RUDDER STOCK ASSEMBLY AG116.pdf

OVERHAUL DESCRIPTION

FOR OFFICIAL USE ONLY

ITEM NAME RUDDER STOCK ASSEMBLY

STOCK NUMBER 2040-01-486-0550

PART NUMBER 901WMEC-562-004

USED ON

Items as received by the contractor must be complete and of the proper cited part number. Discrepancies shall be reported to the Coast Guard Contracting Officer.

OVERHAUL REQUIREMENTS:

1. This statement of work covers the inspection of a previously used 270 WMEC rudder assembly identified below. Any subsequent repair work as a result of the inspection results, as well as preservation, packaging and marking will be addressed during the overhaul phase.

NSN: 2040-01-486-0550

Name: RUDDER, ASSEMBLY Part Number: 901 WMEC-562-4

2. Applicable Documents:

a) USCG Drawing 901 WMEC-562-4 Rev D, 270 WMEC RUDDER ASSEMBLY.

b) USCG Drawing 901 WMEC-562-5 Rev F, A & B CLASS RUDDER STOCK AND

STEERING GEAR A & D.

c) USCG Drawing 905 WMEC-562-1 Rev G, 270 WMEC RUDDER .

d) NAVSEA Technical Publication T9074-AS-GIB-010/271 Requirements for Nondestructive Testing Methods.

e) MIL-STD 2035A Nondestructive testing acceptance criteria.

f) NFPA 306, National Fire Protection Association- Standard for the Control of Gas Hazards on Vessels.

g) MIL-DTL-2845E Packaging and storage of propulsion systems.

h) COMDTINST M10360.3C, Coatings and color manual.

i) MIL-C-104, Creates, wood lumber and plywood sheathed.

j) 270 rudder stock inspection form.

k) ANSI B1.5 Acme Screw Threads.

2.1 In the event of a conflict between the text of this statement of work (SOW) and the references cited herein, this SOW shall take precedence.

3. Requirements: The rudder assembly shall consist of all items shown on reference 2a and wrench shown on reference 2b, sheet 6, detail 43A. Any missing items shall be noted in a condition found report (CFR).

3.1 If more than one rudder assembly is received, each component shall be visually inspected for match marks to determine which components belong as a matched set either by serial number or any such markings available.

3.2 Upon receipt of the rudder stock and blade, unship them from their shipping container/pallet. Visually inspect the container/pallet configuration and submit a condition found report. Retain the shipping containers and hardware for reuse.

3.2.1 The skid construction for the rudder stock shall be consistent with reference 2g, section 3.15.6.2 with the exception that lagging strips are not required. A plywood enclosure including a top and four sides shall completely enclose the rudder stock.

3.2.2 The rudder blade skid construction shall be consistent with a skid similar to that shown in figure 11 of reference 2g and constructed in accordance with reference 2i.

3.3 The rudder stock shall be cleaned of all preservative coating, dirt, rust, grease and brought to a clean metal finish. Any preservative waste shall be disposed of in accordance with local regulations.

3.3.1 With the rudder stock placed in a lathe between centers, an inspection shall be conducted and documented on inspection form reference 2j.

Any difference in configuration of the rudder stock as compared to reference 2.b shall be documented in CFR.

3.3.2 The rudder stock taper, radius, keyways, threads and nuts shall be non destructive tested per reference 2d by use of either magnetic particle or dye penetrant inspection method. The acceptance criteria shall be determined by the use of reference 2e. Submit a CFR of all findings.

3.3.3 The thread pitch diameter, major and minor diameter and thread thickness of the rudder stock and rudder nut shall be inspected using reference 2.k to determine if they are within tolerance. The rudder nut shall be threaded onto the rudder stock and inspected for full engagement up to the shafts shoulder and checked for proper fit. Submit a Condition found report of all findings.

3.3.4 Inspect the condition and fit of all existing keys to the stock and submit findings. The keys shall have a tap fit into the keyways with the use of a soft face mallet.

3.3.5 Verify full thread engagement of the lifting hoist ring into the stock.

3.4 Visually inspect the rudder blade configuration to determine if an access opening plate exist on both sides as indicated on reference 2c, general note

20. Document any damage or configuration differences found between the rudder and the drawing in a CFR.

3.4.1 The rudder void shall be drained and gas free in accordance with reference 2f or applicable Yard procedure. The rudder shall be certified safe for hot work.

