1.06_TIN 061_710 RI 3140-012-0697 (70kw) rev C Chg 1 final_23YRA20,23YRA21.pdf

SUBMEPP

NO. 3140-012-0697 Rev C Chg 1

TRIDENT PLANNED EQUIPMENT REPLACEMENT

PROGRAM (TRIPER)

REFURBISHMENT INSTRUCTION

TITLE: 70 KW, 400 Hz Motor Generator (MG) Set (TIN 061 or 710)

(Commercial Refurbishment Activity)

Note: This Refurbishment Instruction revision/change is valid for FY 2021/2023 contracts/delivery orders only.

SUBMEPP APPROVAL

1843MRP

COMPONENT ENGINEER CODE

1831SW

PROGRAM MANAGER CODE

12/7/2020

DISTRIBUTION STATEMENT D. Distribution authorized to DOD and DOD contractors only (Administrative/ Operational use). Other requests shall be referred to COMNAVSEASYSCOM or higher DOD authority.

DESTRUCTION NOTICE. Destroy by any method that will prevent disclosure of contents or reconstruction of the document.

DATE

REVISIONS/CHANGES

REV DESCRIPTION SUBMEPP

APPROVAL & DATE

Chg

Update to current technical and program requirements //s// G. L. Lehouillier

//s// K. E. Schussler

6/1/2005 A Upgraded to comply with the requirements of SUBMEPP

Work Procedure MS-01, Chg 4 dtd 6/27/2012, updated references, made applicable to FY14/15 contracts.

Added RPIN 710 (SSGN 70 KW MG).

C. H. Delano III M. B. Packard

3/18/14

B Upgraded to comply with the requirements of SUBMEPP Work Procedure MS-01, Chg 6 dtd 7/30/15, updated references, made applicable to FY16/17 contracts.

//s//D.L.Pendleton //s//J. C. Beaudoin 12/8/15

C Updated to comply with requirements of SUBMEPP Work Procedure MS-01 Chg-12 EC-2 dtd 12/18/18.

Updated references and made applicable to FY 19/20 contracts. See DR #99863 for detailed list of specific changes/rationale.

//s// C. H. Delano III //s// S. Woodley

1/28/19

C Chg1

Update DD1423 CDRLs. M. Porter S. Woodley 12/7/20 i

1. PURPOSE

1.1 This Refurbishment Instruction provides requirements for refurbishment of 70 KW, 400 Hz Motor Generator (MG) sets (TIN 061 or TIN 710) at commercial activities.

1.2 Component boundaries are the 70 KW MG set, including the air cooler, as shown in Enclosure (3).

2. RESPONSIBILITIES

2.1 SUBMEPP is responsible for the following:

2.1.1 Reviewing and approving all data identified in the Contract Data Requirements List (DD Form 1423) for which SUBMEPP is identified in Block 6 (Requiring Office).

2.1.2 Reviewing and processing all Waivers and Deviations.

2.1.3 Reviewing and processing all welding and NDT procedures required on this contract.

2.1.4 Reviewing and approving all repair procedures required on this contract.

2.1.5 Providing the content of this Refurbishment Instruction and applicable Maintenance Standards and resolving technical problems associated with either document.

2.1.6 SUBMEPP reserves the right to witness testing and final inspections at their discretion.

2.2 The Refurbishment Activity is responsible for the following:

2.2.1 Refurbishing the 70 KW Motor Generator (TIN 061 or TIN 710) in accordance with this Refurbishment Instruction. Ensuring all inspections, tests, certifications, repairs, replacement of parts, reports, and records necessary to satisfy the requirements of this Refurbishment Instruction are completed and approval for shipping is received from NAVSUP WSS.

2.2.2 Ensuring all Mandatory Replacement Parts and required materials are available prior to starting refurbishment. To the maximum extent possible, ensuring that long lead time and unplanned/Contingency Parts frequently used are available or can be acquired within a reasonable timeframe.

2.2.3 Identifying to SUBMEPP any technical deficiencies discovered in this Refurbishment

Instruction and/or its Enclosures, or if tolerances or requirements cannot be met, during the refurbishment process. User Activity Comments on this Refurbishment Instruction should be provided to SUBMEPP Code 1831 by fax to 207-438-6250 or by email to stacy.woodley@navy.mil.

2.2.4 If hardware or software delivery schedules cannot be met, or if problems arise that are beyond the scope of this Refurbishment Instruction or a normal refurbishment, the refurbishment activity shall notify SUBMEPP Code 1831 via NAVSUP WSS.

mailto:stacy.woodley@navy.mil

2.2.5 Ensuring that configuration of refurbished units meet requirements identified in this Refurbishment Instruction and its Enclosures.

2.2.6 Reporting to NAVSUP WSS when equipment is received for refurbishment, when equipment is scheduled for assembly and operational testing, and requesting destination for shipping and routing.

2.2.7 Marking each sheet in the refurbishment data package with the TRIPER Serial Number (TSN).

2.2.8 Identifying any out-of-specification conditions, providing a technical rationale/justification for acceptance of a waiver or deviation, and identifying the root cause for the non-conformance.

2.2.9 Retaining all non-submitted records generated during performance of this contract for a period of 5 years and making any and all records available to SUBMEPP upon demand.

2.2.10 Providing final review/approval of testing events prior to issue of data package to SUBMEPP.

2.2.11 Storing Government Furnished Material (GFM) in a segregated, secure, and accountable area. GFM that is found to be unusable shall be identified to NAVSUP WSS and SUBMEPP for disposition instructions. The specific deficiencies (material, dimensional, or configuration) shall be identified for unusable GFM.

2.2.12 Maintaining a quality system that meets the requirements identified in this Refurbishment

Instruction.

2.2.13 Ensuring that all certification forms, reports, Maintenance Standard markups, etc. are signed and dated. Each signature must include a clearly printed name the first time it is used. All test reports and data must contain actual values and units of measure or a direct reference to a drawing, tech manual, spec, etc. All applicable repair records/procedures shall document current revision levels. Submit the final cert data package to SUBMEPP Code 1831 via mail or fax.

