Specification_R-233-0320_updated_2017.docx

ATTACHMENT

No.

REVISION No.

G CHANGE No.

SPECIFICATION

FOR

THE

INSPECTION

AND

OVERHAUL

OF

WOODWARD

GOVERNORS

USED ONBOARD VARIOUS

COAST GUARD

VESSELS

R-233-0320

ORIGINATED

BY

B

Staab

DATE

06/

ORIGINATOR'S

COMMAND

ENGINEERING

LOGISTICS

CENTER

(ELC)

DEPARTMENT/DIVISION AUXILIARY EQUIPMENT BRANCH

UPDATED

BY

B.M. Andrews

(Revision

G)

Supply

DATE

08/ 2017 .

INTERNAL

REVIEWER

Gary

Pehrson, Wayne

Nickel, Andy

Ollerman

DATE

08/ 2017 .

SOWRB

APPROVAL

DATE

Attachment C

SPECIFICATION FOR THE INSPECTION AND OVERHAUL OF WOODWARD

GOVERNORS USED ONBOARD VARIOUS COAST GUARD VESSELS

1.0 SCOPE

1.1. This document sets forth the requirements for the receipt, disassembly, inspection, condition report, overhaul, reassembly, calibration, testing, preservation, packaging, packing, and marking of Woodward Governors used onboard various Coast Guard vessels.

1.2. GOVERNMENT FURNISHED PROPERTY (GFP) - The listed items are managed by U. S. Coast Guard Surface Forces Logistics Center, Baltimore, MD.

1.2.1. The Contractor shall provide protective storage for the GFP when not in use and safe handling when in use. The storage area shall, at a minimum, be closed on all sides, dry, and locked when the property is not in use.

Para-

8510-177 378 WHEC, MGT Over Speed

8554-052

400 WAGB,MDE

USCG

SFLC

DATE

06/2003

R-233-0320

REVISION

G 08 /2017

PAGE

of

2.0 APPLICABLE DOCUMENTS

2.1. GENERAL – The documents listed in this section are specified in sections 3, 4 or 5 of this 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 insure the completeness of this list, document users are cautioned that they must meet all specified requirements of the documents cited in section 3, 4, or 5 of this specification, whether or not they are listed here.

2.2. GOVERNMENT AND COMMERCIAL 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 Department of Defense Single Stock Point of Specification and Standards (DODSSP) and supplements thereto. The Coast Guard does not possess or have access to Original Equipment Manufacturer (OEM) documents pertaining to the inspection, repair or testing of these pumps. It is the responsibility of the vendor to obtain all the required documents from the OEM.

2.2.1. Coast Guard Specifications – United States Coast Guard SFLC Specification D- 000-0100 Rev G dated 02/2006, Bar Coding for USCG Surface Forces Logistics Center Procured Material.

2.2.2. DoD 4140.01-M-1, Dated 7 Sep 2007; Compliance for Defense Packaging: Phytosanitary Requirements for Wood Packaging material (WPM).

2.2.3. American Society for Quality (ASQ) – ASQ Q9001-2008, dated 2008, Quality Management Systems-Requirements.

2.2.4. National Conference of Standards Laboratories (NCSL) – NCSL Z540.3-2006 dated 01/01/2006, Requirements for Calibration Measuring and Test Equipment.

2.2.5. Woodward Governor Company

a. Bulletin number 25075A (dated 1975), Commercial Preservation Packaging for Storage of Mechanical-Hydraulic Controls.

b. Test Specification (TSP) for each governor listed in paragraph 1.2.1. a. through s.

c. Calibration Data, Woodward PG-TRTL Governor TSP 1230, post Fleet Rehabilitation and Modernization (FRAM) modified for Woodward p/n 8571- 584 (378 WHEC, Main Diesel Engine).

d. Test Record for p/n 8571-584 (378 WHEC, Main Diesel Engine) TSP 10652, FM FRAM modified.

e. Test Record for p/n 8570-378 (400 WAGB, Main Diesel Engine) TSP 329, Sheet 425, 425A, 425B, E/C 86136; Attachment 2 of this specification.

f. Test Record for p/n 8540-569 and 8540-619 (175 WLM, Main Diesel Engine) TSP 10257MH "Revised Test Specifications 3161 Governor Used on the 175 WLM MDE.

