140 Rudders Repair Supply Spec 020719 - Edit.pdf

JPH_0119

WORK ITEM 1: 140 WTGB Rudder, Repair

1. SCOPE

1.1 Intent. This supply item describes the requirements for the Contractor to receive a rudder blade previously removed from an operating 140 foot USCG WTGB class Ice Breaking Tug and inspect and repair it for future service.

1.2 Government-Furnished Property.

MTI ITEM DESCRIPTION NSN

P/N

CAGE

QTY

(EA.)

ESTIMATED COST

($/UNIT)

Y 140 WTGB; Rudder Blade NSN: 2040-01-115-3498 1 ea.

2. REFERENCES

COAST GUARD DRAWINGS

Coast Guard Drawing 140 WTGB 562-003, Rev -, Rudder Coast Guard Drawing 140 WTGB 562-002, Rev C, Rudder Stock Bearing Details

COAST GUARD PUBLICATIONS

Surface Forces Logistics Center Standard Specification 0740 (SFLC Std Spec 0740), 2014, Welding and Allied Processes

OTHER REFERENCES

American Welding Society (AWS) Specification D1.1 Structural Code, Steel, 2000 edition.

ASQ/ISO/IEC 17025:2005, General requirements for the Competence of Testing and Calibration

Laboratories ASTM E1003, Dated 15 Jan 2013, Standard Practice for Hydrostatic Leak Testing ASTM B369, Dated 01 Apr 2009 (R 2016), Standard Specification for Copper-Nickel Alloy

Castings ASTM D6880/D6880M, Dated 2011, Standard Specification for Wood Boxes ASTM D7478/D7478M, Dated 2011, Standard Specification for Heavy Duty Sheathed Wood

Crates MIL-A-22262B (SH), Abrasive Blasting Media Ship hull Blast Cleaning, Dtd. 21 Mar. 96 MIL-PRF-16173E, Corrosion Preventive Compound Solvent Cutback, Cold Application, Dated

6/January/1993.

CGRodriguez Cross-Out

MIL-PRF-24647C, Paint System, Anticorrosive and Antifouling, Ship Hull Dated 24/September/2001

MIL-PRF-121G, Type 1, grade A, class II, Barrier materials, greaseproof, waterproof, flexible, heat-sealable

MIL-STD-129R, Feb 2014 Military Marking for Shipment and Storage ISO/IEC 16388-2007 Information technology — Automatic identification and data capture techniques — Code 39 bar code symbology specification.

ISO 9001, Dated 15 Sep 2015, Quality Management Systems – Requirements The Society for Protective Coatings, SSPC-SP 10, Near White Blast Cleaning, Sept. 2000 edition.

The Society for Protective Coatings, NACE NO. 5/SSPC-SP12, Joint Surface Preparation

Standard.

3. REQUIREMENTS

3. REQUIREMENTS

3.1 General.

3.1.1 Tech rep. Not applicable.

3.1.2 Notifications & Inspections. The contractor shall be responsible for notifying the Contracting Officer in writing no less than seven (7) calendar days prior to the contractor being ready for any Quality Assurance (Q.A.) inspections or testing required herein.

3.1.3 Welding.

3.1.3.1 Weld Quality: All welds shall be thoroughly fused with base metal. Welds shall be free of craters, undercutting, overlaps, porosity, or cracks. All welding shall conform to AWS D1.1.

3.1.3.2 Welder Qualification: Welders shall have a valid qualification record certified by one or more of the following organizations. This qualification shall be for the same particular service application, filler material type, position of welding, and welding process.

• a) The American Welding Society

• b) The American Bureau of Shipping

• c) Department of the Navy

3.1.3.3 Contractor shall make welder certifications available to the Contract Administrator prior to contract award. A copy of the welder certifications shall also be available for the Coast Guard Quality Assurance Representative.