2.3 NAVSUP WSS is responsible for the following:

2.3.1 Providing contract administration and funding for fixed price refurbishment and unplanned work.

2.3.2 Providing or verifying TRIPER Serial Numbers and identifying required final configuration

(TIN 061 or TIN 710) of units undergoing refurbishment.

2.3.3 Providing delivery dates and shipping instructions.

2.3.4 Providing TRIPER nameplates to the refurbishment vendor, as requested.

2.3.5 Providing “F” Condition assets for refurbishment

70 KW MG Set (TIN 061) NSN 4Y 6125-01-331-6866.

70 KW MG Set (TIN 710) NSN 4Y 6125-LL-H88-2451.

2.3.6 Providing GFM regulator (TIN 366) to refurbishment activity for use during MG set testing.

3. ENCLOSURES AND REFERENCES

NOTES: 1. Revision/Amendment/Change level and date of Enclosures and references are current as of 12/31/20.

2. The effective dates of specifications are provided at least once in this Refurbishment Instruction. If the revision/amendment/change specified cannot be invoked, notify SUBMEPP Code 1831 before proceeding. Use of later specification rev/amend/chg dates are acceptable. If a specification that is not stated in the Refurbishment Instruction is required, use the most current published specification rev/amend/chg date.

3.1 Enclosures.

Encl. Document ID Title

(1) DD Form 1423 Contract Data Requirements List

(2) QA Form12 Departure From Specification Request

(3) TRIPER Boundary Drawing - TIN 061/710

(4) Receipt Inspection Form

(5) Final Inspection Form

3.2 References.

Ref. Document ID Revision Date

a. ASQ 9001, Quality Management Systems-Requirements Oct 2015

b. ASQ Q10012, Measurement Management Systems - Requirements for Measurement Processes and Measuring Equipment

Apr 2006

c. DI-MISC-80678, Certification/Data Report Base 12 Sep 1988

d. ASTM D7478/7478M, Standard Specification for Heavy Duty Sheathed Wood Crates

1 Sep 2017

e. MIL-E-16298, Electric Machines Having Rotating Parts, Accessories and Associated Support Items: Packaging of

D 7 Mar 1989

f. DI-MISC-80875, Welding Procedures Base 30 Jun 1989

g. DI-NDTI-80603, Test Procedure A 14 Nov 2006

h. MIL-STD-2035, Nondestructive Testing Acceptance Criteria A 15 May 1995

i. DI-SESS-80640, Request For Variance (RFV) D 7 Apr 2015

j. Refurbishment Activity’s NAVSEA Approved Refurbishment Procedures for EDY 70KW MG Set

k. NAVSEA S9074-AQ-GIB-010/248, Welding, Brazing Procedure and Performance Qualification

1 Aug 1995

Ref. Document ID Revision Date

l. NAVSEA S9074-AR-GIB-010/278, Requirements for Fabrication Welding and Inspection, and Casting Inspection and Repair for Machinery, Piping, and Pressure Vessel

Chg A 14 Feb 2013

m. NAVSEA T9074-AS-GIB-010/271, Requirements for Nondestructive Testing Methods

ACN 1 11 Sep 2014

n. DI-MISC-80876, Welding Procedure Qualification Test Report

Base 30 Jun 1989

o. S9300-A6-GYD-010, Electrical Workmanship Inspection Guide for Surface Ships and Submarines

3 30 Apr 2013

p. NAVSEA S9310-AC-HBK-010 Commutator/Slip Ring Maintenance Handbook

6 30 Apr 2017

q. NAVSHIPS S9086-KC-STM-010, Chapter 300, Electrical Plant-General

9 1 May 2012

r. SUBMEPP Maintenance Standard 3140-081-011, Overhaul 70 KW MG

D CH-5 3 Mar 2020

s. DI-NDTI-80809, Test/Inspection Report B 24 Jan 1997

t. MIL-STD-129, Military Marking R CH-1 24 May 2018

u. General Dynamics/Electro-Dynamic Drawing 9258358-1 C 17 Oct 1994

v. NAVSEA Dwg 1385778, Resilient Mounts, Type EES N 10 May 1977

w. NAVSEA S9314-B1-MMA-010, 70KW DC-to-400 Hz Motor Generator and Associated Controls [for TIN 061 only]

2 CH A 4 Jun 2015

x. NAVSEA S9314-D4-010, 70KW DC-to-400 Hz Motor Generator and Associated Controls [for TIN 710 only]

CH-B 25 Feb 2016

4. GENERAL REQUIREMENTS

4.1 Quality Assurance (QA)/Quality Program: The contractor’s quality program/inspection system shall be in accordance with reference (a) and all local instructions necessary for compliance. The calibration system shall be in accordance with reference (b).

4.1.1 Government inspection at subcontractor or vendor facilities. The Government reserves the right to inspect at source supplies or services not manufactured or performed within the contractor’s facility. Government inspection shall not constitute acceptance, nor shall it in any way replace contractor inspection or otherwise relieve the contractor of their responsibility to furnish an acceptable end item. When inspection at subcontractor’s plant is performed by the Government, such inspection shall not be used by contractors as evidence of effective inspection by such subcontractors. The purpose of this inspection is to assist the Government representative at the contractor’s facility to determine the conformance of supplies or services with contract requirements. Such inspection can only be requested by or under authorization of the Government representative.

4.1.2 Government inspection requirements. When Government Source Inspection (GSI) is required at the subcontractor’s facility, the contractor shall add to their purchasing document the following statement:

“Government inspection is required prior to shipment from your plant. Upon receipt of this order, promptly notify the Government representative who normally services your plant so that appropriate planning for Government inspection can be accomplished.”

