL Z540-1-1994 - DATED 1994, General Requirements for Calibration Laboratories and Measuring and Test Equipment

3. REQUIREMENTS

3.1 General. The Contractor shall provide all labor, equipment and material required to refurbish the GFP propeller(s) to a serviceable condition in accordance with MIL-STD-2185(SH).

3.1.1 Serviceable condition is defined as being capable of functioning and performing in the same manner as an identical new propeller although it may not have the appearance of newness.

3.2 Governement Furnished Equipment (GFE) and Government Furnished Property (GFP) - The Contractor shall provide protective storage for the GFE and 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 unattended.

3.3 Material - Each propeller blade is constructed of ABS-4. The Contractor shall determine the alloy by chemical composition analysis prior to any repairs.

3.4 Test & Inspection Data Requirements, Receiving Inspection Report - Each propeller received by the Contractor shall be inspected upon receipt and a report outlining the required repairs and pricing submitted to the Contracting Officer for approval. The Contractor shall measure and inspect all propeller surfaces and dimensions using electronic measuring equipment, accurate to within .001”, as much as practicable. The Contractor shall demonstrate an inspection process that ensures tolerances for all hydrodynamic surfaces are met. The use of modern marine propeller computer assisted inspection systems such as Prop Scan, Hale Measurement Recording Instrument (MRI), digital laser scanning or an equivalent system shall be utilized. No further work will be authorized until the submitted report is reviewed and approved.

3.4.1 The Receiving Inspection Report shall contain, at a minimum, the following data.

· a. Shipping container condition (see 5.2 of this specification)

· b. Propeller blade radius

· c. Pitch at the following sections - (0.5 thru 0.95 radiuses)

· d. Average pitch of each blade at the following sections - (0.5 thru 0.95 radiuses)

· e. Blade section width at the 0.4 thru 0.95 radiuses

· f. Thickness at point of maximum thickness (PMT), at the 0.4 thru 0.95 radiuses

· g. Track

· h. Fairing rod clearances

· i. Surface finish of blade surfaces, fillets, and bore

· j. Surface inspections (Visual and 100 percent dye penetrant examination in accordance with section 3.5.1. of this specification)

· k. Hub bore visual and dimensional inspections

· l. Estimated time required for repairs

· m. Estimated total labor and material cost of repairs

· n. Photo documentation in accordance with section 3.14. and 3.14.1.a, b., and c. of this specification

3.4.2 If at any time during the pre-repair inspection or authorized repairs, the Contractor believes the propeller may be beyond economical repair, the Contracting Officer shall be notified immediately and provided a description of the propeller’s condition to support this assessment.

3.5 Surface Inspections.

3.5.1 A visual inspection shall be performed on all exterior surfaces in accordance with MIL-STD-2035, section 4.

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

3.5.2 The Contractor shall perform a dye penetrant inspection over 100 percent of the blade surfaces including the palm top and bottom surfaces, and fillets in accordance with T9074-AS-GIB-010/271. The acceptance criteria of MIL-STD-2035 Table IV shall be used for evaluations.

3.5.3 The Contractor shall document all defects resulting from the visual and dye penetrant inspections. All defects or indications shall be indicated by type and size on visual inspection sheets. A separate visual inspection sheet shall be submitted for each of the following: the blade pressure face, the blade suction face, the fillets, and the palm top and bottom surfaces.

3.5.4 Photo documentation shall be provided in accordance with section 3.14. and 3.14.1.c. of this specification.

3.6 Propeller repairs. - Repairs shall be made utilizing the following methods in declining order of preference:

3.6.1 Straightening

3.6.2 Material removal (grinding). The material removal shall be limited to the minimum required to achieve the repair.

3.6.3 Clad welding

3.7 Repair tolerances. - Each Propeller shall be repaired within the repair tolerances listed in ISO 484/1 Class II (medium accuracy) and USCG Drawing 240 WLBB 245-3 REV A, DATED 06-20-2007, PROPELLER DRAWING.

NOTE

If Class II medium accuracy is not achievable after attempting to repitch due to original fabrication/constraints of propellers, then Class III (wide tolerances) shall be obtained as the minimum acceptable standard. Notate these occurrences (Class III best achievable) on reports.

3.8 Qualifications of welding procedures. Welding procedures, welding procedure qualifications, and welder performance qualifications shall be certified in accordance with DOD-STD-2185 or approved in accordance with the American Bureau of Shipping. The welding procedures and qualification documents shall be submitted for approval with the solicitation.

