StatementOfWorkTaperBolts(R3)CGC_PSTAR.pdf

DTJ 20Aug2020 Rev 3

WORK ITEM 1: Coupling Bolts, Provide

1. SCOPE

1.1. Intent. This Statement of Work (SOW) provides the requirements for the manufacture, inspection, preservation, packaging, packing, and marking of Shaft Coupling Bolts used on the propulsion shafting system of USCGC POLAR STAR.

1.2. Government-furnished property. None

2. REFERENCES

COAST GUARD DRAWINGS

Coast Guard Drawing 400-WAGB 4301-1, Rev Y, Arrgt. Of Shafting

COAST GUARD PUBLICATIONS

Coast Guard Technical Publication (TP) 4989, Rev -, Main Reduction Gear Drives

USCG-SFLC Specification D-000-0100 Rev. G, Dated 02/06; Bar Coding for USCG-SFLC Material.

OTHER REFERENCES

American Society of Mechanical Engineers (ASME) B1.1, 2003, Unified Inch Screw Threads, (UN and UNR Thread Form)

MIL-S-24093A(SH) w/INT AMENDMENT 1, 10 July 2012, Steel Forgings, Carbon and Alloy Heat Treated.

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

MIL-PRF-16173E(SH) w/INT. AMENDMENT 2, Dtd 19 October 2017, Corrosion Preventive Compound, Solvent Cutback, Cold-Application

MIL-STD-2073-1E w/CHANGE 4, 22 April 2019, Standard Practice For Military Packaging.

MIL-PRF-121G, 30 Apr 2001, Barrier Materials, Greaseproof, Waterproof, Flexible, Heat Sealable.

NCSL Z540.3, Dated 03 Aug 2006; Requirements for the Calibration of Measuring and Test Equipment.

ANSI/ASQ 9001 –, Dated October 2015, Quality Management Systems – Requirements – T1040

SAE-J-448, Dated 01 Jan 1963, Surface Texture Standard (SAE).

2.1. Document availability. The documents listed in this section are referenced in sections 3, 4 and 5 of this work item and form a part of this SOW 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.. To obtain the referenced documents see section 6.1.

2.2. Work item order of precedence. In the event of a conflict between the text of this work item and the references cited herein, this work item shall take precedence, unless otherwise specified herein.

Nothing in this work item, however, supersedes applicable laws and regulations unless a specific exemption has been obtained.

3. REQUIREMENTS

3.1. General – The Contractor shall provide all labor and materials required to manufacture, test, inspect, preserve, package, pack and mark the Coupling Bolts used to connect the propulsion shaft main motor hub to the reduction gear disconnect coupling flange used onboard the U.S. Coast Guard’s 399’ WAGB Cutter (USCGC POLAR STAR), in accordance with references cited in section 2 and this SOW.

All required inspections, documents and certifications specified herein will be observed by SFLC Quality Assurance (SFLC QA) personnel at the Contractor’s facility.

A total of sixteen (16) Coupling Bolts, Item 6 shall be provided.

Item Number shown in the Table below refer to Detail 17-D-1 on Sheet 2 of CG Dwg 400 WAGB 4301-1 Rev (Y).

TABLE 3.1 – COUPLING BOLT REQUIREMENS

ITEM

NO.

DESCRIPTION QTY ACN P/N MATERIAL

06 Coupling Bolt 16 5306-01-F19-5873 40-9756-0000 Mil-S-24093 CL-C, Type 2

3.2. Material – The Coupling Bolts shall be manufactured from material that is conforming in all aspects to the characteristics and requirements of Type II Class C Forged Steel set forth in MIL-S- 24093A(SH) as invoked by CG Drawing 400 WAGB 4301-1 Rev.(Y).

3.3. Material Certification – The Contractor shall provide reports on Forgings, Chemical analysis and Mechanical properties/requirements of proposed Coupling Bolts and Nuts to the Contracting Officer for approval prior to machining.