4.1.3 Purchasing documents. Purchasing documents to subcontractor must cite applicable portions of contract Quality Management Systems (e.g. ASQ 9001, ASQ Q10012, etc.) and product requirements that apply to supplies being purchased. When, under authorization of the Government representative, copies of the purchasing document are to be furnished directly by the subcontractor or vendor to the Government representative at their facility rather than through Government channels, the contractor shall add to their purchasing document a statement substantially as follows:

“On receipt of this order, promptly furnish a copy to the Government representative who normally services your plant or, if none, to the nearest Defense Contract Management Agency (DCMA) office. In the event the representative or DCMA office cannot be located, our purchasing agent should be notified immediately.”

4.1.4 Referenced data. All documents and referenced data for purchases applying to a

Government contract shall be available for review by the Government representative to determine compliance with the requirements for the control of such purchases. Copies of purchasing documents required for Government inspection purposes shall be furnished in accordance with the instructions of the Government representative.

4.1.5 Government QA system evaluation and acceptance. The contractor’s inspection system and supplies generated by the system shall be subject to evaluation, verification, and inspection by the Government representative to determine its effectiveness in supporting the quality requirements established in the contract. The Government has the right to disapprove the Quality System or portions thereof when it fails to meet contractual requirements.

4.1.6 Use of the contractor’s inspection and test equipment. The contractor’s gages and measuring and test equipment shall be made available for use by the Government representative when required to determine conformance with contract requirements. When conditions warrant, the contractor’s personnel shall be made available for operations of such devices and for verification of their accuracy and condition.

4.1.7 Use of Government Furnished Equipment (GFE) or Government Furnished Material (GFM).

When material or equipment is furnished by the Government, the contractor shall develop documented control procedures that require at least the following:

4.1.7.1.1 Visual examination upon receipt to detect damage during transit.

4.1.7.1.2 Inspection for completeness and proper type.

4.1.7.1.3 Verification of material quantity received.

4.1.7.1.4 Periodic inspection and precautions to assure adequate storage conditions and to guard against damage from handling and deterioration during storage.

4.1.7.1.5 Functional testing, either prior to or after installation, or both, as required by contract to determine satisfactory operation.

4.1.7.1.6 Identification and protection from improper use or disposition.

4.1.7.1.7 Reporting to the Government any GFE or GFM property found damaged, malfunctioning, or otherwise unsuitable for use. In the event of damage or malfunction during or after installation, the supplier shall determine and record probable cause and necessity for withholding material from use.

4.1.7.1.8 For GFE material and as required by the terms of the bailment agreement, the contractor must establish procedures for adequate storage, maintenance, and inspection of bailed Government Material. Records of all inspections and maintenance performed on bailed property shall be maintained.

4.2 Inspection and Acceptance Clause: Inspection of the supplies and/or services to be furnished on this contract shall be made by representatives of the DCMA/SUPSHIP at the contractor’s or subcontractor’s plant. Acceptance will be at the contractor’s plant by DCMA/SUPSHIP or by SUBMEPP representatives when authorized by the Procurement Contracting Officer. The vendor shall provide advance notification to the NAVSUP WSS and SUBMEPP to permit the Government to determine whether SUBMEPP representatives will participate jointly with DCMA in the following events:

Event Min. Advance Notice Required (Workdays) Performance Test 10 Final Inspection 10

4.3 TRIPER Serial Number: Verify that the TRIPER nameplate is installed on the component and that the

TSN is legible. If a replacement nameplate is needed, contact NAVSUP WSS Code N97121.

4.4 Mandatory Replacement Parts: Mandatory replacement parts specified in the MS, reference (r), shall be replaced regardless of condition. These parts should be purchased at the beginning of the contract to prevent delays due to hard-to-obtain parts. The contractor is invited to recommend additions or deletions to the mandatory replacement parts list at any time dur ing the refurbishment as material conditions or available GFM inventory changes.

4.5 Contingency Replacement Parts: “Contingency” (“C”) or unplanned replacement parts in the MS, reference (r), are to be replaced only if, upon inspection, existing parts do not meet the requirements of reference (r) and repairs to existing parts are impractical.

4.5.1 Unplanned replacement parts that fail to meet the acceptance criteria can be repaired in lieu of replacement if it is in the best interest of the Government (i.e., if it is more cost effective or more time effective). Repair or replacement must be approved by the Government prior to accomplishment. The method of repair and repair procedures must be approved by SUBMEPP.

4.5.2 Contingency replacement parts should be sourced out at the beginning of the contract. This is especially important for long lead time parts that could impact delivery. For hard-to-obtain parts, possible sources include the National Stock System (NSS), Original Equipment Manufacturer (OEM), and “F” condition assets in stock.

4.6 Workmanship Standards:

4.6.1 Electrical Workmanship Standards. Soldered connections, cable lug terminal installation, identification sleeves , locking devices, lacing, seizing and dressing of conductors, and cleanliness and corrosion requirements shall be in accordance with reference (o), Electrical Workmanship Inspection Guide for Surface Ships and Submarines.

4.6.2 Commutator undercut and bevel shall meet the requirements of references (r), (q), and (p).

4.6.3 All threaded fasteners shall have one to four threads protrusion. (Adjusting/jacking screws excluded).

4.6.4 All welds or weldments shall be smooth with the base material and include no visible slag.

Any grinding or cutting area shall not have sharp edges and should be blended smoothly with the base material to avoid any induced stresses.

4.6.5 All nuts shall be consistently used throughout the component, and be made of the proper material -no mixing of type or material within a fastening application. Pal nuts are not allowed.

4.6.6 All required nameplates, calibration stickers, calibration/precaution tags, and markings required by the equipment drawings and by this task have been fastened to a visible location that will not affect equipment integrity.

4.7 Welding Requirements: If production or repair welding is required, welding procedures in accordance with NAVSEA S9074-AQ-GIB-010/248, reference (k), NAVSEA S9074-AR-GIB-010/278, reference (l), and DI-MISC-80875, reference (f), must be submitted and approved prior to production or repair welding.

See paragraph 7.3 for data requirements.

