ATTACHMENT_2_SPECIFICATION_BALMAR_98_Series_Alternator_Revision_A.pdf

USCG-SFLC

06 JUL 2017

R-XXX-XXXX

REVISION No. CHANGE No.____

SPECIFICATION OR

STATEMENT OF WORK

COVER SHEET

OVERHAUL AND SUPPLY SPECIFICATION FOR

BALMAR 98 SERIES ALTERNATOR

SPECIFICATION NUMBER

ORIGINATED BY Chris Robinson DATE ____

Revision (A) ORIGINATED BY Chris Robinson____ DATE 07/07/2017

Revision (B) ORIGINATED BY DATE _______

Revision (C) ORIGINATED BY DATE _______

Revision (D) ORIGINATED BY DATE _______

Revision (E) ORIGINATED BY DATE _______

ORIGINATOR'S COMMAND SURFACE FORCE LOGISTICS CENTER (SFLC)

DEPARTMENT/DIVISION SMALL BOAT PRODUCT LINE ENGINEERING CELL

INTERNAL REVIEWER DATE _____

SOWRB APPROVAL DATE _______

BALMAR REPAIR AND SUPPLY SPECIFICATION

1.0 SCOPE

1.1. General -This document sets forth the requirements for the overhaul / recondition of the following assets to Original Equipment Material (OEM) specifications, parts, and standards:

a. Balmar 98 Series Alternator

These alternators shall be opened, disassembled, inspected, reported, overhauled, reconditioned, tested, preserved, packaged, marked, tracked and shipped back to the Coast

Guard Yard, Baltimore, MD.

1.2. Government Furnished Property (GFP) – The below listed items are property of, and managed by the USCG Surface Forces Logistic Center (SFLC) Baltimore, MD.

a. Balmar 98 Series Alternator (P/N 9824-220-BL, NSN 6115-01-491-5109) $2637.23

2.0 APPLICABLE DOCUMENTS

2.1. Document Availability – To obtain the referenced documents see section 3.8

2.2. Government Documents – The following specifications and standards form a part of this specification to the extent specified herein. Unless otherwise specified, the documents listed here by number and date shall be those in the current Department of Defense Single

Stock Point (DODSSP) for military specifications, standards, and related publications.

2.3. SFLC Standards

a. N/A

2.4. Military Specifications

a. MIL-D-3464E, Dated 21 Apr 1987, Desiccant, Activated Bag

b. MIL-STD-2073-1E, Dated May 2008, Standard for Military Packaging

2.5 Commercial Documents – The Following documents form a part of this specification to the extent specified here. The documents shall be the version listed by number and date from the referenced industry organization. Commercial documents may be listed in the

Department of Defense Single Stock Point (DODSSP)

a. American National Standards Institute (ANSI)/ National Conference of Standards

Laboratories (NCSL)

b. ANSI/NCSL Z540, Dated 2006, Requirements for the Calibration of Measuring and

Test Equipment

c. ANSI/ASQC Q9003, Dated 1994, Quality Systems – Model for Quality Assurance in

Final Inspection and Test

d. ANSI/EASA AR100, Dated 2006, Recommended Practice for the Repair of Rotating

Electrical Apparatus

e. American Society for Testing and Materials (ASTM)

2.6 Specification Order of Precedence – In the event of a conflict between the text of this specification and the references cited herein, this specification shall take precedence.

2.6.1 Departure from Specification - Departure from this specification shall not be allowed unless approved by the Coast Guard Contracting Officer.

a. If the contractor finds it necessary to implement change or depart from applicable specifications, they shall request permission.

b. Request for change by contractors shall clearly describe the changes proposed, the reasons for and advantages of the changes proposed, and the contract’s price increase or decrease (if any) that would result.

3.0 REQUIREMENTS

3.1. General - The contractor shall open, disassemble, inspect, report, recondition / overhaul, test, preserve, package, mark, track and ship each alternator within 60 days of receipt date.

