Attachment_1_-_R-644-0635_Overhaul_Spec.doc

USCG – SFLC

SPEC: R-644-0635

DATE: 8/2017

REVISION No. . CHANGE NO. .

OVERHAUL OF U.S. COAST GUARD 87’ WPB

WATER CLOSETS

R-644-0635 ORIGINATED BY: W. L. Bohnak (PBPL) . DATE 3/2012 .

UPDATED BY: Joshua Meese (PBPL) . DATE 8/2017 .

ORIGINATOR’S COMMAND Surface Forces Logistics Center (SFLC) .

DEPARTMENT / DIVISION Patrol Boat Product Line (PBPL) .

INTERNAL REVIEWER . DATE .

SFLC QA APPROVAL . DATE .

SWORB APPROVAL . DATE .

1.0 SCOPE

1.1. General – This overhaul specification sets forth the requirements for the receipt, cleaning, disassembly, inspection, condition/test reports, overhaul, reassembly, testing, preservation, packaging, packing, marking and bar-coding of the Water Closets used on 87’ WPB Coast Guard vessels.

1.2. Government Furnished Property (GFP) – The listed item is managed by the Coast Guard Surface Forces Logistics Center at Curtis Bay, MD.

a. National Stock Number:

NSN: 4510-01-574-8421

Item Name:

Water Closet Part Number:

5470513 Manufacturer:

Evac Oy Application:

87' WPB Sanitation System

1.2.1. Descriptive Data – Water Closet, Compact Base unit, Stainless Steel. Unit consisting of the following major parts; disc valve, regulator, cable harness, check valve, sluice filter, and water filter.

a. All references to water closet shall include all internal parts listed above. The cost estimate and overhaul shall include these items.

2.0 APPLICABLE DOCUMENTS

2.1. General – The documents listed in this section are specified in sections 3, 4, and 5 of this overhaul specification. This section does not include documents cited in other sections of this specification or recommended for additional information or as examples. While every effort has been made to ensure the completeness of this list, document users are cautioned that they must meet all specified requirements cited in sections 3, 4, and 5 of this specification, whether or not they are listed.

2.1.1. Government Documents – The following specifications, standards, publications, and handbooks form a part of this overhaul specification to the extent specified herein. Unless otherwise specified, the versions in effect are those listed in the GSA Index of Federal Specifications, Standards and Commercial Item Descriptions or the current Department of Defense Single Stock Point of Specifications and Standards, (DODSSP), and supplements thereto, cited in the solicitation or contract.

2.2. Coast Guard Documents – The following documents form a part of this overhaul specification to the extent specified herein. The documents listed shall be by title and effective date unless otherwise documented.

2.2.1. Specifications

a. USCG-SFLC SPECIFICATION D-000-100 Rev. G, Change 1, Dated 02/06, Bar Coding for USCG Surface Forces Logistics Center material.

2.2.2. Technical Publications

a. TP 4529, Compact Vacuum Toilet 500 series

2.3. Other Government Documents – The following documents form a part of this overhaul specification to the extent specified herein. The documents listed shall be by title and effective date, unless otherwise documented.

2.3.1. Military Performance Specifications

a. MIL-PRF-81309F, Dated 3/31/2005 – Corrosion Preventative Compounds, Water Displacing, Ultra-Thin Film.

2.4. Commercial Documents – The following documents form a part of this overhaul specification to the extent specified herein. The documents listed shall be by title and effective date unless otherwise documented.

2.4.1. National Conference of Standards Labs (NCSL)

a. NCSL Z540.3-2006 – Dated 1/1/2006, Calibration Laboratories and Measuring Equipment

2.4.2. American Society for Quality (ASQ)

a. ASQ Q9001-2008, Dated 1/1/2008, Quality Management Systems - Requirements

2.5. Document Availability – To obtain the referenced documents see section 6.1.

2.6. Order of Precedence – In the event of a conflict between the text of this overhaul specification and the references cited herein, this specification shall take precedence, unless otherwise specified herein. Nothing in this specification, however, supersedes applicable laws and regulations unless a specific exemption has been obtained.

3.0 REQUIREMENTS

3.1. General – Contractor shall provide all labor and materials to perform overhaul services on the Evac Oy water closet compact base unit vacuum toilet, listed in section 1.2 and in accordance with all applicable documents listed in section 2.0 and this specification.

3.2. Responsibility for GFP – 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, protected from the weather and locked when the equipment is not in use or being serviced.

3.3. Arrival Inspection – Contractor shall conduct an arrival inspection to determine the water closet conforms to the description in section 1.2.

