Repair Specification for AQ22 shafts.docx

PROPULSION SHAFT PREPAIR SPECIFICATION FOR AQ22HS

REVISION No. . CHANGE NO. .

PROPULSION SHAFT REPAIR

SPECIFICATION FOR AQ22HS

ORGINATED BY A.G. Ollerman . DATE 05/2013 .

ORIGINATOR’S COMMAND Surface Forces Logistics Center (SFLC) .

DEPARTMENT / DIVISION Ice Break Buoy and Construction Tender Product Line .

INTERNAL REVIEWER . DATE .

SWORB APPROVAL . DATE _________.

1.0

SCOPE

1.1. This specification sets forth the requirements repair Aqua-met 22HS propulsion shafts. This specification also describes the inspection, preservation, packaging, packing and marking of the propulsion shafts.

1.2. GOVERNMENT FURNISHED PROPERTY for repair:

a. 160’ WLIC, NSN: 2010-01-076-3907, Part Number: 160WLIC-4301-003 Piece-1

b. 65’ WYTL, NSN: 2010-01-534-9802, Part Number: 65WYT 4301-4

c. 75’ WAGL, NSN: 2010-01-557-1512, Part Number: 75-WAGL-4301-4-PC1

2.0 APPLICABLE DOCUMENTS

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

2.2. GOVERNMENT DOCUMENTS - The following specifications and standards form a part of this specification to the extent specified herein.

2.2.1. SPECIFICATIONS, DOD

a. MIL-DTL-2845E (SH) DATED Aug 18, 1999, Packaging of Main propulsion Shafting, Bearings, Boat & Ship Propellers and associated Repair Parts.

b. MIL-STD-2191 (SH) DATED Nov 5, 1992 DOD Standard Practice, Repair Welding, Weld Cladding, Straightening, And Cold Rolling Of Main Propulsion Shafting.

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. DRAWINGS

a. 160-WLIC-4301-003 Rev B, Dated 09/09/11; Shafting Arrangement and Details

b. 65B-WYT-4301-4 Rev A, Dated 09/09, Propulsion Shaft Single Sheet Detail 65-WYT-4301-2 Rev A, Dated 05/09, 65601 Thru 65615 Shafting Plan

c. 75-WAGL-4301-5 Rev E, Dated 04/09, Shafting Machining Details to Suit I-F 1312 MDE

2.3.2. US COAST GUARD SPECIFICATIONS

a. USCG-ELC SPECIFICATION D-000-0100 (latest REV) Bar Coding for use on Surface Forces Logistics Center material.

2.4. 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.

2.4.1. Society of Automotive Engineers (SAE)

a. SAE-J-448A Dated 6/63 Surface Texture

b. SAE J-755 Dated 6/80, Marine Propeller Shaft Ends and Hubs

2.4.2. National Conference of Standards Laboratories (NCSL)

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

2.4.3. American Society for Testing Materials (ASTM)

a. ASTM A 276-04, DATED 01 Feb 2004, Standard Specification for Stainless Steel Bars and Shapes.

b. ASTM A 564/ A564M – 04 Dated 01 Mar 2004, Standard Specification for Hot-Rolled and Cold-Finished Age-Hardening Stainless Steel Bars and Shapes.

2.4.4. American Boat and Yacht Council (ABYC)

a. ABYC P-6 Dated July 2002, Propeller Shafting Systems

2.5. 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.

3.0 REQUIREMENTS

3.1. GENERAL - The contractor shall provide all labor and materials required to repair used propulsion shafts, and or manufacture new shafts. The contractor shall also provide all labor and materials necessary to inspect, preserve, package, pack & mark the propulsion shafts as outlined in this specification.

3.1.1. The shaft material shall be as follows: Brand name or equal in production methods, chemistry, and mechanical properties of Aquamet 22HS.

3.1.2. Tapers, shall be machined by a computer numerically controlled (CNC) lathe.

1.1.2. The Shaft End Taper(s) – The shaft(s) end tapers shall be blue fit to a “certified ring gage” with a tolerance of +0.0015” – 0.000” per foot of diameter. Ring Gage shall be constructed in accordance with NAVSEA S9243-A5-MMD-010. “The certified ring gage shall be furnished by the contractor”. Required shaft taper dimensions are as follows:

a. 160 WLIC (NSN: 2010-01-076-3907) - 0.750”/Ft. for Propeller end and 1.000”/Ft. for Coupling end.

b. 65 WYT (NSN: 2010-01-534-9802) – 0.750”/Ft. for Propeller and Coupling ends.

c. 65B WD & 75 WAGL (NSN: 2010-01-557-1512) - 0.750”/Ft. for Propeller and Coupling ends.