4.8 NDT Requirements: If NDT (Liquid Penetrant Testing, Ultrasonic Testing, Magnetic Particle Testing, or

Radiographic Inspection) is required, procedures in accordance with NAVSEA T9074-AS-GIB-010/271, reference (m), and DI-NDTI-80603, reference (g), must be submitted and approved prior to conducting NDT. See paragraph 7.6 for data requirements.

4.9 User Activity Comments: User Activity Comments on this Refurbishment Instruction should be provided to SUBMEPP Code 1831 by fax to 207-438-6250 or by email to stacy.woodley@navy.mil.

4.10 Mercury Exclusion: Mercury or mercury containing compounds shall not be intentionally added or come in contact with hardware or supplies furnished under this contract.

5. REFURBISHMENT REQUIREMENTS

5.1 The 70 KW MG shall be inspected and refurbished in accordance with reference (r) and reference (j) requirements, as applicable. TIN 061 units will use Grade R312 brushes listed in Attachment 2 of reference (r). TIN 710 will use Grade AC-98 or Mersen Grade 535 brushes, piece 71 in Attachment 2 of reference (r).

5.1.1 Activities must be certified by NAVSEA prior to rewinding 70 KW MG sets. Only activities whose refurbishment procedures have been reviewed and approved by NSWCCD Philadelphia, Code 934 are certified to strip, rewind, and vacuum pressure impregnating (VPI) 70 KW MG set components.

5.1.2 Guidance for obtaining certification to refurbish motor generator sets using VPI methods may be found in Appendix C of reference (q) or Attachment 3 of reference (r).

5.1.3 If rewind of any coil is required, Quality Assurance sample coils must be created and a completed Sample Coil Evaluation Form (reference (r) Attachment 3) must be submitted to SUBMEPP. Sample coil(s) must be inspected by a Government representative prior to shipment of the motor generator. Sample coil(s) are to be retained at the vendor’s facility for 7 years. Sample coils may be scrapped in accordance with vendor policy after the seven-year retention period without further Government direction.

5.2 The repair methods procedures to restore parts that fail reference (r) acceptance criteria require SUBMEPP approval prior to use. Repairs should restore repaired area to minimum drawing requirements and should not degrade service life. Repair procedures may be submitted as part of the Condition Report, but must be submitted and approved prior to repair. The decision to repair or replace a part must be made in the best interest of the Government with time and cost factors considered. All repairable parts remain the property of the Government, who reserves the right to require the contractor to repair parts when economically beneficial.

5.3 When refurbishment is complete, the 70 KW MG set shall comply with General

Dynamics/Electro Dynamic Drawing 9258358-1, reference (u).

6. TESTING REQUIREMENTS

6.1 The 70 KW MG shall be tested in accordance with reference (r).

6.1.1 The 70 KW MG set air cooler must undergo hydrostatic testing in accordance with reference

(r). When major repairs as defined by Attachment 6 of reference (r) have been accomplished, elevated pressure (major repair/H-pressure) testing is required. If major repairs are not required, mechanical joint tightness (minor repair/J-pressure) testing is required.

6.1.2 The 70 KW MG set must be operationally tested using a GFM regulator (TIN 366) in accordance with reference (r). If the GFM regulator is set up for operation with a 10 KW MG set, it must be realigned in accordance with reference (x) or (w) for use with a 70 KW MG set.

6.1.3 The refurbished motor generator set must be structure-borne noise tested in accordance with reference (r) Attachment 4. Structure-borne noise acceptance criteria is specified in reference (r).

6.2 Submit test results to SUBMEPP Code 1831 for review and approval in accordance with paragraph 7.4.

Test results must include test document identification along with expected/actual results of each test performed. Each report shall be traceable to and include the TRIPER Serial Number.

7. DATA REQUIREMENTS

NOTE: Contract Data Requirements will be in accordance with Contract Data Requirements List (CDRL), Enclosure (1), and requirements below. All data shall be traceable to the applicable units by referencing the Contract Line Item Number, TRIPER Serial Number, and manufacturer’s serial number.

Configuration Control: Request for Deviations or Waivers shall be submitted on QA Form 12, Enclosure (2), or in accordance with reference (i). Instructions for filling out QA Form 12 are included in Enclosure (2). Requests for Waivers or Deviations shall address root cause and corrective action taken, or planned, to prevent recurrence. All non-conformances shall reference manufacturer serial number and TRIPER Serial Number. All requests must have written approval prior to acceptance/shipment of components. Submit copies of approved documents to SUBMEPP in the final certification data package.

NOTE: Authority for the approval of Type II (minor) non-conformances is specifically withheld from

DCMA.

7.1 Sequence No. - A001 Receipt Inspection Report: A Receipt Inspection Report (see Enclosure 4) shall be submitted to provide information on the overall condition of the 70 KW MG set prior to repair work.

Configuration information (drawing number, serial numbers, etc.) and material condition (damage, missing pieces, shipping crate damage, etc.) should be noted. If missing subassemblies or shipping damage is noted, SUBMEPP shall be immediately notified to determine material correction or replacement. The Receipt Inspection Form can be in the contractor’s format, but must include inspector(s) signature/date and all information in the Receipt Inspection Form of Enclosure (4).

7.2 Sequence No. - A002 Condition Report: A Condition Report shall be submitted within 10 weeks of the receipt inspection of each component. The Condition Report shall list all parts which will require repair or replacement, including unplanned replacement parts. The Condition Report must include a description of the defects and repairs required for refurbishment. The Condition Report shall list all parts requiring inspection by the Maintenance Standard, reference (r), and shall include the recording of each Maintenance Standard inspection requirement for each part.

7.3 Sequence No. - A003 Welding Procedures and Weld Procedure Qualification Test Report: Welding procedures shall be in accordance with references (k), (l), and (f). Welding procedures shall be submitted for approval prior to production or repair welding. Weld procedure qualification test report shall be in accordance with DI-MISC-80876, reference (n), and paragraph 4.6 of NAVSEA S9074-AQ- GIB-010/248, reference (k). This includes procedures for foundry repairs to castings and tack welds.