3.4.2 The rudder hub taper bore, counter bore, keyway, threaded plug openings shall be clean of any rust, dirt, grease, etc. and solvent cleaned. Visually inspect the machine surface for any noticeable defects. Measure and record the dimensions and surface finishes of the large and small ends of the taper, key and keyway. Submit findings in a CFR report.

3.4.3 Blank, mask and/or plug all openings and machine surfaces for protection and preparation for grit blast of the rudder exterior and rudder nut pocket area. The rudder blade shall be grit blast all over to near white in accordance with Appendix A.30.I of reference 2h.

3.4.4 Using references 2 d & e, visually inspect all welds and non destructive test any weld that is suspect to be damaged or does not meet the drawing weld requirements. Determine the extent of any need for repair and submit all findings and recommendations in a CFR.

SHELF LIFE CD 0

1. This statement of work covers the inspection of a previously used 270 WMEC rudder assembly identified below. Any subsequent repair work as a result of the inspection results, as well as preservation, packaging and marking will be addressed during the overhaul phase.

NSN: 2040-01-486-0550

Name: RUDDER, ASSEMBLY Part Number: 901 WMEC-562-4

2. Applicable Documents:

a) USCG Drawing 901 WMEC-562-4 Rev D, 270 WMEC RUDDER ASSEMBLY.

b) USCG Drawing 901 WMEC-562-5 Rev F, A & B CLASS RUDDER STOCK AND

STEERING GEAR A & D.

c) USCG Drawing 905 WMEC-562-1 Rev G, 270 WMEC RUDDER .

d) NAVSEA Technical Publication T9074-AS-GIB-010/271 Requirements for Nondestructive Testing Methods.

e) MIL-STD 2035A Nondestructive testing acceptance criteria.

f) NFPA 306, National Fire Protection Association- Standard for the Control of Gas Hazards on Vessels.

g) MIL-DTL-2845E Packaging and storage of propulsion systems.

h) COMDTINST M10360.3C, Coatings and color manual.

i) MIL-C-104, Creates, wood lumber and plywood sheathed.

j) 270 rudder stock inspection form.

k) ANSI B1.5 Acme Screw Threads.

2.1 In the event of a conflict between the text of this statement of work (SOW) and the references cited herein, this SOW shall take precedence.

3. Requirements: The rudder assembly shall consist of all items shown on reference 2a and wrench shown on reference 2b, sheet 6, detail 43A. Any missing items shall be noted in a condition found report (CFR).

3.1 If more than one rudder assembly is received, each component shall be visually inspected for match marks to determine which components belong as a matched set either by serial number or any such markings available.

3.2 Upon receipt of the rudder stock and blade, unship them from their shipping container/pallet. Visually inspect the container/pallet configuration and submit a condition found report. Retain the shipping containers and hardware for reuse.

3.2.1 The skid construction for the rudder stock shall be consistent with reference 2g, section 3.15.6.2 with the exception that lagging strips are not required. A plywood enclosure including a top and four sides shall completely enclose the rudder stock.

3.2.2 The rudder blade skid construction shall be consistent with a skid similar to that shown in figure 11 of reference 2g and constructed in accordance with reference 2i.

3.3 The rudder stock shall be cleaned of all preservative coating, dirt, rust, grease and brought to a clean metal finish. Any preservative waste shall be disposed of in accordance with local regulations.

3.3.1 With the rudder stock placed in a lathe between centers, an inspection shall be conducted and documented on inspection form reference 2j.

Any difference in configuration of the rudder stock as compared to reference 2.b shall be documented in CFR.

3.3.2 The rudder stock taper, radius, keyways, threads and nuts shall be non destructive tested per reference 2d by use of either magnetic particle or dye penetrant inspection method. The acceptance criteria shall be determined by the use of reference 2e. Submit a CFR of all findings.

3.3.3 The thread pitch diameter, major and minor diameter and thread thickness of the rudder stock and rudder nut shall be inspected using reference 2.k to determine if they are within tolerance. The rudder nut shall be threaded onto the rudder stock and inspected for full engagement up to the shafts shoulder and checked for proper fit. Submit a Condition found report of all findings.

3.3.4 Inspect the condition and fit of all existing keys to the stock and submit findings. The keys shall have a tap fit into the keyways with the use of a soft face mallet.

3.3.5 Verify full thread engagement of the lifting hoist ring into the stock.

3.4 Visually inspect the rudder blade configuration to determine if an access opening plate exist on both sides as indicated on reference 2c, general note

20. Document any damage or configuration differences found between the rudder and the drawing in a CFR.

3.4.1 The rudder void shall be drained and gas free in accordance with reference 2f or applicable Yard procedure. The rudder shall be certified safe for hot work.