2.3. 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. Nothing in this document, however, supersedes applicable laws and regulations unless a specific exemption has been obtained.

3.0 REQUIREMENTS

3.1. GENERAL - Inspections, overhaul and testing of each governor shall be accomplished in accordance with the Original Equipment Manufacturer (OEM) procedures, specifications, references and standard practices and all applicable documents listed in section 2.0 of this specification.

3.1.1. It is the Contractor’s responsibility to obtain the OEM procedures, specifications, references, standard practices and Woodward Test Specifications from Woodward Governor Company, the OEM.

NOTE: The Contractor shall obtain and be in possession of these documents prior to the start of any work.

3.1.2. The overhaul requirements described herein are considered the minimum necessary and are not intended to replace any procedures, controls, examinations, or tests normally employed by the Contractor to assure the quality of the product. The overhaul of the governors is intended to return the governor’s performance and appearance to a like new condition.

3.2. GOVERNOR RECEIVING REPORT- Upon receipt of each governor the Contractor shall uncrate and remove any preservative and all protective coverings to prepare the governor for a detailed disassembly inspection.

3.2.1. The Governor Receiving report shall contain the arrival date and time the governor was received as well as the name of person who signed for the governor. The Governor Receiving report shall also contain a listing of the quantity, part number and serial number of the governors.

3.3. DISASSEMBLY INSPECTION - Each governor received by the Contractor shall be disassembled and inspected to determine the total estimated cost to repair including material, labor and testing costs. A detailed report shall be compiled and submitted to the Contracting Officer to include the following information:

a. Date of inspection

b. Inspector’s name

c. Identification of each governor by serial number, part number, and stock number

d. Condition of shipping crate and cost of any repairs. The Contractor shall conduct a thorough inspection of the shipping crate to ascertain any needed repairs up to and including a complete replacement of the shipping container. If the as received condition allows for re-use with minimal repairs, the Contractor shall confirm that the shipping crate/packaging conforms to the Phytosanitary Requirements for Wood Packaging Material (WPM) in accordance with paragraph C2.1.1 of DoD 4140.01-M-1, Compliance for Defense Packaging, Ref. 2.2.2 of this specification.

e. List of each part requiring replacement, by actual part number, and their applicable costs

f. Cost of overhaul labor

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

h. Configuration/upgrade recommendations and their associated costs.

i. Inspection data sheets describing all deficiencies found and the proposed corrective action.

j. Dimensional inspection noting all items that are out of tolerance.

k. Annotate if the governor is configured for a lifting eye and if it has a lifting eye installed.

3.3.2. The estimate shall include all material, parts, labor, testing, preservation, packing, packaging and marking costs.

3.4. OVERHAUL REQUIREMENTS – Each governor shall be overhauled, calibrated, and tested in accordance with the documents cited in section 2.0 of this specification.

a. All replacement parts shall be new and manufactured in accordance with Woodward Governor Company, the Original Equipment Manufacturer (OEM).

b. Each overhauled governor shall be restored to the performance and operating standards of a new governor.

c. Each overhaul shall include disassembly and cleaning of all parts of all contaminants including but not limited to dirt, grease, oil and paint.

d. All gaskets, seals, o-rings, bearings, and parts worn or damaged beyond manufacturer’s tolerances shall be replaced.

e. Each governor shall be assembled by Woodward Governor factory trained service technicians to insure that all OEM specified clearances, procedures, calibrations and torque values are applied.

f. Each data plate shall be updated to reflect the newly overhauled configuration.

g. Each governor that is configured with a lifting eye “threaded socket” shall have a lifting eye installed.

3.4.1. The following applies to Governor (378 WHEC, Main Diesel Engine) p/n 8571- 584, paragraph 1.2.1.e. of this specification.

a. This governor shall be calibrated to meet TSP 1230, (post FRAM modified) and tested in accordance with TSP 10652, FM FRAM modified.