3.3.1. The assembly delivered for overhaul services is intended to be a complete Evac Oy water closet (compact base unit) without seat or shroud.

3.3.2. The Contractor shall notify the Contracting Officer via Condition Found Report (CFR) within five (5) calendar days of receipt verifying the units received are correct and identify any missing components, incorrect items or, otherwise questionable conditions that may hinder the overhaul process or the make and/or model delivered for overhaul services do not conform to the intended make and/or model cited in section 1.2.

a. If after arrival inspection the item received is not as listed in section 1.2 the Contractor shall prepare the item for shipment back to SFLC Baltimore, MD in accordance with the Contracting Officer’s instructions.

3.4. Initial Disassembly, Inspection and Estimate (Standard Overhaul) – Contractor shall disassemble, clean and inspect the water closet to obtain the overall condition and determine the estimated cost of a standard overhaul. A detailed CFR and overhaul plan including mandatory replacement parts, materials, labor, overhaul, testing, preservation, packaging, packing, marking, bar-coding and crate repair or replacement costs if necessary shall be submitted to the Contracting Officer for approval within 15 days of receipt. Overhaul is intended to restore the water closet to a condition that is equal to that of a new Evac Oy compact base unit, model 500 series; part number 5470513. Contingency replacement parts shall be listed, priced and submitted with the initial inspection report and estimate. No further work shall be accomplished until the report is approved in writing by the Contracting Officer.

Note: Previous overhauls of these water closets revealed instances where the units were not completely cleaned of all foreign matter. The Contractor shall make sure all components are completely and thoroughly clean and disinfected of all material not associated with the water closets even if it entails replacing components that cannot be thoroughly cleaned and disinfected.

a. The initial inspection CFR and overhaul plan shall consist of, at a minimum, the following information:

1. Date of Inspection

2. Identification of base units by serial number, part number and stock number.

3. Condition of shipping crate and any cost for repair or replacement.

4. Pricing for standard overhaul.

5. List and pricing of any contingency parts, if required.

6. Overhaul labor hours

7. Labor rate.

8. Comments if any pertaining to unusual observations during inspection and disassembly.

3.5. Replacement Parts – All replacement parts used for this specification shall be new Original Equipment Manufacturer (OEM) parts. Reclaimed, recycled or aftermarket parts are not acceptable and shall not be used. The overhaul facility or any sub-contractors shall not manufacture parts to be used on overhauled assemblies.

3.5.1. Mandatory Replacement Parts: The mandatory replacement parts listed in enclosure 1 shall be replaced on each water closet unit regardless of condition. The overhaul of the water closet using only mandatory replacement parts will constitute a standard overhaul.

3.5.2. Contingency Replacement Parts: The contingency replacement parts listed in enclosure 1 shall only be replaced as needed if the Contractor determines the parts are worn or damaged. The contingency parts shall be listed separate from the mandatory replacement parts for a standard overhaul.

3.5.3. Label Plates: A new label plate shall be used if the original plate is not legible or in poor condition. The label plate shall contain water closet unit make, model and serial number as well as all water closet performance information as a minimum requirement.

3.6. Water Closet Disposition – The Coast Guard shall determine the disposition of any water closet unit delivered to the overhaul facility that is found to be not suitable for overhaul for whatever reason.

3.6.1. If the Contracting Officer deems the water closet unfit to overhaul one of the following options shall be used to dispose of the water closet at the Contracting Officer’s discretion:

a. Reassemble, repackage, mark “Condition S” and return the water closet to USCG SFLC Baltimore, MD as scrap.

b. Contractor to scrap on site. Contractor shall retain all parts for Coast Guard review and dispose of per Contracting Officer.

c. The Contractor may provide pricing to replace any water closet deemed unfit for overhaul. The water closet shall be the exact make and model as listed in section 1.2 and meet the requirements of section 5.0.

3.7. Testing Requirements – After completion of overhaul, Contractor shall conduct an operational test of water closet assembly in accordance with OEM testing requirements per the Manufacturers Technical/Service Manuals. All testing shall be accomplished using Contractor supplied calibrated test equipment. Any failed water closet assembly shall be corrected and re-tested as necessary until a successful test is achieved.

3.8. Final Inspection and Test Report – A detailed final inspection and test report shall be submitted to the Contracting Officer via CFR for approval prior to scheduling SFLC quality assurance personnel. A copy of the inspection and test report shall be turned over to the Coast Guard Quality Assurance representative upon arrival for final inspecting and testing. The inspection and test report shall contain the following information as a minimum:

a. Contractor name, address and telephone number.

b. Contract number and delivery order number as applicable.

c. Water Closet unit model & serial number.

d. Date of test

e. Description and results of each test conducted including test fluid used.

f. Name of the person conducting the testing.

g. Test equipment used, nomenclature, serial number, and calibration date.