3.4.2 The rudder hub taper bore, counter bore, keyway, threaded plug openings shall be clean of any rust, dirt, grease, etc. and solvent cleaned. Visually inspect the machine surface for any noticeable defects. Measure and record the dimensions and surface finishes of the large and small ends of the taper, key and keyway. Submit findings in a CFR report.

3.4.3 Blank, mask and/or plug all openings and machine surfaces for protection and preparation for grit blast of the rudder exterior and rudder nut pocket area. The rudder blade shall be grit blast all over to near white in accordance with Appendix A.30.I of reference 2h.

3.4.4 Using references 2 d & e, visually inspect all welds and non destructive test any weld that is suspect to be damaged or does not meet the drawing weld requirements. Determine the extent of any need for repair and submit all findings and recommendations in a CFR.

3.4.5 The thickness of the shell plate, including areas of erosion or pitting shall be ultrasonically (UT) inspected in accordance with the applicable Yard DSOP. Nominal plate thickness is 3/8? thick. A minimum of 25 shots per side shall be taken to include the access pocket area. Any questionable areas shall have additional 5-10 shots taken in the general locality to determine the extent of the damaged area. Submit UT results along with a sketch that details the damaged areas.

3.4.6 Conduct a rudder void air test at 5 PSI with no pressure drop allowed over a ten minute duration. A relief valve shall be used and set at 8 PSI to prevent over pressurization. An SFLC Quality Assurance Representative (QAR) shall witness this test. The results of the all air test shall be documented and reported in a CFR. Any minor leaks detected shall be repaired and the air test continued.

3.5 Remove and retain the protective blanks covering the rudder taper.

Solvent clean the taper surface in preparation for blue fit inspection. The rudder blade shall be placed in the vertical position as typically installed on the vessel and properly restrained for the purpose of taking blue fit impression readings.

3.5.1 Inspect the fit between rudder stock and rudder blade taper by lightly coating the rudderstock taper with a thin film of bluing paste. With the key in place, lower the rudderstock into the blade, until the rudder blade supports the weight of the rudderstock. Tighten the rudder nut by the use of the rudder nut wrench and a 20lb maul until the nut can no longer be advanced. Disassemble the rudderstock from the blade by use of a portable hydraulic jack. The use of a thick steel plate that is wider then the jack diameter is recommended to distribute the force as not to damage the lower pocket plate under the jack. Inspect the blue impression on the rudderstock taper for a minimum 75% contact. The blue impression shall be uniform over the entire taper. An SFLC QAR shall be present on during the final blue fit inspection. Submit a CFR stating the approximate percentage of blue fit that has been determined. If the blue fit is not uniform or only slightly less than 75%, proceed with hand fitting until a uniform a 75% contact had been achieved. Removal of material by hand fitting shall only be accomplished on the rudder blade taper. Remove all bluing paste upon completion of the inspection.

3.5.2 While the rudder and stock are assembled and with the rudder nut removed, record the amount of rudder draw from the shoulder of small end of the rudder stock taper to the bottom shoulder of rudder blade casting and submit findings.

3.6 The fore mentioned inspections and test are the responsibility of the contractor. Upon completion of all inspections and test, CFR report(s) shall be submitted along with supporting documentation. Upon review of the report(s) by SFLC, further instructions will be provided regarding either disposition instructions or a request for a repair estimate. The estimate request will address the specifics of each finding within the CFR and also provide further guidance with regard to overhaul or modifications.

4. Quality Assurance: The contractor shall be responsible for notifying the Contracting Officer Technical Representative (COTR) at least seven (7) calendar days prior to the inspections shown below for verification by an

SFLC (QAR):

4.1 Rudder void air test (3.4.6).

4.2 Taper blue fit inspection (3.5.1).

5. Preservation, Packaging, Packing, & Marking (PPP&M): PPP&M will be addressed separately after completion and submittal of all inspection reports.

3.4.5 The thickness of the shell plate, including areas of erosion or pitting shall be ultrasonically (UT) inspected in accordance with the applicable Yard DSOP. Nominal plate thickness is 3/8? thick. A minimum of 25 shots per side shall be taken to include the access pocket area. Any questionable areas shall have additional 5-10 shots taken in the general locality to determine the extent of the damaged area. Submit UT results along with a sketch that details the damaged areas.