3.2 Rudder repairs.

3.2.1 The contractor shall provide all labor and materials to perform the below specified work on the rudder. The rudder will have come off operating vessels and require various repairs before reintroduction to operating vessels. Each individual rudder will have unknown and unique degrees of damage.

3.3 Rudder receipt Inspection.

3.3.1 Ensure each rudder is uniquely identified either by existing numbers/stamps on rudder, or Contractor devised system of marking. Each rudder shall undergo a full inspection as follows:

3.3.2 Visual Inspection.

3.3.2.1 Carefully inspect the rudder for obvious damage. Document discovered damages in sketches, photos, etc.

3.3.3 Drawing compliance Inspection.

3.3.3.1 Inspect the rudder for compliance to Drawing 140 WTGB 562-003. Measure and document all critical dimensions.

3.3.3 Plate thickness inspections.

3.3.3.1 Perform Ultra Sonic Thickness (UT) of plating, to determine any reduction in thickness, in accordance with SFLC Std Spec 0740, Appendix C and Drawing 140 WTGB 562-003.

3.3.3.2 Follow a grid pattern of 1 shot per square foot over the entire surface of the rudder blade with special attention paid to the leading edge. A report with a diagram of the rudder blade and the measured thicknesses shall be provided to the USCG representative for review and approval.

3.3.4 Air test.

3.3.4.1 Perform an air test of rudder.

3.3.4.2 Air Test: The rudder void shall be air test at 3 PSI for 30 minutes with no leakage allowed. The gage shall have an indicated range of no more than 10 psi. Gage shall be of sufficient size so that any reduction of pressure shall be immediately apparent. Any leaks shall be examined to determine the cause and addressed in a condition found report. A copy of the air test report shall be attached to the rudder blade during packaging

3.3.5 Final Inspection Report.

3.3.5.1 Submit a final written report on each Rudder. Include all noteworthy discoveries, damage, deficiencies. Include results of all tests. Include recommended repair options. Include recommendations to scrap a rudder, if repairs are not feasible and are potentially more costly then fabricating a new replacement rudder.

4. QUALITY ASSURANCE

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

4.2 Records. The contractor shall maintain records of all inspections and tests. The records at a minimum shall indicate the nature and number of observations made, the number and type of deficiencies found, and the corrective action taken.

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

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

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

4.6 Inspections and tests. The inspections/tests required here and in the appropriate subsection in section 3 are the minimum required and are not intended to supplant any controls, examination, inspections or tests normally employed by the contractor to assure the quality of the item in question. The following tests and inspections will be witnessed by an SFLC Quality Assurance Representative:

4.6.1 Completed rudder repair inspections, resultant from initial as-found inspections and reports. See section 3.2 and 3.3.5.

4.6.2 Preservation, packaging, packing and marking inspection. See section 5.

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

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

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

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

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

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

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

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

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

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

5. PRESERVATION, PACKING, MARKING, AND SHIPPING

5.1 Preservation. Each tested and approved rudder shall be preserved as follows:

5.1.1 Rudder Blade Preservation.

5.1.1.1 Painting, Rudder Blade Exterior.

5.1.1.1.1 Surface Preparation: In preparation for painting the rudder exterior surface shall be sand blasted to near white metal in accordance with SSPC-SP10/NACE No. 2 using grit conforming to MIL-A-22262.

Blasting shall result in an anchor profile of 1.5 to 3.5 mils. All machine finished surfaces at risk of damage from sand blast and paint operations shall be blanked off or otherwise protected while this work is being performed. Do not paint mating flange’s surface.

• a) Alternative Method: To NACE NO. 5/SSPC-SP12 to WJ-2 and SC-1.

5.1.1.1.2 Paint Coating: Paint coating shall be two coats, 5 to 6 mils dry film thickness of anti-corrosive Epoxy in accordance with MIL-PRF-24647.

5.1.1.2 Flow Coating, Rudder Interior. The rudder internal cavity shall be flow coated with corrosion preventative compound that conforms to MIL-PRF-16173, Class II, Grade 3, to coat all surfaces.