3.8.1. The inspection report shall depict the final condition of the water closet assembly after all work has been completed.

3.8.2. All defects if any, even those deemed acceptable, shall be documented on the inspection report.

3.8.3. Contractor shall provide written certification the water closet was reconditioned to the same standards as new. One copy shall be place in the crate with the water closet in a water proof envelope and one copy shall be provided to the Contracting Officer.

3.9. Calibration – All test equipment and attached gages shall be calibrated and have a current calibration sticker attached. Calibration shall be traceable to National Standards.

3.10. Assembly – The overhauled water closet assembly shall be delivered to the Coast Guard completely assembled, clean and disinfected and ready for installation. The Contractor shall preserve, package, pack, mark and bar-code each water closet assembly in accordance with section 5.0 of this specification.

3.10.1. Contractor shall supply a waterproof instruction sheet containing the manufacturer’s set up procedure. The sheet shall be placed with the water closet inside a polyurethane bag.

3.11. Notifications and Inspections – Contractor shall notify the Contracting Officer no less than ten (10) calendar days prior to any required inspections and/or monitored testing required herein by Coast Guard Quality Assurance (QA) personnel.

4. QUALITY ASSURANCE

4.1. General – 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, meet the requirements of ASQ-Q9003 and be available for review by the Coast Guard.

4.1.1. The Quality Assurance Plan shall be submitted to the Contracting Officer for review and approval prior to contract award. Once approved, the plan need not be re-submitted unless changes are requested.

4.2. Records – Contractor shall maintain records of all inspections and tests. The records shall indicate the nature and number of performed observations, the number and type of deficiencies found and the corrective action taken.

4.3. Calibration System – Contractor, as well as any subcontractors, shall maintain a test equipment calibration program in compliance with NCSL Z540.3. The program shall be documented and traceable to the National Institute of Standards and Technology (NIST).

4.3.1. The calibration system records shall be maintained for inspection for the duration of any contract referencing this overhaul specification.

4.4. Responsibility for Inspection – Contractor shall be responsible for the performance of all inspection requirements specified herein. Contractor shall provide space, personnel and test equipment to conduct all inspection requirements. All inspection and testing shall be performed at the Contractor’s facility prior to the Coast Guard’s acceptance of the contracted items. 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. Contractor shall notify the Contracting Officer prior to the scheduled commencement of any inspections required by this overhaul 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 requirement in this 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 & Tests – The inspections & tests required herein are the minimum necessary and are not intended to replace any controls, examinations, or tests normally employed by the Contractor to assure the quality of the product. The following inspections and documentation may be witnessed or observed by an SFLC Quality Assurance Representative IAW section 3.0 of this overhaul specification at the discretion of the Contracting Officer:

a. Test requirements as described in section 3.7.

b. Calibration certificates as listed in section 3.9.

c. Inspection of preservation, packing, packaging, marking and bar-coding in accordance with section 5.0.

4.7. Failure Responsibility – If a water closet assembly fails to pass any inspection or test, the Contractor shall report the failure and their recommended fix to the Contracting Officer. If approved, the corrective action on the materials or processes shall be taken in accordance with this section.

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

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

4.7.2. After all corrective action has been taken the inspection/test shall be continued or repeated at the option of the Contracting Officer.

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

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

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

4.8. Test & Inspection Reports – A copy of any standard Contractor test or inspection report shall be submitted to the Contracting Officer.

4.9. Warranty – The Contractor’s standard new water closet warranty applies.

4.10. Packing and Packaging Inspection – The Contracting Officer shall be notified ten (10) days prior to the packing, packaging, marking and bar-coding of the overhauled water closet.

5.0 PRESERVATION, PACKAGING, PACKING, MARKING AND BAR-CODING

5.1. General – Each overhauled water closet shall be disinfected and cleaned, preserved, packaged, packed, marked and bar-coded as specified herein.