The contractor shall provide all labor, equipment, special tools, parts and materials required to accomplish the following:

a. Receive the 98 Series alternator

b. Perform Open and Inspect

c. Overhaul the Alternator

d. Perform Testing

e. Perform Preservation

f. Perform External Preservation and Painting

g. Serialize Numbering / Tracking

h. Package

i. Preserve and Properly Label Shipping Container

j. Ship back to Coast Guard Yard Baltimore, MD

3.2. Government Furnished Property – The Government reserves the right to supply

Government Furnished Property (GFP) at anytime during the existence of this contract. The contractor shall provide protective storage for the GFP when not in use, and safe handling when in use.

3.2.1. The storage area shall at a minimum be closed on all sides, dry, and locked when unattended.

3.3. Internal Inspection – For any alternator overhaul that will exceeds 65% shall be deemed

Beyond Economical Repair (BER), and shall be disposed of by contractor after notifying

Contracting Officer and COR via email of alternator quantity and Serial numbers.

Contractor shall identify of the Cumulative Tracking Report (Appendix B).

3.4. Overhaul Parts – The contractor shall use only BALMAR OEM parts and service techniques which meet the OEM specifications and standards. All parts shall be inspected for critical dimensions and wear limits and replaced as authorized by the Contracting

Officer (KO) to meet OEM recondition / overhaul specification and parameters. All temporary markings and tags including the CG-5236 Serviceable / Unserviceable Tag shall be removed.

3.5. Beyond Economical Repair- For alternators deemed BER, Government shall only be charged cost of open and inspect.

3.6. Documentation – This specification sets forth the requirements for the following documentation.

a. Testing Report, Appendix A

b. Cumulative Tracking Report, Appendix B

c. Warranty Report for Coast Guard Unit, Appendix C

d. “F” Condition Coast Guard unit Shipping Report, Appendix D

3.7. Cumulative Tracking Report – The contractor shall maintain and submit, by the 15 th of each month, to the COR, the Cumulative Tracking Report, Appendix B for all alternators received and in possession of pertaining to this contract.

3.8. Warranty - A warranty of twelve months from date of installation. The inception date of the warranty will commence on the date of installation of the unit into the vessel. The inception date may be delayed without additional preservation of the unit for 12 months of storage. Storage commences upon receipt of alternator at the designated Coast Guard facility warehouse. This warranty covers the entire reconditioned / overhauled alternator.

The contractor shall contact the field unit to arrange a resolution of a claim within 24 hours after receiving notification by the Coast Guard of a warranty claim. The contractor shall contact SFLC’s Contracting Officers Representative (COR) to evaluate the contractors proposed duration of warranty repair time.

Following acceptance of a warranty claim by the contractor, in the event the Coast Guard decides the proposed warranty repair time compromises the Coast Guards mission and decides on removal and or replacement, the contractor shall coordinate and fund all necessary shipping arrangements for the failed alternator to be returned to the contractor’s facility for repairs and returned to the designated Coast Guard facility after repairs have been completed.

The contractor shall repair / recondition the failed alternator to the condition level necessary for the contractor to honor a new full warranty. In the event that the work is found not to be warranted, the contractor shall stop work immediately and contact the

Contracting Officer for authorization. In the event that full restoration or reconditioning of the unit to full warrantable condition requires more extensive work than will be covered under the warranty, the contractor shall stop work immediately and contact the Contracting

Officer for authorization.

The contractor shall submit to the Contracting Officer an inspection report for approval containing any parts and pricing for any work / repairs that are required that were not a result of the specific casualty, and not covered under warranty.

3.9. Notifications & Inspections – The contractor shall be responsible for notifying the

Contracting Officer’s Contracting Officer’s Representative (COR) at least 10 calendar days prior to inspections or monitored testing required herein. At this time, prior to the arrival for inspection / testing, the contractor shall provide the exact inspecting / testing sheet with

OEM specifications and parameters to the COR via email attachment.

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 and best commercial practices. The inspection system shall be documented, meet the requirements of ASQC-Q9003-1994 and be 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 ANSI/NCSL Z540, Dated 2006. 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 conducting all inspection requirements. All inspection and testing shall be performed at the contractor location, or at other facilities acceptable to the Coast

Guard. The Coast Guard reserves the right to verify or witness, any of the inspections that are deemed necessary to assure that supplies and services conform to the prescribed requirements.

4.5. Responsibility for Compliance – 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. Tests & Inspections – The inspections / tests is the minimum required to meet OEM specification, parameters and standards. This inspection / test is not intended to replace any controls, examination, inspections or tests normally employed by the contractor to assure the quality of the overhaul / recondition.