3.8.1 ABS certification to perform weld repairs in Severity Zone A shall be submitted for approval with the solicitation.

3.8.2 Welding on the pressure face critical areas or severity zones shall not be undertaken without prior approval of the Contracting Officer.

3.8.2.1 CRITICAL AREA - 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)

3.8.2.2 SEVERITY ZONES – The severity zones are described in ABS Guide for Bronze and Stainless Steel Propeller Castings dated 2007, Part 7, Section 10, paragraph 1.5.5(b). (Reference Figures 2 and 3 of 7-A-10)

3.8.3 Welding repairs of the propellers shall meet the requirements of DOD-STD-2185 or the American Bureau of Shipping.

3.8.4 The Contractor shall document all welding performed on the visual inspection sheets for each propeller. Each weld shall be dimensionally identified by location, length, width, and depth.

3.8.5 Photo documentation shall be provided in accordance with section 3.14. and 3.14.1.d. of this specification when applicable.

3.9 SURFACE FINISH - Surfaces of the the propeller blades, fillets, and hub shall be ground fair and polished to the finishes outlined below in accordance with SAE-J-448A as follows.

· a. Propeller blade surfaces - 63 micro inches or better.

· b. Propeller blade fillets – 125 micro inches or better.

3.9.1 All high spots, burrs, abrasions, nicks, corrosion, and foreign matter shall be removed from propeller glands, hub bores, flanges, and mating surfaces.

3.9.2 All exposed threaded areas shall be chased and tapped.

3.10 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 N = Maximum operating speed of unit. (254 RPM)

U = Maximum allowable residual unbalance in oz.

W = Weight of rotating part in pounds.

3.10.1 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

3.10.2 The addition of this weight shall be easily detected and discernible to the balance machine operator.

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

3.10.4 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. The area from which metal is taken shall not come within 10 percent of the chord length to the leading or trailing edges. Coordinate material removal between static and dynamic efforts, if prudent wait for more sensitive dynamic balancing data to be produced before material removal.

3.10.5 The actual amount of unbalance for each propeller shall be documented (initial and after any balancing efforts) on each Final Inspection Report.

3.11 Test & Inspection Data Requirements, Final Inspection Report After completion of all welding, stress relieving and repairs, the contractor shall perform final dimensional, balancing, and visual and dye penetrant surface inspections for each propeller blade set. The final inspection report shall depict the final condition of each propeller blade set.

3.11.1 The report shall be submitted to the Contracting Officer for approval, and approval shall be obtained prior to authorization to ship each repaired propeller blade set.

3.11.2 The Final Inspection Report shall contain, at a minimum, the following data.

· a. Propeller blade radius

· b.. Pitch at the following sections - (0.5 thru 0.95 radiuses)

· c. Average pitch of each blade at the following sections - (0.5 thru 0.95 radiuses)

· d. Blade section width at the 0.4 thru 0.95 radiuses

· e. Thickness at point of maximum thickness (PMT), at the 0.4 thru 0.95 radiuses

· f. Track

· g. Fairing rod clearances

· h. Surface finish of blade surfaces, fillets, and bore

· i Surface inspections (Visual and 100 percent dye penetrant examination in accordance with section 3.5.1. of this specification)

· j. Hub bore visual and final dimensions

· k. Include all balancing data as required in section 3.10.

· l. Visual inspection data for all weld repairs in accordance with section 3.8.4 of this specification

· m. Photo documentation in accordance with section 3.14. and 3.14.1.a, b., and c. of this specification

3.11.3 Areas of each propeller that have not been affected by the repair work do not have to be re-inspected for the final report provided the propeller was not stress relieved. However, inspection data for the entire propeller shall be included in the final dimensional inspection report.

3.12 STAMPING - Each propeller blade shall be stamped with the listed information, or the presently stamped information shall be changed if incorrect.

3.12.1 The stampings shall be at least 1/4” high legible printing, or the same height of the existing stamping if only corrected.

3.12.2 The stampings shall include at a minimum the items listed.

· a. Company Name

· b. Date of Repair Completion

· c. Serial Number (supplied by the Contracting Officer if none exists)

· d. Direction of Rotation (LH or RH)

· e. Type of Material

· f. Weight

3.13 Notifications and inspections. The Contractor shall be responsible for notifying the Contracting Officer at least ten (10) calendar days prior to any inspections or monitored testing required herein.

