MEPS_Repair_Spec_REVISION_3.pdf

REVISION No. CHANGE No.

SPECIFICATION OR

STATEMENT OF WORK

COVER SHEET

TITLE

Mobile Electric Power Solutions Generator and Alternating Current Unit (ACU) Repair

REPAIR SPECIFICATION

SPECIFICATION NUMBER

X-XXX-XXXX

ORIGINATED BY Chris Robinson DATE 04/26

Revision (A) ORIGINATED BY Chris Robinson DATE 11/21/16 ___

Revision (B) ORIGINATED BY Chris Robinson DATE 04/10/17 ____

Revision (C) ORIGINATED BY Steven Bolen DATE 02/08/19____

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

1.0 Scope

1.1 Purpose - This specification is for the repair of non-

ready for issue Mobile Electric Power Solutions (MEPS)

Generator and Alternating Current Unit (ACU) and for the supply of new MEPS Generators and ACU’s.

The contractor will reassemble the exchanged/remanufactured MEPS generator and ACU with only

MEPS OEM equipment.

The generator and ACU shall be tested, preserved, painted, and packaged. The generator and ACU (one of a pair) are installed in the U.S. Coast Guard 45 FT.

Response Boat Medium (RB-M), and the 42 FT. Near Shore

Lifeboat (NLB). The generator and ACU will be provided to the contractor in a reinforced cardboard shipping container.

1.2 Government Furnished Property - This specification sets

forth the requirements for the following equipment:

a. MEPS Generator (NSN: 2920-01-644-6491, P/N: 7102252-

00) $2761.00

b. Alternating Control Unit (8kW) (ACU) (NSN: 2920-01-

644-6478, P/N: 8806124-300) $5304.00

c. Alternating Control Unit (10kW) (ACU) (NSN: 2920-01-

658-3064, P/N: 4106023-21) $4768.50

d. MEPS Generator (6.3kW)(P/N 7632002‐5) $2347.00

2.0 APPLICABLE DOCUMENTS

2.1 Applicable Documents - The following documents form a

part of this specification to the extent specified herein.

2.2 Government Documents

a. Power Generation System With Victron Multiplus

24/5000/120/100 (TP-5795)

2.3 Commercial Documents

a. ANSI/ASQ/ISO Q9001-2000, 13 Dec 2000, Inspection

System

b. ANS/ISO/IEC 17025:2005 for Part 1 and ANSI/NCSL

Z540.3-2007 for Part 2, General Requirements for

Calibration Laboratories and Measuring and Test

Equipment.

c. MEPS Inc Generator Test Plan.

e. MEPS Inc Alternating Current Unit Test Plan.

f. ASTM D3951-10 Standard Practice for Commercial

Packaging

2.4 Specification Precedence - Any conflict between this

Specification and applicable documents identified in this

Specification shall be resolved in this order:

a. This specification

b. Applicable documents

2.4.1 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 by contractors for change 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 repair each Generator &

ACU within sixty (60) calendar days after approval of the

Core Condition report (Appendix A) by the Contracting

Officer. The contractor shall provide all labor, equipment, special tools and materials required to accomplish the following sequence of activities:

MEPS Generator

a. Receive the generator.

b. Uncrate the generator.

c. Submit Core Condition Report (Appendix A) and GFP

Report (Appendix F).

d. Disassemble and clean the generator.

e. Evaluate the resistance of each phase of each stator. (2 Stators)

f. Inspect for short circuits between phases and between phases to ground.

g. Provide Inspection Report (Appendix B) and

Replacement Parts List (Appendix D) within 10 days of Generator receipt.

h. Repair and replace damaged or non-working components.

Note: If repairs exceed 65% of the replacement cost of the component, it shall be returned to the USCG within 15 days and disposed in accordance with USCG property disposal procedures.

i. Clean end-bells & paint as necessary

j. Replace front and rear bearings.

k. Re-assemble the generator to OEM specifications.

Perform full Acceptance Test In accordance with OEM specifications

l. Package and mark generator crate.

MEPS Electronic Control Unit (ACU)

a. Receive the ACU.

b. Uncrate the ACU.

c. Submit Core Condition Report (Appendix A).

d. Disassemble and clean the ACU.

e. Inspect the functionality of electronics.

f. Provide Inspection Report (Appendix B) and

Replacement Parts list (Appendix D) within 10 days of receipt of ACU.

g. Repair and replace damaged or non-working components.

h. Re-assemble the ACU to OEM specifications.

i. Perform full Acceptance Test IAW OEM specifications.

j. Package and mark ACU crate.

