2019 Various Rudders repair supply spec (CW047).doc

JPH_1219

WORK ITEM 1: Rudder, Repairs

1. SCOPE

1.1 Intent. This supply item describes the requirements for the Contractor to receive various rudder blades and rudder stocks removed from operating vessels and inspect and repair them for future service.

1.2 Government-Furnished Property.

P/N

CAGE

($/UNIT)

2. REFERENCES

Coast Guard Drawings

Coast Guard Drawing 160 WLIC 2200-001 (Including BM-32), Rev E, Steering Machinery Arrangement Rudder Stock & Fitting

Coast GuardDrawing 65BUS 2200-001, Rev 3, Rudder Bearings &Details

Coast GuardDrawing 65BUS 2200-004, Rev -, Rudder Arrg, Fabr & Bill of Materials

Coast Guard Drawing 65 WYT 2200-001, Rev A, Rudder

Coast Guard Drawing 75 WAGL 2200-010, -Rev D, Main Rudder Stock And Fittings For Jastram S2-16-2-35 Steering System

Coast Guard Drawing 75 WAGL 2200-011, Rev D, Flanking Rudder Stock And Fittings For Jastram S2-16-2-35 Steering System

Coast Guard Drawing 75F WLR 562-003, Rev 4, Steering Rudders & Stocks

Coast Guard Drawing 75F WLR 562-005, Rev 6, Flanking Rudders & Stocks

Coast Guard Drawing 642 WAGL 2200-002, Rev E, Rudders & Stocks

Coast Guard Drawing 180-TE 2200-1, REV C, Rudder, Rudder Stock & Bearings Coast Guard Publications

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.

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 Rudders and stock repairs.

Table 1 – Rudder DATA

RUDDERS

65 WLR B

75 WLR C

75 WLR E

75 WLIC A

75 WLIC B

75 WLIC D

Steering Rudder Blade

(includes Lower Steering Rudder stock integral with blade)

75WAGL-2200-10

2040-01-530-9095

3.2.1 The contractor shall provide all labor and materials to perform the below specified work on the rudders and stocks described in Table 1 above. The various rudders and stocks will have come off operating vessels and require repairs before reintroduction to operating vessels. Each individual rudder and/or stock will have unknown and unique degrees of damage.

3.3 Rudder receipt Inspection. For line items 1-9 of above table.

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 damage in sketches, photos, etc.

3.3.3 Drawing compliance Inspection.

3.3.3.1 Inspect the rudder for compliance to drawings. Measure all critical dimensions,

3.3.3 Plate thickness inspections.

3.3.3.1 Perform UT thickness examination of plating, to determine any reduction in thickness

3.3.4 Air test.

3.3.4.1 Perform an air test of rudder.

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.

3.3 Stock/Post receipt Inspection. For line items 10-18 of above table..

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

3.3.2 Visual Inspection.

3.3.2.1 Carefully inspect the stock/post for obvious damage. Document discovered damage in sketches, photos, etc.

3.3.3 Drawing compliance Inspection.

3.3.3.1 Inspect the stock/post for compliance to drawings. Measure all critical dimensions,

3.3.5 Final Inspection Report. For line items 10-18 of above table..

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

3.4 Additional Repairs. For line items 1-18 of above table..

3.4.1 Since it is unknown what exactly will be required it can be assumed the following are representative examples of expected types of required work:

· Weld repairs on rudder blade plating.

· Steel plate renewal on rudder blades.

· Weld build up on stocks.

· Machining surfaces/holes/threads etc. to correct dimension (after weld build up).

· Procuring/fabricating and installing sleeves on rudder stocks.

· Fabricating keys and palm bolts.

3.5 Matching/Fitting Rudder Blades to Stocks. For line items 19-27 of above table..

3.5.1 The rudder blades and rudder stocks are married to each other by fitted keyways, and keys. Each specific pair may be unique per its specific drawings.

3.5.2 Whenever pairing a combination rudder blade and rudder stock is exercised by Contracting, the contractor shall take the following action:

3.5.2.1 Fabricate and fit shared key. This will require shared keyway dimensions and even perhaps hand fitting.

3.5.2.2 Fabricate and fit all connected hardware. This often requires shared fitted bolts inside carefully reamed holes. Other hardware can (but not limited) to nuts and washers. The intent is direct assembly onto a Cutter in drydock, with no custom machining or part fabrication required.

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 Stock repair inspections. See section 3.4

4.6.2 Rudder repair inspections. See section 3.4.

4.6.3 Rudder assembly fit inspections. See section 3.5.

4.6.4 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 assembly shall be preserved as follows:

5.1.1 Stock Preservation. All unpainted steel surfaces of the stock shall be preserved with corrosion preventative compound MIL-C-16173. The preserved surfaces shall be wrapped with greaseproof barrier paper per MIL-PRF-121. Three wraps of eight ounce weight canvas shall be applied over the barrier paper and secured with duct tape.

5.1.2 Preserve the stocks flange below the sleeve (do not paint sleeve) in accordance with rudder blade exterior painting specified below. Do not paint mating flange’s surface.

5.1.3 Rudder Blade Preservation.

5.1.3.1 Painting, Rudder Blade Exterior.

5.1.3.1.1 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.

5.1.3.1.2 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.

5.1.3.2 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 stock and rudder blade shall be packaged in its own individual wooden shipping container.

5.2.3 Loose Parts. After QA and acceptance of fit the following parts shall be packaged unattached to rudder blade in separate box inside main container. These parts are installed at final shipboard assembly:

· a) keys

· b) fitted bolts

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.

EXAMPLE ONLY for a 160 WLIC RUDDER BLADE and STOCK:

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