3.14 Photo documentation. The Contractor shall provide Photo Documentation to the Contracting Officer as part of the Pre-repair Inspection Report, during in-process welding repairs (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 Contracting Officer during the overhaul phases outlined below.

3.14.1 Photo documentation phases:

· a. During initial receipt of the propeller with photographs showing the suction face, pressure face, hub markings and two photographs of the shipping crate taken at 90 degrees apart.

· b. Prior to the repair of the propeller with close-up views showing any damage, erosion, corrosion that will affect cost or repair cycle time.

· c. During the pre-repair dye penetrant inspection showing any porosity or cracks.

· d. During repair of the propeller whenever significant cropping or welding is required.

· e. 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.

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

· g. Prior to shipment, showing container markings.

3.14.2. In addition to providing electronic photographs at the various overhaul phases indicated, the Contractor shall provide a final Compact Disc (CD) to the Contracting Officer that includes all of the pictures referenced in 3.14.1. The pictures on this CD shall be organized in “jpg format” within folders labeled as follows: Receiving Inspection (photos referenced in 3.14.1.a.); Pre-repair Inspection (photos referenced in 3.14.1.b. and c.); In Process Repair (photos referenced in 3.14.1.d; Post Final Inspection (photos referenced in 3.14.1.e.; and Preservation, Packaging, and Markings (photos referenced in 3.14.1.f. and g.).

4.0. QUALITY ASSURANCE

4.1 General. The contractor shall maintain an inspection system which shall insure that each item offered to the Coast Guard for acceptance or approval conforms to the contract requirements. The inspection system shall be documented and meet the requirements of ISO 9001 and available for review by the Coast Guard.

4.2 Records. The 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. The contractor as well as any subcontractors shall be required to maintain a test equipment calibration program in compliance with ASQ/ISO/IEC 17025. The program shall be documented and traceable to the National Institute of Standards (NIST).

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

4.5 Responsibility for compliance. All items shall meet the provisions of sections 3 & 5. The inspections set forth in this specification shall become part of the contractor’s overall inspection system or quality program. The absence of any inspection requirements in the specification shall not relieve the contractor of the responsibility of assuring that all products or supplies submitted to the government for acceptance comply with all requirements of the contract. Sampling for quality conformance does not authorize submission of known defective material (either indicated or actual) nor does it commit the government to acceptance of defective material.

4.6 Inspections and tests. The inspections/tests required here and in the appropriate subsection in section 3 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. The following tests and inspections will be witnessed by an SFLC Quality Assurance Representative:

4.6.1 Dimensional inspection. See section 3.4.

4.6.2 Surface inspections. See section 3.5.

4.6.3 Balancing inspection. See section 3.10.

4.6.4 Stamping inspection. See section 3.12.

4.6.5 Packaging, packing and marking inspection. See section 5.

4.7 Failure responsibility. If the specified item fails to pass any inspection/test the contractor shall report the failure and the recommended fix to the Contracting Officer. If approved, the corrective action on the materials or processes shall be taken in accordance with this section.

· The Contracting Officer reserves the right to totally reject any failed item without considering any suggested corrective action.

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

· After all corrective actions have been taken the inspection/tests shall be continued or repeated at the option of the Contracting Officer.

· Acceptance shall be withheld until re-inspection has been shown that the corrective action was successful and the item satisfactorily passes all inspections and tests.

· All corrective actions shall be documented as part of the contractor’s inspection system and submitted for approval to the Contracting Officer.

· 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. One copy of any required inspection, test or tolerance check done on each delivery order shall be sent to the Contracting Officer for review and approval prior to authorization of Quality Insurance Inspection.

4.8.1 Quality assurance representative. A copy of any test, inspection or tolerance report shall be turned over to the Quality Assurance Representative upon arrival at the contractor’s plant.

4.9 Packing inspection. The Contracting Officer shall be notified prior to the packaging and marking of the completed units in accordance with section 5.2 of this specification.

5. PRESERVATION, PACKING, MARKING, AND SHIPPING

5.1 PRESERVATION & PACKAGING

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 blades.

· a. After cleaning, tape conforming to SAE AMS-T-22085 and strippable compound preservative shall be applied to each propeller in accordance with MIL-DTL-2845 paragraph 3.14.1.3.

· b. After the application of strippable compound, galvanized sheet metal blade edge protectors shall be installed, using corrosion resistant hardware, in accordance with MIL-DTL-2845, paragraph 3.14.1.4.