3.4.2. The following applies to Governor, Diesel Engine, p/n 8575-262 (210B WMEC), NSN 2990-01-148-9821 paragraph 1.2.1.h of this specification.

a. All governors arriving at the Contractor’s facility marked with part numbers 369413, 8558-555, or 8571-624 shall be repaired, configured, calibrated, marked and upgraded in accordance with new Woodward spec 8575-262. This new part number (8575-262) specifies (but is not limited to) the following new settings:

1. Removal of the droop linkage as per new Bill of Material (see Woodward Data Sheet)

2. 10 psi governor setting: 440-460 rpm governor speed

3. 59 psi governor setting: 1074-1084 rpm governor speed

4. High speed dump valve setting of 1130-1140 governor rpm

5. Zero psi air idle: 432-437 governor speed

3.4.3. The following applies to Governor, Diesel Engine, p/n 8570-378 (400 WAGB, Main Diesel Engine), NSN 2990-01-225-7497, paragraph 1.2.1.k of this specification.

a. See Attachment 2, TSP 329, Sheet 425, 425A, 425B, E/C 86136

3.4.4. The following applies to Governor, Diesel Engine, p/n A8540-619 (175 WLM, MDE), NSN 2910-01-430-0125, paragraph 1.2.1.r of this specification.

a. This governor shall be calibrated to function properly on a Caterpillar 3508 Propulsion Diesel Engine with serial number prefixes: 9WN, 3HM and 3HW; Woodward part number 3161.

b. If not previously accomplished, indicate the special calibration by annotating the Woodward part number on the label plate (WG CO PART NO) with the suffix "GA" after the Woodward part number (Ex: 8540-619 GA

3.5. FINAL ACCEPTANCE TEST - Each overhauled governor shall be tested at an authorized Woodward Governor test facility. Each governor shall be calibrated to meet the current applicable Woodward TSP except as modified in paragraph 3.4 of this specification.

3.5.1. A detailed test report shall be compiled and submitted to the Contracting Officer for approval, to include the following information:

a. Date of test

b. Tester's name

c. Identification of each governor by serial number, part number, and stock number

d. Comments, if any, pertaining to any unusual observations during testing

e. A chronological list of all tests and calibrations performed with the resultant values/readings including pass/fail criteria.

f. Dimensional report with all final clearances and tolerances.

g. Signature of Government witness, if any.

3.6. NOTIFICATIONS & INSPECTIONS - The Contractor shall notify the Contracting Officer at least ten (10) calendar days prior to any inspections or testing required herein.

4.0 QUALITY ASSURANCE

4.1. RESPONSIBILITY FOR INSPECTION - The Contractor is responsible for the performance of all inspection requirements specified herein. The Contractor shall provide space, personnel and test equipment needed to conduct all required inspections. All inspections and testing shall be performed at the Contractor's plant or at other facilities acceptable to the Coast Guard. The Coast Guard reserves the right to verify or have performed any of the inspections set forth in this specification where such inspections are deemed necessary to assure that supplies and services conform to the prescribed requirements.

4.2. RESPONSIBILITY FOR COMPLIANCE - All items shall meet the requirements of this specification. 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 this specification shall not relieve the Contractor of the responsibility of assuring that all products or services 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.

4.3. QUALITY SYSTEM - The contractor shall maintain a documented Quality System in accordance with ANSI/ASQ Q9001-2008.

4.4. INSPECTIONS AND TESTS - The inspections and tests required herein are the minimum required and are not intended to replace any controls, examinations, inspections or tests normally employed by the Contractor to assure the quality of the equipment.

4.4.1. Arrival/Disassembly Inspection in accordance with paragraph 3.2.

4.4.2. Final Acceptance Test in accordance with paragraph 3.4.

4.5. CALIBRATION SYSTEM - The Contractor, as well as any subcontractors, shall maintain a test equipment calibration program conforming to NCSL Z540.3-2006. The calibration system records shall be maintained for inspection for the duration of any contract referencing this specification.