3.3.1. If more than one forging is used to manufacture the Coupling Bolts then reports on Chemical analysis and Mechanical properties/requirements of each forging used, shall be provided to the Contracting Officer for approval prior to machining.

3.3.2. Mechanical properties report(s) for forging(s) shall include Charpy V notch Hardness test results.

3.4. Serial Number – Contractor shall assign serial number(s) to each individual coupling bolt. Serial number shall consist of Contractors CAGE Code with the associated production number of the coupling bolt, (i.e. 456XYZ-001).

3.4.1. The Contractor shall stamp the serial number using block numbers / letters sized between 1/8” and 1/4".

3.4.2. Contractor shall stamp “coupling bolt” serial number on face of threaded end of coupling bolt.

Serial number to be stamped to one side of bolt center in a semi-circular fashion.

3.5. Dimensions – All dimensions and dimensional tolerances shall be as indicated/specified on SFLC Rough Detail Drawing, Encl (1) and Detail 17-D-1 CG Dwg 400 WAGB 4301-1 Rev (Y), of this SOW with the following clarifications:

3.5.1. Bolt body/shank section shall be machined as a straight bolt not tapered.

3.5.2. 9.900” bolt body/shank section, (measured between bolt head washer face to ½” before start of threaded portion of bolt), shall be machined to an outside diameter (O.D.) of 3.750” (+ 0.010” / -0”). Bolt body/shank shall have a final surface finish of 125 Ra.

3.5.3. Diameter transitions i.e. area between bolt head and bolt head washer face, shall be radiused as follows.

a. Both ends/sides of transition area between coupling bolt body/shank and threads shall have 1/4" radius.

b. Transition area between coupling bolt washer face and coupling bolt body/shank shall have 1/16” radius.

3.5.4. All machined sharp edge(s), shall be broken in accordance with good machining practice.

3.5.5. If not specified fractional dimensions shall be +/- 1/64”, decimal dimensions shall be plus or minus ten thousandths of an inch (+/- 0.010”).

3.6. Surface Finish Standards – All surface finishes shall be in accordance with SAE-J-448 Surface Texture Standard (SAE). All surface finishes shall be finished to RA number indicated on SFLC Rough Detail Drawing, (encl. (1)) and detail 17-D-1 of CG Dwg 400 WAGB 4301-1 Rev (Y) of this SOW.

3.6.1 Bolt Center Requirement – All coupling bolts shall be finished with machined alignment centers.

Alignment centers shall be located on bolts longitudinal axis at center of bolt hex head and threaded end of bolt. Centers are required and will be used to set up bolt for final installation machining.

3.7. First Article Inspection – If a first article coupling bolt sample is required by the purchase order, the Contractor shall perform a first article inspection in accordance with paragraph 3.8.

3.7.1. If required a first article inspection shall be performed by the Contractor and USCG SFLC QA at the Contractor’s facility. The first article(s) shall be manufactured to and meet all requirements of this SOW and shall pass all the tests and inspections listed in sections 3.8 and 4.6 of this SOW.

3.7.2. Number of First Article Test Units – Unless otherwise specified in the Contract, one (1) coupling bolt shall be required for first article testing purposes.

3.7.3. Waiver of First Article Requirements – The Contracting Officer reserves the right to waive all or part of the first article requirements specified herein.

3.7.4. Rejection Criteria – The results of the first article inspection will be reviewed by the Contracting Officer to determine compliance with the requirements of this specification. Failure of any of the tests or inspections described herein will be cause for rejection of the first article. If the first article is rejected, the Contractor will be notified in writing by the Contracting Officer and allowed 14 calendar days to fix or resubmit a new first article. Repair or replacement of the first article shall be by the Contractor at the Contractor's expense.

3.7.5. Upon successful completion of the first article inspection, the Contracting Officer will provide the Contractor with written authorization to begin fabricating production quantities.

3.7.6. Standardization – Materials, parts, design, and fabrication methods used in the production quantities shall be identical to those used in the first articles, unless otherwise authorized in writing by the Contracting Officer.