· c. A plywood cover shall be used to cover the bottom side of the palm to protect the seal area during shipment and storage of the propeller. This cover shall be attached using bolts through the blade bolt holes and plywood washers in contact with blade machined surfaces.

5.1.2 The GFE supplied Dummy Hub shall be preserved as it was received for return to the Coast Guard.

5.2 Packing. Each propeller shall be individually packed in accordance with MIL-DTL-2845 paragraph 3.14.2.1, Figure 3.

5.2.1 If the original shipping container received by the Contractor is in good material condition and complies with 5.2 of this specification, the container shall be reused.

5.2.2 If a new shipping container is required, the Contractor shall notify the Contracting Officer within fifteen days after receipt of the GFP.

5.2.4 Should new containers be required, the Contractor shall notify the Contracting Officer within fifteen days after receipt of the GFE and GFP.

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 container. 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 painted background.

5.3.1 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, QUANTITY and UNIT OF ISSUE (1) SE and the words COAST GUARD ELC MATERIAL.

5.3.2 See below for marking lay out.

a.

Type 1 – PROPELLER, RIGHT HAND (RH)

STOCK NUMBER: 2010-01-518-9869

ITEM NAME: PROPELLER, RH

PART NUMBER: 240 WLBB-245-001

SERIAL NUMBER: As stamped on hub

CONTRACT NUMBER: As indicated on contract

DELIVERY ORDER NUMBER: As indicated on contract

SHIPPING WEIGHT: As Determined by Contractor

CONDITION CODE: CONDITION A

QUANTITY & UNIT OF ISSUE:

1- EA

COAST GUARD ELC MATERIAL

b.

Type 1 – PROPELLER, LEFT HAND (LH)

STOCK NUMBER: 2010-01-519-0135

ITEM NAME: PROPELLER, LH

PART NUMBER: 240 WLBB-245-002

SERIAL NUMBER: As stamped on hub

CONTRACT NUMBER: As indicated on contract

DELIVERY ORDER NUMBER: As indicated on contract

SHIPPING WEIGHT: As Determined by Contractor

CONDITION CODE: CONDITION A

QUANTITY & UNIT OF ISSUE:

1- EA

COAST GUARD ELC MATERIAL

5.3.3. Photo documentation shall be provided in accordance with section 3.14. and 3.14.g. of this specification.

5.3.4 Bar coding. U.S. Coast Guard requires bar coding of the NSN, IAW ISO/IEC 16388-2007 Code 39 Symbology.

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

5.4 Shipping. The Contractor shall ship, and deliver the parts and components to the government address specified in paragraph 5.4.1. Notify the Contracting Officer Representative (COR) and Contracting Officer about the shipment 7 days in advance. Provide timely shipping information to COR including the name of the shipping company, date of shipment leaving Contractor’s facility, and expecting arrival date and time at the government facility. No shipment shall arrive outside of government normal business hours as determined by the Contracting Officer.

5.4.1 Address. Unless otherwise specified, the Contractor shall ship, and deliver all parts to the following government addresses:

· U.S. Coast Guard

· Surface Forces Logistics Center

· 2401 Hawkins Point Rd. Bldg. 88

· Baltimore, MD 21226

6 NOTES

6.1 Document sources.

6.1.1 Government document sources.

· 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

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

Naval Publication and Forms Center

5801 Tabor Ave.

Philadelphia, PA 19120

215-697-2000

6.1.2 Coast Guard document sources.

· USCG Surface Forces Logistics Center

2401 Hawkins Point Road

Baltimore, MD. 21226-5000

Phone: 410-762-6171

ATTN: Contracting Branch, CPD1

6.1.3 Commercial document sources.

· Society of Automotive Engineers Inc. (SAE)

400 Commonwealth Drive

Warrendale, PA 15096

1-877-606-7323

FAX: 1-724-776-0790

· American Society for Testing & Materials (ASTM)

100 Barr Harbor Drive

West Conshohocken, PA 19428

610-832-9500

FAX: 610-832-9555

· American Society for Quality Control (ASQC)

611 East Wisconsin Ave.

Milwaukee, WI 53202

414-272-8575

FAX: 414-272-1734

· International Standard Organization (ISO)

1, ch. De la Voie-Creuse

CP 56 – CH-1211 Geneva 20

Switzerland

Phone +41 22 749 01 11 Fax: +41 22 733 34 30