4.6. FAILURE RESPONSIBILITY - If a governor fails to pass any inspection or test, the Contractor shall report the failure and the recommended corrective action to the Contracting Officer. If approved, the corrective action on the materials or processes shall be accomplished in accordance with this section.

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

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

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

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

4.6.5. 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.

4.7. TEST AND INSPECTIONS - The Contractor shall demonstrate, in the presence of the USCG Quality Assurance Representative that each governor overhauled under this contract has been calibrated in accordance with, and meets the parameters of the current applicable Woodward MASTER TSP as modified in paragraph 3.3 of this specification.

4.8. REPORTS - One copy of any required inspection, test or tolerance check shall be sent to the Contracting Officer and the COR, including one copy of the most current MASTER Woodward TSP for each governor covered herein.

4.8.1. A copy of any test, inspection, or calibration record, and the current Woodward TSP for the governor to be tested shall also be turned over to the Quality Assurance Representative (QAR) upon his arrival at the Contractor's plant.

a. A copy of the report, signed/stamped by the QAR, shall be packed in the crate with each governor.

b. Additionally, the internal wiring diagram shall be packed in the crate with each governor.

4.9. PACKING INSPECTION – The Contracting Officer shall be notified prior to the packing and marking of the completed units in accordance with section 3.5 of this specification.

5.0 PRESERVATION, PACKAGING, PACKING AND MARKING (PPP&M)

5.1. PRESERVATION – All governors shall be preserved and packaged in accordance with Woodward Governor Company bulletin 25075A, dated 1975 titled Commercial Preservation Packaging for Storage of Mechanical-Hydraulic Controls, Attachment 3.

5.1.1. Each governor shall be completely assembled and ready for installation.

5.1.2. All openings shall be sealed with plastic caps.

5.2. PACKAGING & PACKING

5.2.1. Each overhauled and preserved governor shall be sealed in accordance with Woodward Governor Company bulletin 25075A.

a. A copy of the test, inspection/calibration record and TSP, signed/stamped by the Coast Guard QAR, shall be packed in the crate with each governor.

b. Additionally, the internal wiring diagram shall be packed in the crate with each governor.

5.2.2. Each overhauled, tested and preserved governor listed as GFP in paragraphs 1.2.1.a.,1.2.1.d., 1.2.1.e., 1.2.1.f., 1.2.1.g., 1.2.1.h., 1.2.1.i., 1.2.1.k., 1.2.1.l., 1.2.1.m., 1.2.1.o., 1.2.1.r., 1.2.1.s.shall be individually packed in a wooden box, constructed as described and pictured in Attachment No. 1, Pictures 1 thru 9.

5.2.3. If the Contractor deems the containers the governors were received in to be in compliance with paragraph 5.2 and 2.2.2 of this specification, the containers can be reused.

5.2.4. Should new containers be required, or existing containers repaired, labor and material costs to accomplish this shall be listed on the Arrival/Disassembly Inspection Report as described in paragraph 3.3 of this specification.

a. All packaging and packing material shall meet the Phytosanitary Requirements for WPM in accordance with paragraph C2.1.1. of DoD 4140.01-M-1, Compliance for Defense Packaging, (section 2.2.2. of this specification).

b. The lower (skid) base shall be constructed of 4” X 4” solid lumber skids (2 each) and ¾” X 20” X 20” plywood, with a ¾” X 1 ¾” X 20” nailer strip screwed to the front and back of the base to allow the cover to be attached (screwed) to it (see picture No. 1, Attachment 1).

c. The unit base shall be constructed of 3/4” X 16” X 16” plywood and 2” X 4” solid wood supports (see picture’s No. 2 & 3, Attachment 1). The unit base may require a hole of sufficient diameter to allow passage of the drive shaft of the governor.

d. The governor shall be attached to the unit base, through the governor base plate, using 4 - 3/8” X 2.5” bolts (minimum), 8 washers, 4 lock washers, and 4 nuts.