Procedure submittals should include information on the component/application, contract number, facility, and Refurbishment Instruction (including rev/chg).

7.4 Sequence No. - A004 Reassembly Quality Assurance Report (RQAR): The RQAR shall include a fully completed copy of the Maintenance Standard (reference (r)), including all testing data, and a completed copy of Enclosure (5). The RQAR shall identify any TMAC, TZ, TRID, or A&I accomplished during the refurbishment. ALL data entries require a signature and date to verify the recording.

If rewind of any coil is required, Quality Assurance sample coils must be created and a completed Sample Coil Evaluation Form (reference (r) Attachment 3) must be submitted to SUBMEPP. Sample coils must be inspected by a government representative prior to shipment of the motor generator.

Distribute copies of the Evaluation Form(s) as indicated in Enclosure (1).

7.5 Sequence No. A005 – Non Destructive Test (NDT) Procedures: The contractor’s NDT procedure(s) must be in accordance with reference (m) and reference (g) and shall be submitted to SUBMEPP for approval prior to accomplishing inspections. NDT acceptance standards shall be in accordance with reference (h). Previously approved procedures may be utilized, however they must be identified, and SUBMEPP concurrence obtained.

7.6 Sequence No. A006 - NDT Reports: Reports shall be submitted showing the satisfactory results of tests, including Visual Testing (VT) of existing welds. Inspection and acceptance shall be in accordance with references (h) and (s). Test reports shall include both root layer and completed weld data. Test reports shall be identifiable to material by part, heat number, unique serial number, etc. Each report shall reference the vendor’s approved NDT procedure by number and revision, if applicable, and the applicable acceptance standard. Each report shall be signed and dated.

7.8 Sequence No. A007 - Certification of Compliance: Certification of Compliance (COC) shall be submitted in accordance with reference (c) to certify that refurbishment work and testing performed meet the requirements of this Refurbishment Instruction. The COC must include a positive statement indicating if welding or NDT were accomplished, identify the procedures used, and identify any welding accomplished that did not require weld qualification tests per NAVSEA S9074-AR-GIB- 010/278 para 4.2.1.1. Reports shall be identifiable by TRIPER Serial Number and shall include a signature by the appropriate QA Office/Code indicating review and concurrence that all required work was accomplished, all required data has been submitted, and that the submitted data meets specified requirements (including any approved waivers or deviations).

7.9 Data submitted to SUBMEPP that does not meet the specified requirements is considered deficient and will require resolution prior to acceptance.

7.9.1 For any data deficiency found by SUBMEPP, contractor will be required to determine if the deficiency exists with the data (e.g. hardware is within specification, data was incorrectly recorded) or the hardware (hardware is not within specification).

7.9.1.1 Hardware deficiencies: The contractor must either correct hardware deficiencies or request they be accepted as-is on a request for waiver. The contractor shall provide corrected data pages for hardware that was reworked.

7.9.1.2 Data deficiencies: If corrections are required to the data, the contractor shall provide corrected data pages.

7.9.2 Corrected Data Pages: When corrected data pages are required due to data or hardware deficiencies, the contractor shall provide corrected data pages that indicate what was corrected and an explanation of why the corrections were made. The corrections shall be initialed and dated.

7.9.3 SUBMEPP may reject any software package with unresolved deficiencies after a reasonable effort has been undertaken with the contractor to correct the deficiencies.

8. PREPARATION FOR SHIPMENT

8.1 Painting: Painting shall be in accordance with reference (r).

8.2 Cleanliness: The 70 KW MG set shall be free of foreign material and oil residue (from weeping bearing grease). Light carbon residue is acceptable.

8.3 TRIPER Nameplates: Verify TRIPER nameplates are installed.

8.3.1 TRIPER nameplates that are illegible, damaged, or missing shall be replaced as necessary (NAVSUP WSS will supply). Attach nameplate to the MG frame using corrosion resistant metallic screws, drive pins, or epoxy, and locate as shown in Enclosure (3) so it will be visible after installation of the unit on the ship.

8.3.2 The contractor shall mark the nameplate to identify the unit with the TRIPER Serial Number

(TSN) assigned by NAVSUP WSS for this task. Individual serial numbers will have to be stamped into the nameplate, using 3/16” letters and filled with red paint prior to installation on the components. The nameplate shall be filled in as shown below. Marking shall be a minimum of 0.003 inches deep.

8.4 Packaging, Handling, and Shipping:

8.4.1 Crating and packaging shall be in accordance with references (r), (d), and (e).

TRIPER PROGRAM

S/N 061TRXXXXX

or

710TRXXXXX

8.4.2 The component shall be mounted to the shipping/storage container by means of resilient mounts (6E2000) installed in accordance with reference (r). Each MG set should arrive supported in its shipping container by resilient mounts; these mounts are intended to be reused. These resilient mounts are for shipping and storage purposes only. If new resilient mounts are needed due to embrittlement, chipped or painted rubber, or other damage, use mounts 6E2000 as shown on NAVSEA drawing 1385778, reference (v).

8.4.3 One copy of the completed Refurbishment Data Report must be placed in a waterproof bag and shipped with the equipment.

8.4.4 Package the MG for shipping and storage using the following guidelines:

8.4.4.1 Prior to installing the MG set in the crate, lay a large sheet of Griffolyn® or equivalent sealing material inside the crate so that the entire MG set can be wrapped and sealed in an airtight bag formed with this material. Note that special sealing tools are required to form the airtight bags.

8.4.4.2 Place the MG set in the crate on top of the sealing material being careful not to rip the sealing material.

8.4.4.3 Cut the sealing material to size to form the bag and prepare for sealing. Install a humidity indicator, part number MS20003-2 or equivalent, at a convenient location on the outside of the MG set. Install a 6” x 12” clear plastic window in the bag, at that location, so that the humidity indicator can be inspected without opening the bag.