3.1.3. The blue fit shall be a minimum of 80% contact

3.2. DIMENSIONS - All dimensions and dimensional tolerances shall be as indicated on the specified drawing.

3.2.1. If not specified, tolerances shall be as listed below:

a. Fractional dimensions + / - 1/64”

b. Decimal dimensions (xx) + / - 0.01”, (xxx) + / - 0.001, (xxxx) +/- 0.0005”

c. Fractional dimensions on shaft length shall be + / - 1/16”

3.3. SURFACE FINISH STANDARDS - All surface finishes shall be in accordance with SAE-J-448A “Surface Texture” to RMS 32 finish.

3.4. MEASUREMENT PROCEDURES - Runout readings using a dial indicator shall be taken by supporting the shaft on precision rollers (two total) 24 inches from the ends of the shaft, or between lathe centers. (No additional supports shall be used.)

3.4.1. Runout readings shall be determined as follows: Conduct a dial indicator survey of the shaft run-out at stations 24” apart to determine the magnitude and location of any bend.

a. Each station shall be marked at the position of the maximum run-out on the periphery of the shaft.

3.5. RUNOUT, CONCENTRICITY, ECCENTRICITY & TAPER INSPECTION - The runout, concentricity, and eccentricity shall be as specified below.

3.5.1. Shaft Total Indicated Runout (T.I.R) - The outside diameter of each shaft section shall be concentric with the axis of rotation to within 0.005” T.I.R.

3.5.2. Taper Concentricity & Eccentricity - Shall be concentric with the axis of rotation to within 0.002” T.I.R.

3.6. WELDING – Weld repairs on used shafts are permitted but shall be accomplished in accordance with MIL-STD-2191 (SH) and an ABS or NAVSEA approved weld procedure for the specified shaft material.

3.7. STRAIGHTENING - Shall be accomplished by the “cold press” method only. No heat will be used to straighten shafts repaired in accordance with this specification.

3.8. KEYWAYS- Shall be machined in accordance with the applicable drawing

3.9. TEST/INSPECTION REPORTS

3.9.1. All reports prepared for submission shall contain at a minimum the data listed herein.

a. Prime Contractor Company Name, address, telephone Number

b. Testing Contractor (if different from above)

c. Contract & Delivery Order No

d. Test equipment used, Nomenclature, S/N, Calibration date

e. Shaft serial number

f. All test and inspection information as required in section 3.10.1. of this specification

3.10 TEST & INSPECTION DATA REQUIREMENTS

3.10.1 Each shaft shall be tested/ inspected as specified herein:

1. Liquid dye penetrant test of all areas in way of keyways, tapers, threads, and bearings.

2. Total Indicated Runout (TIR) in accordance with the drawing.

3. Taper Inspections shall be in accordance with section 3.1.3 & 3.5.2 herein and contact impression requirements as specified herein.

4. Dimensional inspection in accordance with the drawing.

5. The completed Receiving Inspection Report with cost to repair shall be submitted to the Contracting Officer within 10 calendar days of receipt of the shaft, for approval prior to starting any repairs.

3.11. MARKING - All shafts shall be marked on the coupling end face with a stamped-in serial number at least 1/8” high on the coupling end face as directed on each delivery order.

3.12. NOTIFICATIONS & INSPECTIONS - The contractor shall notify the Contracting Officer at least seven (7) calendar days prior to inspections or monitored testing required herein.

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 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 ANSI/NCSL Z540-3. The program shall be documented and traceable to the National Institute of Standards (NIST).

4.4. The calibration system records shall be maintained for inspection for the duration of any contract referencing this specification and shall be submitted to the Quality Assurance Inspector upon request.

4.5. 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 in order to conduct all inspection requirements. All inspections shall be performed at the Contractor’s plant or at other facilities acceptable to the Coast Guard. The Coast Guard Quality Assurance Representative will witness the inspections set forth in this specification. Such inspections are deemed necessary to assure that supplies and services conform to the prescribed requirements.

4.6. TESTS/INSPECTIONS - The inspections/tests required here and in section 3.9 & 3.10 are the minimum required and are not intended to supplant any controls, examinations, inspections or tests normally employed by the Contractor to assure the quality of the propulsion shafts.

4.6.1. Shaft Inspections – See section 3.10.of this specification.

4.7. FAILURE RESPONSIBILITY - If a shaft fails to pass any inspection or test, the Contractor shall report the failure and their recommended corrective action to the Contracting Officer. If approved, the corrective action on the materials or processes shall be taken in accordance with this section.

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

4.7.2. The inspection/test shall be discontinued until any approved corrective action has been taken.

4.7.3. After all corrective action has been taken the inspection/test shall be continued or repeated, at the option of the Contracting Officer.