Note: If repairs exceed 65% of the replacement cost of the component, it shall be returned to the USCG and disposed in accordance with USCG property disposal procedures.

3.2 MEPS Generator and ACU – MEPS and ACU’s shall be repaired within sixty (60) calendar days after approval of Core

Condition Report, Appendix A. The generator and ACU shall be stored inside and protected from all weather.

3.3 MEPS Generator and ACU Parts – All gaskets, seals, O

rings and copper seals shall be replaced as new. The contractor shall use only MEPS O.E.M parts meeting O.E.M.

specifications. All MEPS Generators and ACU’s supplied to the contractor under this contract will be repaired at an authorized MEPS distributor facility.

3.4 New Components – All new components are tested upon

manufacture and reports are included with component. All new parts shall conform to the preservation, packaging, and marking requirements of this Specification.

3.5 Labor - All labor is to be performed by MEPS certified

and authorized technicians.

3.6 Core Condition Report - The contractor shall submit

Appendix A to the contracting officer in writing within ten (10) calendar days after receipt of the MEPS

Generator and ACU. The contractor shall submit Appendix B to the contracting officer in writing within ten (10) calendar days after receipt of the generator or ACU.

3.7 Replacement Parts List - The contractor shall complete

Appendix D following the core inspection and submit to the contracting officer in writing within ten (10) calendar days after receipt of the MEPS Generator and

ACU. The contractor shall list any parts not considered mandatory, requiring replacement to affect repairs. (ex.

Generator stator)

3.8 Core Acceptance Criteria - The contractor shall accept

the core based on a visual inspection as per Appendix A.

If during the internal core inspection the contractor identifies concerns with the core condition, conditions will be negotiated per paragraph 2.4.1.

3.9 Documentation - This specification sets forth the

requirements for the following documentation.

a. Core Condition Report, in accordance with Appendix A

b. Inspection Report, in accordance with Appendix B

c. Cumulative Tracking Report, Appendix C

d. Test Report, Reference 2.3.c and 2.3.d.

e. Replacement Parts List, Appendix D

e. Warranty Sheet, Appendix E

f. Government Furnished Property Report (GFP)

3.10 Warranty - A standard warranty of 90 days to repair or

rebuild.

4.0 Quality Assurance

4.1 General - The contractor shall maintain an inspection

system, which shall ensure each item, offered to the

Government for acceptance conforms to contract requirements. The system shall be documented and in compliance with ANSI/ASQC Q9003.

4.2 Records - The contractor shall as a minimum maintain

records of all inspections and tests. The records shall indicate the nature and number of observations made, type of deficiencies found, and the corrective action taken.

Records shall be furnished upon arrival of the

Contracting Officer's Representative.

4.3 Contractors Calibration System - The contractor shall

maintain a calibration and maintenance system to control the accuracy of measurement and test equipment used in the fulfillment of this contract in accordance with

ANSI/NCSL Z540-1. The system shall include as a minimum, prescribed calibration intervals, source of calibration, and a monitoring system to insure adherence to calibration schedules. Calibration standards shall be traceable to the National Institute of Standards and

Technology (NIST). Documentation in support of this requirement shall be readily available for Government review.

4.4 Responsibility For Inspection - The Contractor shall be

responsible for all inspections/test requirements specified herein. The contractor shall provide space, personnel, and test equipment to conduct all inspection requirements. All testing and inspection shall be at the

Contractors facility or other facilities acceptable to the Government. The Government reserves the right to verify or have performed any of the inspection/tests set forth in this specification where such inspections are deemed necessary to assure that supplies or services conform to the prescribed requirements.

4.5 Required Tests – In accordance with reference 2.3.c, and

2.3.d each MEPS Generator and ACU provided under this contract shall be operationally tested to assure minimum performance prior to acceptance.

4.6 Test Report - The contractor shall deliver a test report, reference 2.3.c & 2.3.d, within seven (7) calendar days after completion of tests. The test report shall consist of the data obtained during the MEPS Generator and ACU test. One copy of the test report shall be packed and delivered with each MEPS and ACU delivered under this contract.

5.0 PRESERVATION, MARKING AND PACKAGING

5.1 PRESERVATION (External) - Upon completion of final test, the MEPS Generator and ACU shall be prepared as follows:

5.1.1 Surfaces shall be cleaned and free of grease/oil.

5.1.2 All loose scale and paint shall be removed; uneven paint layers shall be sanded smooth.

5.1.3 The following items will be masked and not painted:

a. Electrical connectors and wires

b. Identification plates

c. Front and rear seals

d. Couplings

5.1.4 On all exposed metal surfaces the Contractor shall apply one coat of primer to all components allowing primer to dry.