3.8. Post Manufacture Inspections & Tests- Contractor shall perform the following inspections and tests after final machining work is complete on the first article as well as the production quantities. The results shall be recorded on a Post Manufacturing Inspection Report applicable to either the first article or production quantities and submitted to the Contracting Officer for approval.

3.8.1. Each coupling bolt shall be dimensionally inspected for conformance to requirements of section 3.5., SFLC Rough Detail Drawing, (encl. (1)) and detail 17-D-1 of CG Dwg 400 WAGB 4301-1 Rev (Y) of this SOW.

3.8.2. Using the findings from the Post Manufacturing Inspection, the Contractor shall prepare a report detailing the post manufacturing condition of each coupling bolt assembly. The report shall include but not be limited to the following.

a. Dimensional Data

b. Surface Finish

c. Individual Assembly Weight

3.8.3. Post Manufacturing Inspection Report -The results of testing and inspections conducted by the Contractor in section 3.8 shall be recorded on a Post Manufacturing Inspection Report and submitted to the Contracting Officer for review and approval. If this report is determined to be acceptable, the Contracting Officer will authorize SFLC Quality Assurance personnel to schedule first article or final inspections and testing as outlined in section 4.6 of this SOW.

3.9. Reports – All reports prepared for submission shall contain at a minimum, the following information.

a. Prime Contractor company name, address, and telephone number.

b. Testing Contractor contact info (if different from above).

c. Contract Number, Delivery Order Number or Project Order Number and Serial Number of each Coupling Bolt if more than one is manufactured.

d. All test and inspection information required herein.

3.10. Preservation, Packaging, Packing - Shall be in accordance with MIL-DTL-2845(SH), MIL-PRF- 1617E w/INT AMD 2, and MIL-STD-2073-1E w/CHANGE 4, of this SOW.

3.11. Notifications & Inspections – The Contractor shall be responsible for notifying the Contracting Officer at least ten (10) working days prior to said Contractor being ready for any inspections or testing.

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 in accordance with ANSI/ASQ 9001, of this SOW 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 NCSL Z540.3 of this SOW. 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 to perform all of the inspection requirements. Inspection and testing shall be performed at the Contractor’s plant or other facilities acceptable to the Coast Guard. The Coast Guard reserves the rights to verify or have performed any of the inspections that are deemed necessary to assure that supplies and services conform to the prescribed requirements.

4.5. Responsibility for Compliance – All items shall meet the provisions of sections 3 & 5 of this SOW. The inspections set forth in this SOW shall become part of the Contractor’s overall inspection system or quality program. The absence of any inspection requirements in the SOW 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. Tests & Inspections – 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.

NOTE** Tests and inspections below will be witnessed by an SFLC Quality Assurance Representative.

4.6.1. First Article Inspection.

4.6.2. Full Dimensional Inspection and Material Certification in accordance with sections 3.3 thru 3.6.1.

of this SOW.

4.6.3. Preservation Inspection.

4.6.4. Packaging, Packing, and Marking (PPP&M) Inspection.

4.7. Test and Inspection Reports – One copy of any required inspection, test or tolerance check report shall be sent to the Contracting Officer.

4.7.1. 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 facility.

4.7.2. 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.

4.8. Failure Responsibility – If the specified item fails to pass any QA 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.

4.8.1. The affected inspection/test shall be discontinued until corrective action(s) have been taken.

4.8.2. Any unsatisfactory QA inspection/test shall be repeated after corrective action(s) unless waived by the Contracting Officer.

4.8.3. Final Acceptance shall be contingent upon satisfactory completion of all dimensional, visual, and PPP&M inspections/tests.

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

4.8.5. 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.

4.9. Packaging Inspection – The Contracting Officer shall be notified prior to the packaging, packing, and marking of the completed units in accordance with section 3.10 of this SOW.

5.0 PRESERVATION, PACKAGING, PACKING, & MARKING

5.1. Preservation – Preservation shall meet the Grade 4 Indoor/Outdoor requirements and standards set forth in MIL-PRF-1617E w/INT AMD 2 of this SOW for each part manufactured.