Attach the window in place with glue manufactured for this purpose.

8.4.4.4 Prepare to install desiccant. The desiccant should not be unnecessarily exposed to ambient environment when removed from the vapor proof desiccant container. The removal of the desiccant and insertion in the bag should be accomplished only when the bag is ready to be sealed around the MG set. Reactivation may be accomplished by following instructions on the desiccant package.

8.4.4.5 Wrap the sealing material over the top of the MG set and seal the edges together to provide an airtight seal.

8.4.4.6 Cover the crate.

8.5 Marking. All shipping containers shall be marked in accordance with the following:

8.5.1 The following information will be stenciled on all four sides and top of the shipping containers in letters two inches high, space permitting:

Sensitive, Low Noise Level Equipment

Handle with Extreme Care

Arrows will be stenciled to Indicate:

This Side Up

8.5.2 All shipping containers shall be marked with the following information:

SUBMEPP TRIPER PROGRAM

Contract No.

TRIPER Serial No. 061 (or 710)TRXXXXX [mark as applicable] Sensitive, Low Noise Equipment Handle with Extreme Care Property of U.S. Government - Intended for Reuse Reusable Container and Cushioning Use for Return of NRFI Assembly Dry Heated, Indoor Storage Required

8.5.3 DD Form 1387, Military Shipment Label, shall be used for all shipments. Reference (t) or

DoD°4500.32-R, Volume I can be used as a guide for completion. Reference (t) can be used as a guide for other markings that may be needed.

9. RELEASE FOR SHIPMENT

9.1 Hardware will not be released for shipment until all software identified in Section 7 of this Refurbishment Instruction has been received and approved by SUBMEPP. NAVSUP WSS has authority to release the hardware for shipment after the software has been reviewed and approved by

SUBMEPP.

9.2 The activity shall ship the unit through the Commercial Asset Visibility (CAV) System.

9.3 NAVSUP WSS shall be notified when the unit is shipped.

CONTRACT DATA REQUIREMENTS LIST

A. CONTR. LINE ITEM NO. B. EXHIBIT C. CATEGORY:

XX TDP TM OTHER

D. SYSTEM/ITEM

70 KW MG

E. CONTRACT/PR NO.

RI NO. 3140-012-0697 Rev C Chg 1

F. CONTRACTOR

1. DATA ITEM NO. 2. TITLE OF DATA ITEM 3. SUBTITLE

4. AUHORITY

(Data Item Descript)

5. CONTRACT REFERENCE 6. REQUIRING OFFICE

7. DD 250 REQ. 9. DIST

STATEMENT

REQUIRED

10. FREQUENCY 12. DATE OF

FIRST

SUBMISSION

14. DISTRIBUTION

DR - DRAFT RG

- REGULAR RP

- REPRO

8. APP CODE 11. AS OF

DATE

13. SUBSEQUENT

SUBMISSION

15. REMARKS

1. A001 2. SUBMEPP RECEIPT INSPECTION 3. N/A

4. DI-MGMT-80389C (SUBRIR)

5. CSD REF. IN PARA. 7.1

6. SUBMEPP

7. LT 9. Dist

10. 12. AS REQ

14. DISTRIBUTION

Statement required AS REQ a. ADDRESSEE b. Copies

8. N/A D 11. N/A 13. AS REQ. D

R

R G

RP

16. REMARKS SUBMEPP CODE 1831 1

Certification documentation must be submitted via WAWF (Wide Area Work NAVSUP WSS N97121 1 Flow) to the maximum extent possible. See Enclosure 1. NAVSUP WSS N743 1

15. TOTAL 3

1. A002 2. SUBMEPP CONDITION REPORT 3. N/A

4. DI-MGMT-82048 (SUBCR)

5. CSD REF. IN PARA. 7.2

7. LT 9. Dist

10. 12. AS REQ

14. DISTRIBUTION

Required

AS REQ a. ADDRESSEE b. Copies

8. N/A

D 11. N/A 13. AS REQ

D R

R G

RP

16. REMARKS SUBMEPP CODE 1831 1

Certification documentation must be submitted via WAWF (Wide Area Work NAVSUP WSS N97121 1 Flow) to the maximum extent possible. Contractor own format is acceptable. NAVSUP WSS N743 1

15. TOTAL 3

1. A003 2. SUBMEPP WELDING PROCEDURES 3. N/A

4. DI-MISC-80875A (SUBWP)

5. CSD REF. IN PARA. 7.3

7. DD 9. Dist

10. 12. Acceptance required prior 14. DISTRIBUTION

AS REQ to welding. a. ADDRESSEE b.Copies

D 11. N/A N/A

13. AS REQ D

R

R G

RP

16. REMARKS

SUBMEPP CODE 1831 1

Certification documentation must be submitted via WAWF (Wide Area Work NAVSUP WSS N97121 1 Flow) to the maximum extent possible. Weld procedures are required to meet the NAVSUP WSS N743 1 requirements within NAVSEA S9074-AR-GIB-010/278. 15. TOTAL 3

G. PREPARED BY

//s// Matt Porter 1843MP

H. DATE

I. APPROVED BY

//s// Stacy Woodley 1831SW

J. DATE

DD Form 1423, JUN 90 Previous editions are obsolete Enclosure (1) Page 1 of 3 Pages

XX TDP TM OTHER

D. SYSTEM/ITEM

70 KW MG

E. CONTRACT/PR NO.

RI NO. 3140-012-0697 Rev C Chg 1

F. CONTRACTOR

1. A004 2. SUBMEPP REASSEMBLY QUALITY

ASSURANCE REPORT

3. N/A

4. DI-QCIC-81890 (SUBRQAR)

5. CSD REF. IN PARA. 7.4

10. 12. 14. DISTRIBUTION

AS REQ AS REQ a. ADDRESSEE b. Copies

D 11. N/A 13. AS REQ D

R G

SUBMEPP Code 1831 1

Flow) to the maximum extent possible. NAVSUP WSS N743 1 Contractor own format is acceptable. 15. TOTAL 3

1. A005 2. SUBMEPP TEST PROCEDURE 3. N/A

4. DI-MISC-80678 (SUBNDT)

5. CSD REF. IN PARA. 7.5

10. 12. Acceptance req’d 14. DISTRIBUTION

AS REQ prior to NDT. a. ADDRESSEE b.Copies

D 11.