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

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

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

4.8. INSPECTION REPORTS - One copy of any required inspection or tolerance check shall be submitted to the contracting Officer.

4.8.1. A copy of any inspection or tolerance check shall also be turned over to the Quality Assurance representative upon his 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 3.12 of this specification.

5.0 PRESERVATION, PACKING, PACKAGING, AND MARKING - Each shaft shall be preserved, packed, packaged and marked as specified herein.

5.1. PRESERVATION - All shafts shall be cleaned and dried in accordance with MIL-DTL-2845 section 3.7.1. No further preservation shall be done.

5.2. PACKING - Each completed shaft shall be packed in accordance with MIL-DTL-2845 section 3.15.6 Level A, except Figure 15 shall be used for the box as modified herein.

a. The sides, bottom, and ends shall be made from 2” thick construction grade lumber sized so that one piece covers the height or width of the area, doubled on the ends. The top shall be made from 1” thick construction grade lumber.

b. Cradles – Shall be made from doubled 2” thick construction grade lumber.

c. Skids- Shall be made from 4” x 4” construction grade lumber. Skids shall be placed on both ends and every 4’ thereafter.

d. The top shall be attached with screws for easy removal, and marked in 2” high red lettering “TOP – REMOVAL WITH SCREW DRIVER” in three places evenly distributed across the top.

5.2.1. Place PVC tubing over all threads and tapers and secure in place.

5.3. COMMON CARRIER PREPARATION - All packaged shafts shall be shimmed after placement on the trailer to firmly support the cross skids in their natural lay.

a. This shimming shall be attached to the cross skidding to prevent the shims from dislodging from the cross skids during transport.

5.4. MARKING - The marking described herein shall be placed in the upper left hand corner of the longest two sides of each box (on opposite ends).

5.4.1. All markings shall be made with machine-made stencils; the lettering shall be at least 1/2” high, in black print lettering on a highly contrasting background.

5.4.2. This marking shall consist of the STOCK NUMBER, ITEM NAME, PART NUMBER, CONTRACT NUMBER, DELIVERY ORDER NUMBER, and SERIAL NUMBERS, GROSS WEIGHT (in lbs.,) condition code i.e.; CONDITION A, unit of issue with quantity (1) and the words COAST GUARD SFLC MATERIAL.

5.4.3. See the marking layout below, and as required on figure 1.

Figure 1.

160 WLIC

COAST GUARD SFLC MATERIAL

REUSABLE CONTAINER

DO NOT DESTROY

65 WYT

COAST GUARD SFLC MATERIAL

REUSABLE CONTAINER

DO NOT DESTROY

65B WLR & 75WAGL (with I-F MDE)

COAST GUARD SFLC MATERIAL

REUSABLE CONTAINER

DO NOT DESTROY

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

a. All bar coded labels shall be in accordance with SFLC specification D-000-0100 (latest Rev).

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, serial number, and the Contract Number.

3. The marking required in 5.4 of this specification can be applied separately or as part of the Bar Code Label.

6.0 NOTES

6.1. GOVERNMENT & COMMERCIAL DOCUMENT SOURCES

6.1.1. MILITARY & DOD DOCUMENTS

a. Specifications and Standards (DODISS Documents) Standardizations Document Order Desk 700 Robbins Ave.

Building #4, Section D Philadelphia, PA. 19111-5094 215-697-1187

b. Naval Publication and Forms Center 5801 Tabor Ave.

Philadelphia, PA 19120 215-697-2000

6.1.2. U.S. COAST GUARD DOCUMENTS

a. USCG SURFACE FORCES LOGISTICS CENTER 2401 Hawkins Point Road Baltimore, MD. 21226-5000

410-762-XXXX

Attn: Contract & Procurement Division CPD-1

6.1.3. COMMERCIAL DOCUMENTS

a. Society of Automotive Engineers, INC. (SAE) 400 Commonwealth Drive Warrendale, PA 15096 412-776-4841 Fax 412-776-5760 www.sae.org

b. American Society for Testing & Materials (ASTM) ASTM International 100 Barr Harbor Drive

P.O. BOX C700

West Conshohocken, PA 19428-2959 610-832-9585 Fax 610-832-9555 www.astm.org

c. American National Standards Institute (ANSI) 25 West 42nd Street (Between 5th and 6th avenues), 4th floor New York, NY 10036 212-642-4900 Fax 212-398-0023 www.ansi.org

d. American Boat and Yacht Council Inc. (ABYC) 3069 Solomons Island Road Edgewater, MD 21037-1416 410-956-1050 Fax 410-956-2737 www.abycinc.org