4.6.1. Each overhaul provided under this contract shall be tested and inspected on an approved compatible alternator tester provided by the contractor to ensure the performance is in accordance with the manufacturer’s OEM requirements and parameters. Prior to the final inspection / test a fixed data plate consisting of overhaul date, model number, part number, created or current item serial number shall be affixed to the alternator.

4.7. Test Reports – The contractor shall submit a completed and signed Test Report, APPENDIX A to the COR by email attachment within 5 calendar days after test completion. One copy of the report shall be packed and delivered with each alternator under this contract.

4.8. Failure Responsibility – The alternator fails the inspection / test if it doesn’t meet all applicable OEM readings and specification listed in APPENDIX A.

The contractor shall report the failure and the recommended solution to the Contracting

Officer. If approved, the corrective action on the materials or processes shall be taken in accordance with this section.

a. The inspection / test shall be discontinued until all corrective action has been taken.

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

c. 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.

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

5.0 PRESERVATION, PACKAGING & MARKING

5.1. Internal Preservation – Preservation in accordance with O.E.M. Policy shall not be started until a successful inspection / test has been completed and accepted by the

Contracting Officer’s Representative (COR). All internal and external preservation shall take into account that alternators may be stored in a controlled temperature warehouse for up to 12 months before installation.

5.2. External Preservation – After completion of the internal preservation, the alternator shall be prepared in accordance with the following procedure.

a. Cleaning and visual check to ensure alternator is free of obvious defects, corrosion, residue, grease, fingerprints, perspiration or any other acid or alkali residues or contamination.

b. All exposed metal surfaces shall be primed and painted as per OEM procedures and allow time to dry.

c. Affix a removable installation tag to alternator stating “Do not over tighten belts or damage to alternator may occur”

d. The contractor shall place the alternator in a sealed plastic bag and secure in a box with adequate packing to prevent damage and movement.

5.3. Packing Inspection- The contractor shall purchase a new box for each alternator and use new packing to secure alternator.

5.4. Marking – Each preserved and packaged item shall be stenciled in black print lettering.

5.4.1. This marking shall consist of the STOCK NUMBER, MODEL NUMBER, ITEM

NAME, SERIAL NUMBER, CONTRACT NUMBER, DELIVERY ORDER

NUMBER, GROSS WEIGHT (in lbs), CONDITION CODE, QUANTITY AND

UNIT OF ISSUE, AND LABELED; COAST GUARD SFLC MATERIAL.

Stock Number (6115-01-491-5109)

Model Number (98 Series)

Item Name (BALMAR Alternator)

Serial Number (as deemed)

Contract Number See Contract

Delivery Order Number See Delivery Order

Shipping Weight As Determined By Contractor

Condition Code Condition “A”

Quantity & Unit of Issue 1 – Each

And the Following:

Coast Guard SFLC Material

Fragile – Do Not Damage --Preserved

5.5 Additional Documents- Each alternator shall be shipped with one (1) copy of the following:

a. Warranty Report for Coast Guard Units, Appendix C,

b. “F” Condition Coast Guard Unit Shipping Report, Appendix D

6.0 NOTES

6.1. Government & Commercial Document Sources

6.1.1. Government Documents

a. Department of Defense Single Stock Point for Military Specifications, Standards, and Related Publications (DODSSP Documents)

Http://dodssp.daps.dla.mil/

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

Naval Publication and Forms Center

5801 Tabor Ave.

Philadelphia, PA 19120

215-697-2000

c. USCG Surface Forces Logistics Center

2401 Hawkins Point Road

Baltimore, MD 21226-5000

410-762-6229

ATTN: Contracting Officer SBPL

6.1.2. Commercial Documents

a. Society of Automotive Engineers INC. (SAE)

400 Commonwealth Drive Warren dale, PA 15096

412-776-4841

FAX 412-776-5760

b. American Society for Testing & Materials (ASTM)

1916 Race Street

Philadelphia, PA 19103-1187

215-299-5585

FAX 215-977-9679

c. American National Standards Institute (ANSI)

1430 Broadway

New York, NY 10018

212-642-4900

d. American Society for Quality Control (ASQC)