e. The top and sides (boxed cover) of the crate shall be constructed using ½” plywood and 2” X 4” solid wood framing (see picture No. 4, Attachment 1). CRES Phillips Head wood decking screws shall be used to attach the boxed cover to the skid base. The screws that require extraction in order to remove the boxed cover shall have a red painted area around them, approximately 1 inch in diameter for visibility. (See picture No.10, Attachment 1)

f. The finished crates shall be 21” X 21” X 40”.

g. The crates shall be assembled using CRES Phillips Head wood decking screws (no nails are to be used).

h. After the governor is sealed in accordance with Woodward Governor Company bulletin 25075A and after the governor is packed in accordance with 5.2.4. a. through f. above, the void between the governor and crate sides and lid shall be filled with spray foam.

5.2.5. Each overhauled, tested and preserved governor listed as GFP in paragraphs 1.2.1.b., 1.2.1.c., 1.2.1.j., 1.2.1.n., 1.2.1.p., 1.2.1.q., shall be individually packaged and packed in wooden boxes constructed of 1/2” plywood, minimum, with internal or external support bracing.

a. A clearance of not less than 2” shall be allowed between the governor and the closest member of the sides, ends or top of the crate.

b. Bubble wrap or spray foam shall be used as packaging material of adequate thickness so as to properly cushion the governor to prevent damage and not to allow movement of the governor within the wooden crate.

c. The crates shall be assembled using CRES Phillips Head wood decking screws (no nails are to be used).

5.3. MARKING - The marking described herein shall be placed on the longest two sides of each box (on opposite ends). The lettering shall be black painted stencil and permanently affixed to each container. The lettering shall be at least 3/4" high, and be applied on a highly contrasting white painted background.

5.3.1. All previous markings and Quality Assurance Decals shall be completely removed from the reusable shipping container prior to application of any new markings.

5.3.2. This marking shall consist of the following information.

RE-INSPECTION DATE 60 Months from Overhaul Date

COAST GUARD SFLC MATERIAL REUSABLE CONTAINER

DO NOT DESTROY

5.3.3. Stenciling on each crate shall be as pictured in picture Nos. 5, 6, 7, & 8, except the Contractor shall include the appropriate stock number and part number for each applicable governor enclosed. Additionally, the stenciling shall be applied to a contrasting white painted background.

5.4. BAR CODING – Two Bar Code labels shall be attached to each governor shipping container (opposite sides) prior to shipment from the Contractor’s facility.

5.4.1. All bar coded labels shall be in accordance with SFLC specification D-000-0100.

a. The actual labels shall be Type “V”, Grade “A”, Style “2”, Composition “b” with plastic laminate.

6.0 NOTES

6.1. GOVERNMENT & COMMERCIAL DOCUMENT SOURCES

6.1.1. GOVERNMENT DOCUMENTS

a. USCG Surface Forces Logistics Center 2401 Hawkins Point Road Baltimore, MD 21226-5000 410-762-

b. Department of Defense Single Stock Point (DODSSP) 700 Robbins Avenue Building #4, Section D Philadelphia, PA 19111-5098

FAX 215-697-9398

http://dodssp.daps.dla.mil/

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

Philadelphia, PA 19120 215-697-2197

6.1.2. COMMERCIAL DOCUMENTS

a. Woodward Governor Company 3800 north Wilson Ave. P.O. Box 3800 Loveland, CO 80539-3800 970-663-3900

b. American Society for Quality (ASQ) 611 E. Wisconsin Ave., P.O. Box 3005 Milwaukee, Wisconsin 53201-3005 800-514-1564 http://asq.org/

c. National Conference of Standards Laboratories (NCSL) 2995 Wilderness Drive, Suite 107 Boulder, CO 80301-5404 303-440-3339

FAX 303-440-3384

info@ncsli.org

d. American National Standards Institute (ANSI) 25 West 43rd Street (Between 5th and 6th Avenues) 4th Floor New York, NY 10036 212-642-4900

FAX 212-398-0023

www.ansi.org

USCG

SFLC

DATE

06/2003

R-233-0320

REVISION

F 09 /2014

PAGE

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