13. AS REQ D

R

R G

RP

16. REMARKS SUBMEPP CODE 1831 1

Flow) to the maximum extent possible. NDT procedures are required to

NAVSUP WSS N743 1

requirements within NAVSEA T9074-AS-GIB-010/271. 15.TOTAL 3

1. A006 2. SUBMEPP TEST INSPECTION REPORT

3. N/A

4. DI-NDTI-80809B (SUBNDTR) 5. CSD REF. IN PARA. 7.6 6. SUBMEPP

10. 12. Prior to shipment of 14. DISTRIBUTION

AS REQ each unit. a. ADDRESSEE b. Copies

R G

SUBMEPP CODE 1831 1

Certification documentation must be submitted via WAWF (Wide

NAVSUP WSS N97121 1

Flow) to the maximum extent possible. NAVSUP WSS N743 1

15. TOTAL 3

G. PREPARED BY

//s// Matt Porter 1843MP

J. DATE

DD Form 1423, JUN 90 Previous editions are obsolete Enclosure (1) Page 2 of 3 Pages

XX TDP TM OTHER

D. SYSTEM/ITEM

70 KW MG

E. CONTRACT/PR NO.

RI NO. 3140-012-0697 Rev C Chg 1

F. CONTRACTOR

1. A007 2. SUBMEPP CERTIFICATION OF COMPLIANCE 3. N/A

4. DI-MISC-80678 (SUBCC)

5. CSD REF. IN PARA. 7.7

10. 12. Prior to shipment of 14. DISTRIBUTION

AS REQ each unit. a. ADDRESSEE b. Copies

8.

R G

SUBMEPP Code 1831 1

Flow) to the maximum extent possible. Contractor own format is

NAVSUP WSS N743 1

Copy in Crate 1

15. TOTAL 4

1. 2. 3.

4. 5. 6.

7. 9. 10. 12. 14. DISTRIBUTION

b. Copies

8. 11. 13. D

R G

15. REMARKS

TOTAL

1. 2. 3.

4. 5. 6.

7. 9. 10. 7. 9.

8. 11. 8.

15. REMARKS

G. PREPARED BY

//s// Matt Porter 1843MP

J. DATE

DD Form 1423, JUN 90 Previous editions are obsolete Enclosure (1) Page 3 of 3 Pages

DEPARTURE FROM SPECIFICATION REQUEST

QA FORM 12

1. DEPARTURE NO. 2. SHIP 3. JCN 4. CWP SER. NO. 5. DATE

6. ORIGINATOR: NAME 7. DEPARTURE TYPE MAJOR MINOR SUBSAFE SOC FBW SFCC

8. ADDITIONAL CLASSIFICATION (SHIPYARD USE ONLY) WAIVER DEVIATION SSDR TVD

ISIC CONCURRENCE (REQUIRED FOR CONDITIONAL DFS) YES NO

9. SYSTEM/COMPONENT/LOCATION & SHORT DESCRIPTION

10. NAVSEA DRAWING/PLAN NUMBER/PIECE NUMBER

11. REFERENCES

12. APPLICABLE SPECIFICATIONS

13. SITUATION/DEGREE OF NON-COMPLIANCE

14. COMMENTS/RECOMMENDATION (TEST CONDUCTED, AFFECTED SYSTEMS)

15. DATE ANSWER REQUESTED BY: 16. SUBMITTING ACTIVITY: TYPED OR PRINT NAME/SIGNATURE (RO/DH)

17. NEW JCN NUMBER FOR CONDITIONAL DEPARTURES: 18. DFS APPROVAL COMMENTS

ISIC APPROVED DISAPPROVED FORWARDED TO TYCOM LOCAL TECH AUTHORITY FOR ACTION

NAME SIGNATURE DATE

TYCOM APPROVED DISAPPROVED FORWARDED TO NAVSEA/NAVAIR/LOCAL TECH AUTHORITY

FOR ACTION

NAME SIGNATURE DATE

LOCAL TECHNICAL AUTHORITY APPROVED DISAPPROVED FORWARDED TO NAVSEA/NAVAIR FOR

ACTION

NAME SIGNATURE DATE

NAVSEA/NAVAIR APPROVED DISAPPROVED TEMPORARY PERMANENT PRECEDENT

NAME SIGNATURE DATE

19. COPY TO:

Enclosure (2)

QA Form 12, Departure From Specification Request, Instructions

1. The refurbishment activity finding or causing a Departure From Specification (DFS) will immediately report the DFS to SUBMEPP Code 1831 using this form.

2. The numbered blocks on QA form 12 correspond with instructions listed below.

BLOCK 1 - DEPARTURE NO – To be filled out by SUBMEPP/NAVSUP WSS.

BLOCK 2 - SHIP HULL NO – To be filled out by SUBMEPP.

BLOCK 3 – JCN – To be filled out by SUBMEPP.

BLOCK 4 - CW P SER. NO – To be filled out by SUBMEPP.

BLOCK 5 – DATE – To be filled out by Contractor. Enter the date the DFS request is filled out.

BLOCK 6 – ORIGINATOR – To be filled out by Contractor. Print or type the name of the originator of the DFS.

BLOCK 7 - DEPARTURE TYPE – To be filled out by SUBMEPP.

BLOCK 8 - ADDITIONAL CLASSIFICATION (N/A for SUBMEPP or Contractor)

BLOCK 9 - SYSTEM/COMPONENT/LOCATION – To be filled out by Contractor. Enter the affected system, component, and location. A short description may be added if needed to fully identify the system/component/location.