611 East Wisconsin Avenue

Milwaukee, Wisconsin 53202 http://dodssp.daps.dla.mil/

6.2. Appendices – The following Appendices form a part of this specification.

Appendix A: Testing Report

Appendix B: Cumulative Tracking Report

Appendix C: Warranty Report for Coast Guard units

Appendix D: “F” Condition Coast Guard Unit Shipping Report

6.3. Glossary

a. Field Unit – United States Coast Guard units located throughout the fifty (50) United

States and it territories.

b. O.E.M. – Original Equipment Manufacturer

c. O.E.P.L. – Original Equipment Parts List

d. Exchange – Exchange of used parts for original equipment manufacturer (OEM) parts.

e. Recondition – to restore to a good or satisfactory condition; repair; make over with

O.E.M. parts to O.E.M. specifications.

f. Overhaul- to make necessary repairs on; restore to serviceable condition with O.E.M.

parts to O.E.M. specifications.

http://dictionary.reference.com/browse/condition

APPENDIX A

TESTING REPORT

DATE & TIME

PART NUMBER

SERIAL NUMBER

DISCRIPTION

PASS OR FAIL

TEST RESULTS TABLE:

OUTPUT CURRENT TABLE:

OUTPUT CURRENT AT 1600 RPM AMPS

OUTPUT CURRENT AT 1800 RPM AMPS

OUTPUT CURRENT AT 2000 RPM AMPS

OUTPUT CURRENT AT 2400 RPM AMPS

OUTPUT CURRENT AT 3500 RPM AMPS

OUTPUT CURRENT AT 4500 RPM AMPS

OUTPUT TESTED AT:

SIGNATURE AND DATE: ______________________________

MAXIMUM ALTERNATOR OUTPUT AMPS

MAXIMUM OUTPUT POWER WATTS

VOLTAGE SET POINT VOLTS

LEAKAGE CURRENT mAmps

RIPPLE CURRENT AMPS

ALTERNATOR TURN ON SPEED RPM

TACHOMETER FREQUENCY HZ

STATOR VOLTAGE VOLTS

APPENDIX B

CUMULATIVE TRACKING REPORT

SUBMIT BY THE 15TH OF THE MONTH

Alternator

In SER. #

Work Order

Delivery

Order #

Date

Received

BER

Y/N

Out Ser. #

APPENDIX C

WARRANTY NOTICE

This item has a warranty for whichever comes first:

12 months of operation from installation

One year storage from date SFLC received alternator from contractor

If any discrepancies are noted upon receipt

1. DO NOT REPAIR OR REPLACE!

2. CALL: USCG SURFACE FORCES LOGISTICS CENTER

CENTRAL ENGINE OVERHAUL

SMALL BOAT PRODUCT LINE (SBPL)

COMMERCIAL (410) 762-6089 / 6229

Have the following information ready when calling the (SBPL)

________ Date Received ________ Date Installed

________ Serial Number ________ Vessel Home Port

________ Hours on Machinery ________ Vessel Hull No

NOTES:

(1) Preventative Maintenance (PMS) should still be performed as per applicable Maintenance

Procedure Cards (MPC’s). PMS does not void the warranty.

(2) If the above procedure is not followed, the warranty may be affected.

APPENDIX D

FOR COAST GUARD UNITS ONLY

SHIPPING REQUIREMENTS FOR "F" CONDITION RETURNS

(“F” Condition = Broken, Not ready for issue)

1. Call SFLC Shipping Supervisor Earl Gephardt at 410-762-6297 to receive shipping CBL or visit http://10.38.65.78/WarehouseShipping/ApplicationHome.aspx for instructions.

2. Returned machinery shall be crated and secured properly in the same package the new alternator came in.

3. Package is to be securely fastened before shipping.

4. Change Crate Marking from "A" Condition to "F" Condition (Black Marker).

5. Change serial number marking on the package from the new alternator to the old alternator being shipped back

9. Ensure any parts removed or swapped (if applicable) are reinstalled on the old alternator before shipping. (Make the “F” Condition alternator complete as possible)

10. Any questions on these requirements please call the Central Engine Overhaul Warranty Phone Line

@ 410-762-6089 / 6229.

http://10.38.65.78/WarehouseShipping/ApplicationHome.aspx