5.2 MARKING - Each shipping container shall be marked in

accordance with 5.2.1.

a. The contractor shall ensure that the serial number and model number on the container sides match the actual MEPS Generator and ACU serial number and model number in the container.

b. Shipments shall be marked in accordance with the current edition of MILSTD-129P w/Change 4, Military

Marking for Shipment and Storage dated September 19, 2007.

c. SFLC is an Inventory Control Point (ICP), material will be stored and transshipped to various users;

therefore material must be packed and labeled suitable for shipment via land, air or sea. The following requirements apply:

a. Each individual part or part container must be marked. Lettering shall be black applied on a highly contrasting background.

b. Markings shall consist of the National Stock Number (NSN), or Acquisition Control

Number (ACN), Item Name, Model Number, Serial Number, Contract Number, Contractor

Part Number, Box X of Y, Shipping Weight, Condition Code, Quantity and Unit of

Issue.

5.2.1 This marking shall be in the format as follows:

STOCK NUMBER 2920-01-644-6491

ITEM NAME MEPS 8kW Generator

PART NUMBER 7102252-00

SERIAL NUMBER “per Delivery Order"

CONTRACT NUMBER See contract

DELIVERY ORDER NUMBER “per Delivery Order”

SHIPPING WEIGHT Determined by Contractor

PRESERVED FOR LONG TERM

STORAGE ON Date Preserved

QUANTITY & UNIT OF ISSUE 1-EA

CONDITION CODE CONDITION A

OTHER DATA AS COAST GUARD SFLC MATERIAL

DIRECTED REUSABLE CRATE, DO NOT

DAMAGE. DO NOT STACK

MORE THAN TWO HIGH

STOCK NUMBER 2920-01-644-6478

ITEM NAME MEPS 8kW

Alternating Current Unit

PART NUMBER 8806124-300

SERIAL NUMBER "per Delivery Order"

CONTRACT NUMBER See contract

DELIVERY ORDER NUMBER “per Delivery Order”

SHIPPING WEIGHT Determined by Contractor

PRESERVED FOR LONG TERM

STORAGE ON Date Preserved

QUANTITY & UNIT OF ISSUE 1-EA

CONDITION CODE CONDITION A

OTHER DATA AS COAST GUARD SFLC MATERIAL

DIRECTED REUSABLE CRATE, DO NOT

STOCK NUMBER

ITEM NAME MEPS 6.3kW Generator

PART NUMBER 7632002‐5

SERIAL NUMBER “per Delivery Order"

CONTRACT NUMBER See contract

DELIVERY ORDER NUMBER “per Delivery Order”

SHIPPING WEIGHT Determined by Contractor

PRESERVED FOR LONG TERM

STORAGE ON Date Preserved

QUANTITY & UNIT OF ISSUE 1-EA

CONDITION CODE CONDITION A

OTHER DATA AS COAST GUARD SFLC MATERIAL

DIRECTED REUSABLE CRATE, DO NOT

STOCK NUMBER 2920-01-658-3064

ITEM NAME MEPS 10kW

Alternating Current Unit

PART NUMBER 4106023-21

SERIAL NUMBER "per Delivery Order"

CONTRACT NUMBER See contract

DELIVERY ORDER NUMBER “per Delivery Order”

SHIPPING WEIGHT Determined by Contractor

QUANTITY & UNIT OF ISSUE 1-EA

PRESERVED FOR LONG TERM

STORAGE ON Date Preserved

CONDITION CODE CONDITION A

OTHER DATA AS COAST GUARD SFLC MATERIAL

DIRECTED REUSABLE CRATE, DO NOT

5.2.2 Large part shipping container lettering shall be at

least ½ inch high or 36 point type. Stenciling is acceptable. General Packaging lettering shall be at least 1/4 inch high or 18 point type.

Plastic Bag lettering may be 12 point lettering.

The contractor shall paint over all other markings not outlined in 5.2.1.

5.3 PACKAGING -

5.3.1. Packaging, handling, shipping, and transportation

procedures shall be in accordance with ASTM D3951-10

Standard Practice for Commercial Packaging. If commercial practices cannot adequately protect and preserve the equipment, the contractor shall package, handle, ship and transport equipment in accordance with MIL-STD-2073-1E Standard Practice for Military Packaging dated May 23, 2008.

5.3.2. Each Part shall be packaged separately, or in its

designated unit of issue.

5.3.3. All parts shall be identified and accounted for by

their NSN or ACN on the packing list.