• Drain, collect, and dispose of remaining compound in accordance with all applicable Federal, state, and local regulations.

• Ensure that the coated surfaces are left exposed to the atmosphere for 24 hours to allow for adequate drying.. Install pipe plugs using a suitable thread sealer after completion of flow coating.

5.1.4 Loose Item Preservation.

5.1.4.1 The loose items listed in 5.2.3 that re subject to corrosion, shall be coated with corrosion preventative compound, Grade 3 in accordance with MIL-C-16173. The preserved surfaces shall be wrapped with two layers of greaseproof barrier paper per MIL-PRF-121.

5.2 Packing. If shipping weight is less than 1000 pounds, packing shall comply with ASTM D6880/D6880M-11 Class 2 Style 2 with skid mounts. If the shipping weight is greater than 1000 pounds, the packing will comply with ASTM D7478/7478M Type 2, Class 2, Style A with skid mounts.

5.2.1 All components shall be protected from physical damage and mechanical malfunction. Cushioning materials, dunnage, blocking, bracing and strapping shall be applied as required to protect the item(s) and the enclosing media and restrict the movement of the item within the container. The materials selected for all blocking and bracing, and the design and application thereof, shall be compatible with the item and its bearing load limitations. Materials shall be as clean and as dry as practicable.

5.2.2 The rudder blade shall be packaged in its own individual wooden shipping container.

5.3 Marking. Each packaged crate/box shall have a water proof label securely attached or water proof stencil in the upper left-hand corner of the two longest sides (two opposite sides if square) of each box IAW MIL-STD-129R. The stencil marking shall be 3/4" -1" inch in height.

5.3.1 Marking layout.

STOCK NUMBER 2040-01-115-3498

ITEM NAME Rudder Blade

PART NUMBER 10251-562-213

CONTRACT NUMBER (See Contract Page 1)

DELIVERY ORDER NUMBER (See Contract)

SHIPPING WEIGHT

As Determined by Contractor

For information only, the previous assumed weight was 7100 lbs

QUANTITY & UNIT OF ISSUE 1 - EA

CONDITION CODE CONDITION A

OTHER DATA AS DIRECTED COAST GUARD SFLC MATERIAL

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

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

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

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

• U.S. Coast Guard

• Surface Forces Logistics Center

• 2401 Hawkins Point Rd. Bldg. 88

• Baltimore, MD 21226

6 NOTES

6.1 Document sources.

6.1.1 Government document sources.

• Department of Defense Single Stock Point (DODSSP)

Building 4, Section D 700 Robbins Avenue Philadelphia, PA 19111-5094 215-697-2667/2179

FAX 215-697-1462

• DOD & Navy Publications & Forms (Other Than DODSSP) Naval Publication and Forms Center 5801 Tabor Ave.

Philadelphia, PA 19120 215-697-2000

6.1.2 Coast Guard document sources.

• USCG Surface Forces Logistics Center 2401 Hawkins Point Road Baltimore, MD. 21226-5000 Phone: 410-762-6171 ATTN: Contracting Branch, CPD1

6.1.3 Commercial document sources.

• Society of Automotive Engineers Inc. (SAE)

400 Commonwealth Drive Warrendale, PA 15096 1-877-606-7323

FAX: 1-724-776-0790

• American Society for Testing & Materials (ASTM) 100 Barr Harbor Drive West Conshohocken, PA 19428 610-832-9500

FAX: 610-832-9555

• American Society for Quality Control (ASQC) 611 East Wisconsin Ave.

Milwaukee, WI 53202

414-272-8575

FAX: 414-272-1734

• International Standard Organization (ISO) 1, ch. De la Voie-Creuse CP 56 – CH-1211 Geneva 20 Switzerland Phone +41 22 749 01 11 Fax: +41 22 733 34 30

WORK ITEM 1: 140 WTGB Rudder, Repair