BLOCK 10 - NAVSEA DRAWING/PLAN NUMBER/PIECE NUMBER – To be filled out by Contractor. Enter the NAVSEA drawing number, plan number and piece number, as applicable, that shows the component or system on which the DFS is initiated.

BLOCK 11 - REFERENCES – To be filled out by Contractor. Enter additional references used (e.g., Training Aid Booklet, Ships Information Book, Ships Systems Manual, Steam and Electric Plant Manual, SUBSAFE Certification Boundary Book, Tech Manual) as applicable. Include contract No. and Contract Line Item Numbers (CLINs) affected.

BLOCK 12 - APPLICABLE SPECIFICATIONS – To be filled out by Contractor. Enter the applicable specifications.

Be descriptive and specific. Enter the reference that provided the specification. This block should fully explain the specifications and include the JID or part applicable (e.g., perform "J" pressure test to test pressure depth after mechanical assembly of joints "XXXX" in which software was replaced). This block must be explicit, so that no reference is required to the work procedure to understand the specifications.

BLOCK 13 - SITUATION/DEGREE OF NON-COMPLIANCE – To be filled out by Contractor. Enter what the actual condition is. Sketches, drawings, QA forms, etc., may be attached, if they clarify the description of the non-conforming condition. Identify components affected by Program Serial Number for TRIPER and AERP or unique component identifier for LLTM.

BLOCK 14 - COMMENTS/RECOMMENDATION (TEST CONDUCTED, AFFECTED SYSTEMS) – To be filled out by Contractor. Enter comments/recommendations pertinent to the job. The comments will include recommendation and justification for approval of the DFS. Enter tests conducted and the results, SAT or UNSAT.

BLOCK 15 - DATE ANSWER REQUESTED BY – To be filled out by Contractor. Enter date.

BLOCK 16 - SUBMITTING ACTIVITY – To be filled out by Contractor. Type or print name and enter signature.

BLOCK 17 - NEW JCN NUMBER FOR CONDITIONAL DEPARTURES – To be filled out by SUBMEPP.

BLOCK 18 - DFS APPROVAL COMMENTS – To be filled out by SUBMEPP.

BLOCK 19 - COPY TO – To be filled out by Contractor. Enter activities to receive copy

Enclosure (2)

Enclosure (3)

TRIPER BOUNDARY DRAWING

ITEM NO.

061 or 710

Enclosure (4)

RECEIPT INSPECTION FORM

RECEIPT INSPECTION FORM

CONTRACT NUMBER ____________________________

TRIPER ITEM NO. ___________________ TRIPER SERIAL NO. ___________________

MANUFACTURER SERIAL NO. ____________________

1) YES___ NO___ SHIPPING CRATE FREE FROM DAMAGE.

2) YES___ NO___ EXTERIOR OF MOTOR GENERATOR HAS NO OBVIOUS DAMAGE

3) YES___ NO___ ALL OPENINGS HAVE BEEN BLANKED; WATER COOLER OPENINGS ARE SEALED.

4) YES___ NO___ PLEXIGLASS VIEWING WINDOWS ARE CLEAN AND NOT EXCESSIVELY

SCRATCHED

5) YES___ NO___ THE MOTOR GENERATOR IS MOUNTED ON TEMPORARY RESILIENT MOUNTS AND

RESILIENT MOUNTS ARE PROPERLY INSTALLED. NOTE: THESE MOUNTS ARE

FOR SHIPPING PURPOSES ONLY.

6) YES___ NO___ THE SHAFT CAN BE ROTATED FREELY BY HAND.

7) YES___ NO___ STATIONARY LEAD WIRES DO NOT CONTACT ROTATING PARTS.

8) ADDITIONAL OBSERVATIONS/COMMENTS:

Signature (Vendor QA) _________________________________ Date _________________

Signature (DCMA) _________________________________ Date _________________

FINAL INSPECTION

CONTRACT NUMBER ____________________________

TRIPER ITEM NO. ___________________ TRIPER SERIAL NO. ___________________

MANUFACTURER SERIAL NO. ____________________

**Prior to shipping the MG, and in the presence of an authorized Government inspector, accomplish a final inspection of the assembled 70 KW, 400 Hz MG set. The condition of the parts shall be noted and recorded. If any deficiencies are found, they must be corrected. Immediately prior to shipping, inspect the items below. If any deficiencies are found, they must be corrected.

1. Perform a visual inspection of the MG set. Verify that there are no signs of overheating, loose connections, etc.

Signature ____________________________ Date _________________

2. Clean the MG set by hand wiping with rags, vacuum cleaner, and 30 psi air. Verify that the equipment is free of foreign material, grease, and excessive carbon residue.

Signature ____________________________ Date _________________

3. Record type of DC brushes installed in MG set.

Grade AC-98 or Mersen Grade 535 required for TIN 710

Grade 312 required for TIN 061

4. Ensure that all leads, bus bars, hardware, and MG parts removed for inspection have been properly reinstalled in accordance with MS 3140-081-011.

Signature ____________________________ Date _________________

5. Ensure all access covers are installed with gaskets that provide a proper seal. Ensure that all viewing covers are in good condition without scratches. Install chipped board or equivalent over all polycarbonate covers to protect during shipping.

6. Disconnect cooling water, drain, and blow down coolers to remove all water residue. Install protective metal covers with gaskets. Ensure that these covers are bolted onto all cooler flanges to prevent damage to the flange faces. Install plugs in all vents and drains.

Enclosure (5)

FINAL INSPECTION

7. Verify TRIPER serial number nameplates are installed on the component.

Signature ____________________________ Date __________________

8. Verify TRIPER serial number on the crate matches the TRIPER serial number on the component.

Signature ____________________________ Date __________________

9. Verify that the MG set is supported in the storage/shipping container by properly installed resilient mounts.

These resilient mounts are for shipping and storage purposes only.

Signature ____________________________ Date__________________

**Signature (Vendor QA) _________________________________ Date _________________

**Signature (DCMA) _________________________________ Date _________________

Enclosure (5)