5.3.4. Large parts shall be shrink-wrapped or otherwise

covered and sealed to prevent water damage. Small parts shall be enclosed in clear plastic packaging.

5.3.5. Multiple identical parts may be repackaged in

designated quantity units (box lot, case lot, pair, etc) for shipping purposes. The packaging shall be identified by the words MULTI-PACK and the quantity per package.

5.3.6. Documents and other enclosures shall be sealed in

a waterproof plastic bag, which shall be permanently affixed to the inside of the shipping container in a conspicuous location. The last line of the package label shall contain the words "DOCUMENTS ENCLOSED"

5.3.7. Parts- Containers:

5.3.7.1. Parts shall be packed in containers meeting ASTM

D 3951 and the requirements herein.

5.3.7.2. Containers with special packing / unpacking

instructions shall be stenciled "CAUTION - THIS ITEM

MAY BE SERIOUSLY DAMAGED UNLESS UNPACKING

INSTRUCTIONS ARE FOLLOWED CAREFULLY.” followed by a notation of the location of instructions.

5.3.8. General items:

5.3.8.1. General components weighing less than 70 lbs

may be packaged in commercial reinforced cardboard packaging, or its equivalent, or packaged in a skid mounted shipping container. If packaged in a skid mounted shipping container then containers shall be completely enclosed and structurally suitable for stacking at least 2-high. The containers shall be suitable for inside covered stowage. Containers shall be assembled with screws to permit ease of removal of the cover or lid from the base.

5.3.8.2. Reinforced cardboard packaging shall be sealed, but shall be suitable for being opened (without total packaging destruction) for inspection, resealing and subsequent shipment to the fleet.

5.3.8.3. The reinforced cardboard packaging shall be

completely enclosed and suitable for stacking. The packaging shall be suitable for long-term inside storage in a warehouse.

5.3.9. Small items:

5.3.9.1. Small items which can fit into express carrier

standard packaging (maximum 17.5 in x 12.5 in x 3 in box. or 38 x 6 x 6 x 6 triangular tube) for shipment with appropriate cushioning may be sealed in clear plastic packaging, or packaged in a commercial reinforced cardboard packaging. If packaged in a cardboard package then the requirement for general packaging applies.

5.3.9.2. Plastic packaging shall be 6 mil thickness and

sufficiently clear for part inspection. Plastic packaging shall have provision for breathing to prevent condensation unless the packaging provides a hermetic seal.

5.3.10. Durability

5.3.10.1. The contractor shall ensure that all

deliverables, when packed in separate shipping containers, will be capable of being transported on standard transportation systems, commercial or military carriers. The contractor shall preserve, package, and mark the containers to ensure complete delivery at destination without damage or deterioration due to the hazards of shipping, handling or storage.

5.3.11. Parts - Packing and Cribbing:

5.3.11.1. Restraints, packing and cribbing shall restrain

and protect the parts within their packaging from damage during shipment and storage:

5.3.11.2. The internal packaging material shall be

sufficient to prevent damage during shipment, handling and storage. Preservation protection must be sufficient to prevent corrosion, deterioration or decay during warehouse storage for a period of at least one year.

5.3.11.3. Cribbing shall be provided to prevent damage

during shipment.

5.3.11.4. Loose fill & Styrofoam packing materials shall

not be used.

5.4. MARKING OF WARRANTED ITEMS

Pursuant to the requirements of FAR 46.706 (b) (5), the contractor shall stamp or mark the supplies delivered or otherwise furnish notice with the supplies of the existence of the warranty (Warranty Notice, Appendix E).

Markings may be brief but should include:

a. A brief statement that a warranty exists.

b. The substance of the warranty.

c. Its duration.

d. Who to notify if the supplies are found to be defective. For commercial items (see 46.709), the contractor’s trade practice in warranty marking is acceptable if sufficient information is presented for supply personnel and users to identify warranted supplies.

5.5. PACKING LIST

All material shipped or delivered under this contract must be accompanied by an itemized packing list that cites the proper contract and delivery order number. Each packing unit shall have a list of all items contained in that unit. The packing list shall include the due-in numbers provided by Surface Forces Logistics Center.

The packing list shall be securely attached to the outside of the container and shall be enclosed in a clear waterproof envelope.

5.5.1. Material Inspection and Receiving Report and

Packing Slip

5.5.1.1. A DHS 700-21 Material Inspection and

Receiving Report shall be accompany each delivery.

5.5.1.2. A Government Representative above will

perform visual inspection to ensure all items listed on the packing slip are provided, and will sign the DHS 700-21 to accept the delivery.