3.4.6 Conduct a rudder void air test at 5 PSI with no pressure drop allowed over a ten minute duration. A relief valve shall be used and set at 8 PSI to prevent over pressurization. An SFLC Quality Assurance Representative (QAR) shall witness this test. The results of the all air test shall be documented and reported in a CFR. Any minor leaks detected shall be repaired and the air test continued.

3.5 Remove and retain the protective blanks covering the rudder taper.

Solvent clean the taper surface in preparation for blue fit inspection. The rudder blade shall be placed in the vertical position as typically installed on the vessel and properly restrained for the purpose of taking blue fit impression readings.

3.5.1 Inspect the fit between rudder stock and rudder blade taper by lightly coating the rudderstock taper with a thin film of bluing paste. With the key in place, lower the rudderstock into the blade, until the rudder blade supports the weight of the rudderstock. Tighten the rudder nut by the use of the rudder nut wrench and a 20lb maul until the nut can no longer be advanced. Disassemble the rudderstock from the blade by use of a portable hydraulic jack. The use of a thick steel plate that is wider then the jack diameter is recommended to distribute the force as not to damage the lower pocket plate under the jack. Inspect the blue impression on the rudderstock taper for a minimum 75% contact. The blue impression shall be uniform over the entire taper. An SFLC QAR shall be present on during the final blue fit inspection. Submit a CFR stating the approximate percentage of blue fit that has been determined. If the blue fit is not uniform or only slightly less than 75%, proceed with hand fitting until a uniform a 75% contact had been achieved. Removal of material by hand fitting shall only be accomplished on the rudder blade taper. Remove all bluing paste upon completion of the inspection.

3.5.2 While the rudder and stock are assembled and with the rudder nut removed, record the amount of rudder draw from the shoulder of small end of the rudder stock taper to the bottom shoulder of rudder blade casting and submit findings.

3.6 The fore mentioned inspections and test are the responsibility of the contractor. Upon completion of all inspections and test, CFR report(s) shall be submitted along with supporting documentation. Upon review of the report(s) by SFLC, further instructions will be provided regarding either disposition instructions or a request for a repair estimate. The estimate request will address the specifics of each finding within the CFR and also provide further guidance with regard to overhaul or modifications.

4. Quality Assurance: The contractor shall be responsible for notifying the Contracting Officer Technical Representative (COTR) at least seven (7) calendar days prior to the inspections shown below for verification by an

SFLC (QAR):

4.1 Rudder void air test (3.4.6).

4.2 Taper blue fit inspection (3.5.1).

5. Preservation, Packaging, Packing, & Marking (PPP&M): PPP&M will be addressed separately after completion and submittal of all inspection reports.

WARRANTY:

A. Standard Manufacturer's Warranty

X B. Item being repaired as an "onboard repair" or a "system stock" item and will be put into inventory. NOT FOR IMMEDIATE INSTALLATION.

Contractor must guarantee item against defects that lead to failure for

180 days after installation for a period of up to two (2) years after delivery to Coast Guard.

GOVERNMENT ACCEPTANCE:

Acceptance will be made at destination by a Government representative.

Acceptance will be contingent upon the representative's verification of no damage in transit, correctness and completeness of order and contractor's conformance to preservation/packaging, packing and marking requirements.

PACKAGING AND MARKING FOR SHIPMENT:

X

A. Each unit shall be packed individually in it's own wooden box which shall be capable of providing adequate protection to the item during multiple shipments. Mark each box in legible black print lettering with the following information:

NATIONAL STOCK NUMBER

ITEM NAME

PART NUMBER

GOVERNMENT ORDER NUMBER

2040-01-486-0550

RUDDER STOCK ASSEMBLY

901WMEC-562-004

PRESERVATION / PACKAGING:

A. Each unit shall be individually preserved and wrapped for protection against deterioration for a period of two (2) years minimum.

X B. See Attachments

B. See Attachments

And the words: "Coast Guard SFLC Material, Condition "A"

RECOMMENDED SOURCES:

UNITED STATES COAST GUARD SFLC

2401 HAWKINS POINT RD

BALTIMORE, MARYLAND 21226-5000

410-762-6800

STEEL AMERICA

400 EAST INDIAN RIVER ROAD

NORFOLK, VA. 23523 - 1756

757-545-5311

WRITTEN BY:

DATE :

STEPHEN TWOMEY

20 MAR 20

Cost Estimate for Overhaul NOT TO EXCEED: $176,000