5.2. Preservation – Each overhauled water closet assembly will be placed in warehouse storage and not for immediate installation. The overhauled water closet assembly shall be individually preserved and wrapped for protection against moisture and deterioration for a period of two (2) years minimum. It is critical the Contractor ensures the overhauled water closet undergo the preservation requirements as specified below:

a. Each water closet shall be drained of and dried of all water and/or test fluid.

b. Contractor shall spray a corrosion preventative, water displacing compound fog into the intake and discharge ports of the water closet assembly to prevent corrosion during storage. The compound shall meet or exceed the requirements of MIL-PRF-81309F Type II, Class 2, Grades a or b. The intake and discharge ports shall have red plastic cap inserts installed and taped in place as soon as fogging is completed.

c. Each water closet shall be bagged in two 8 mil minimum thickness translucent polyurethane bags with one 80 unit desiccant pack in the bag. The bag opening shall be sealed closed with a plastic tie wrap. If the unit is skid mounted using hold down bolts, small holes will need to be cut in the bags to allow for bolting the water closet down. These holes shall be sealed around each skid stud with silicon sealant and rubber gaskets to ensure the bag is sealed.

5.3. Packaging and Packing – Each overhauled and preserved water closet assembly shall be individually packaged in its own framed-in wooden crate. The crate shall be assembled with stainless steel wood screws. The water closet assembly shall be bolted to the inside of the crate and shall be constructed in such a manner as to prevent the water closet from shifting within the crate. Two part foam is required for the entire inside of the crate after the water closet is mounted inside the crate. The crate shall be capable of protecting the water closet assembly from damage during multiple shipments by commercial carrier and long term warehouse storage and handling.

5.3.1. Contractor shall put a waterproof instruction sheet describing the manufacturer’s set up procedures in a polyurethane bag in accordance with section 3.10.1.

5.4. Marking – The marking described herein shall be placed on the two longest sides of each box (on opposite ends) and include the requirements of section 5.5 of this specification.

5.4.1. Other than the marking required in 5.5, all markings shall be done via machine-made stencils where applicable. The lettering shall be at least 1/2” high, in permanent black print lettering on a painted white background.

NOTE: ALL PREVIOUS MARKINGS AND / OR QUALITY ASSURANCE DECALS SHALL BE COMPLETELY REMOVED FROM THE REUSABLE SHIPPING CONTAINER PRIOR TO THE APPLICATION OF ANY NEW MARKINGS.

5.4.2. These markings shall consist of the NATIONAL STOCK NUMBER, ITEM NAME, PART NUMBER, CONTRACT NUMBER, SHIPPING WEIGHT (in lbs.,) condition code ie. CONDITION “A”, unit of issue with quantity (1) and the words COAST GUARD SFLC MATERIAL.

a. The markings shall be in the format as follows:

National Stock Number:

NSN: 4510-01-574-8421

Item Name:

WATER CLOSET

Part Number:

5470513 Contract Number:

SEE CONTRACT

Shipping Weight:

CONTRACTOR PROVIDE

The following statement:

COAST GUARD SFLC

MATERIAL, CONDITION "A", 1 EA

5.5. Bar Coding – The National Stock Number (NSN) shall also be bar coded in addition to the markings required above. Bar coded labels shall be in accordance with SFLC specification D-000-100 Rev. G. The Bar Code Label can be applied separately or as part of the marking required in 5.4 of this specification.

a. The actual labels shall be Type "V", Grade "C", Style "2", Composition "a".

b. Each label shall contain encoded data for the National Stock Number.

5.6. Coast Guard Acceptance – Acceptance will be made at destination by a government representative. Acceptance will be contingent upon representative's verification of no damage in transit, correctness and completeness of order and Contractor’s conformance to preservation, packaging, packing, marking and bar-coding requirements.

6.0 NOTES

6.1. Government and Commercial Document Sources

6.1.1. Coast Guard Documents

a. USCG Surface Forces Logistics Center 2401 Hawkins Point Road Baltimore, MD. 21226-5000

(410) 762-6162 Attn: Dana Solomon Contracting Branch, Code PBPL-CPD www.uscg.mil/hq/elcbalt

6.1.2. Commercial Documents

a. National Conference of Standards Laboratories (NCSL) 2995 Wilderness Place Suite 107 Boulder, CO 80301-5404

(303) 440-3339 Fax: (303) 440-3384 www.ncsli.org

b. American Society of Quality Control (ASQC) 600 N. Plankinton Ave.

Milwaukee, WI 53203

(800) 248-1946 Fax: 414-272-1734 www.asq.org

6.1.3. Other Government Documents

a. Department of Defense Single Stock Point (DODSSP) Building 4, Section D 700 Robins Avenue Philadelphia, PA 19111-5094

(215) 697-6396/6257 Fax: (215) 697-9398 www.assist.daps.dla.mil/quicksearch Mandatory Replacement Parts OEM Part # Description

Contingency Replacement Parts

OEM Part # Description