5.2. Packaging, Packing – Shall be in accordance with Table I, Item “miscellaneous finished forged and rolled steel parts (coupling bolts, nuts, washers, keys and coupling flanges) of MIL-DTL-2845E(SH) of this SOW.

5.2.1. Packaging – After coupling bolt assemblies have been preserved and preservative has set, coupling bolt assemblies shall be packaged in accordance with Method 20 of the latest version of MIL-STD-2073 and this SOW with the following inclusions.

a. Coated coupling bolts and nuts shall be wrapped in Type I material conforming to MIL-PRF-121 of this SOW. Material shall be wrapped around the coupling bolt assemblies in a manner that snugly encloses the coated bolt assemblies to prevent unintentional unwrapping.

5.3. Marking – Each preserved, packaged, and packed item shall be marked in the upper left-hand side of the two longest sides, (two opposite sides if square) of each container. The Markings shall be made with machine-made stencils. The lettering / numbering shall be at least 1/4" high, in permanent black printed characters on a highly contrasting “painted” background.

5.3.1. This marking shall consist of the ITEM NAME, PART NUMBER, SERIAL NUMBER, CONTRACT NUMBER, DELIVERY ORDER NUMBER, PROJECT ORDER (if applicable), SHIPPING WEIGHT ( lbs.), PACKING DATE, CONDITION CODE, CONDITION “A”, QUANTITY and UNIT OF ISSUE (i.e. 1-EA), and the words COAST GUARD SFLC MATERIAL and shall be as shown below:

a. Marking Layout for “Coupling Bolt”

ITEM NSN NUMBER 5306-01-F19-5873

ITEM NAME SHAFT COUPLING BOLT

ITEM PART NUMBER 40-9756-0000

SERIAL NUMBER As provided by the Contractor CONTRACT NUMBER As indicated on the Contract SHIPPING WEIGHT As determined by Contractor PACKING DATE As determined by Contractor

CONDITION CODE CONDITION “A”

QUANTITY & UNIT OF ISSUE 1 - EACH

COAST GUARD SFLC MATERIAL

5.4. Bar Coding – Bar code labels shall be supplied for all Contract Line Item Number(s) (CLINs) except for those that require data submissions only.

5.4.1. All bar coded labels shall be in accordance with USCG-SFLC Specification D-000-0100 Rev. G, of this SOW.

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.

6.0 NOTES

6.1. Government & Commercial Document Sources

6.1.1. Coast Guard Documents

a. USCG Surface Forces Logistics Center

1301 Clay Street Ste 807N, Oakland CA 94612 Baltimore, MD 21226-5000 Contracting Branch (SFLC-LRE) Ph: (510) 637-5941

6.1.2. Commercial Documents

a. National Conference of Standards Laboratories (NCSL)

2995 Wilderness Drive, Suite 107 Boulder, CO 80301-5404 303-440-3339 Fax: 303-440-3384 info@ncsli.org

b. Society of Automotive Engineers, INC. (SAE)

400 Commonwealth Drive

Warrendale, PA 15096 412-776-4841

FAX 412-776-5760

www.sae.org

c. American Society for Testing & materials (ASTM)

100 Bar Harbor Drive PO Box C700 West Conshohocken, PA 19428-2959 610-832-9585

FAX 610-832-9555

www.astm.org

d. American Society of Quality Control (ASQC)

611 East Wisconsin Avenue Milwaukee, WI 53202 414-272-8575 Fax: 414-272-1734 www.asq.com

6.1.3. Other Government Documents

a. Department of Defense Single Stock Point (DODSSP)

Building 4, Section D 700 Robins Avenue Philadelphia, PA 19111-5094 215-697-6396/6257 Fax: 215-697-9398 www.assist.daps.dla.mil/quicksearch

b. DOD & Navy Publications and Forms (Other than DODSSP)

Naval Publication and Forms Center 5801 Tabor Ave.

Philadelphia, PA 19120 215-697-2197

DRAWING NOT TO SCALE