5.5.1.3. The original signed DHS 700-21, with a copy

of the packing slip attached shall be forwarded to the Contracting Officer.

5.5.2. Packing Slip

A packing slip shall be prepared for each box or shipping container. The packaging slip shall include the following information: (1) National Stock Number, (2) Part Number,

(3) Nomenclature, (4) Serial Number, (5) Contract Number,

(6) Delivery Order Number, (7) Line Item Number, and (8)

Quantity.

One copy of the packaging slip shall be submitted with the shipment and shall be attached to the outside of the shipping carton inside a waterproof, clear envelope.

5.6 USCG Inspection and Acceptance

5.1. The Contractor shall be responsible for the

performance of any inspection and test requirements.

Inspection shall take place at Destination. Final acceptance shall be made by a Government representative at Destination. Acceptance shall be contingent upon verification of no damage in transit, correctness and completeness of the order, and conformance to the preservation, packaging, and marking requirements as outlined herein.

5.7. FAILURE TO COMPLY:

Failure to prepare for shipment any item, and/or mark all packages, boxes, etc., as indicated herein shall result in rejection of the shipment and return of the shipment at the contractor’s expense.

6.0 NOTES

6.1 GOVERNMENT & COMMERCIAL DOCUMENT SOURCES

6.1.1 GOVERNMENT DOCUMENTS

a. Surface Forces Logistics Center

2401 Hawkins Point Rd.

Baltimore, MD 21226-1792

Allen Tillman

410-762-6830

6.1.2 COMMERCIAL DOCUMENTS

a. Mobile Electric Power Solutions, Inc

2623 National Circle

Garland, TX 75041

(972) 864-1015

b. American Society for Testing Materials (ASTM)

100 Barr Harbor DR.

P.O. Box C700

West Conshohocken PA. 19428-2959

6.2 APPENDICES - The following appendices apply:

a. Appendix A: Core Condition Report

b. Appendix B: Disassembly Report

c. Appendix C: Cumulative Tracking Report

d. Appendix D: Replacement Parts List

e. Appendix E: Warranty Sheet

f. Appendix F: Government Furnished Property Report

APPENDIX A

Work Order #_________________________________

Port/Stbd ____________________________________

Delivery Order #_______________________________

MEPS/ACU Serial # ________________________________

Core Acceptance is based on the following:

a. Core must have no non-operational damage

b. Core must be a complete unit and not disassembled

NOTE: Missing parts from Appendix A are to be replaced and priced as per section B of this contract.

a. Core acceptable_______________________, non-acceptable_____________

Remarks _______________________________________________________

b. Shipping crate: Acceptable__________, non-acceptable_____________

Remarks _______________________________________________________

APPENDIX B

Delivery Order Number:_________________

Date:_________________________________

MEPS/ACU Serial Number:_____________________

Reason for Replacement

Qty Part No. Part Description Unit Price Amount

Total

APPENDIX C

CUMULATIVE TRACKING REPORT SUBMIT BY THE 15TH OF THE MONTH

MEPS/ACU

Serial

Number

Work #

D/O #

Date

Received

Core

Accepted

Y/N

APPENDIX D

REPLACEMENT PARTS LIST

GENERATOR & ACU

Manufacturer: MEPS

Component NSN/Part Number

Generator 8kW 2920-01-644-6491/7102252-00

Generator 6.3kW 7632002‐5 ACU 8kW 2920-01-644-6478/8806124-300

ACU 10kW 2920-01-658-3064/4106023-21

MANDATORY REPLACEMENT PARTS LIST

No. Description Part No. Qty.

Bearing (Gen) 6305 01

Bearing (Gen) 6203 01

Slip Ring (Gen) 01

Brush Set (2) (Gen) 01

ADDITIONAL REQUIRED REPLACEMENT PARTS LIST

APPENDIX E

WARRANTY NOTICE

This item has a warranty for whichever comes first:

1 year of operation from installation onto the USCG vessel

Or

1000 hours of operation

If any discrepancies are noted upon receipt

1. DO NOT REPAIR OR REPLACE!

2. CALL: USCG SURFACE FORCES LOGISTICS CENTER

ASSET MANAGEMENT SECTION 2

SMALL BOAT PRODUCT LINE (SBPL)

COMMERCIAL (410) 762-6062/6130/6390

Have the following information ready when calling the (SBPL)

________ Date Received ________ Date Installed

________ Serial No. ________ Vessel Home Port

________ Engine Hours ________ Vessel Hull No

3. A Report of Discrepancy (ROD) Form 364 must also be submitted to Surface Forces Logistics

Center.

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.