Work_Item_2_-_Attachment_3_Rddr_R.DOC

WBN_0818

WORK ITEM 2: 2040-01-223-2674, Rudder, Repair

1. SCOPE

1.1 Intent. This supply item sets forth the requirements for the Receipt, Inspection, Overhaul, Packaging, Packing, Marking, Bar-Coding and Shipping of Rudders used on US Coast Guard 110' Coastal Patrol Boats.

1.1.1 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, unless otherwise specified herein. Nothing in this specification, however, supersedes applicable laws and regulations unless a specific exemption has been obtained.

1.2 Government Furnished Property (GFP). The listed items are property of and managed by the USCG Surface Forces Logistics Center, Baltimore MD and will be issued to the Contractor as issuance of a contract or contract delivery order.

P/N

CAGE

($/UNIT)

PN: 562-001-1

CAGE: 81340

PN: N/A

CAGE: N/A

PN: NS-19

CAGE: 79568

PN: USCG-RSK5-01.50

*Government-loaned property, which shall be returned to the Coast Guard upon completion of the contract.

**New or refurbished equipment that the Government may provide for installation in place of existing equipment.

***Government-furnished property, which is to be supplied by the Coast Guard.

2. REFERENCES

Coast Guard Drawings

Coast Guard Drawing 110C WPB-562-001, Rev. G, Rudder Details Coast Guard Publications

Surface Forces Logistics Center Standard Specification 0740 (SFLC Std Spec 0740), 2014, Welding and Allied Processes

Surface Forces Logistics Center Standard Specification 6310 (SFLC Std Spec 6310), 2014, Requirements for Preservation of Ship Structures Other References

MIL-STD-129R, 18 February 2014 Marking for Shipment and Storage

MIL-PRF-16173E, 17 October 2017, Corrosion Preventive Compound, Solvent Cutback, Cold- Application

MIL-A-22262 Revision B, 5 April 1993, Abrasive Blasting Media Ship Hull Blast Cleaning

DOD 4140.01-M-1, 7 Sep 2007; Compliance for Defense Packaging: Phytosanitary Requirements for Wood Packaging Material (WPM)

SAE International, SAE J 448-2011 Standard, Surface Texture

ANSI/ASQC Q9001-2015, DATED 2015 – Quality Systems – Requirements

ASTM D6880/D6880M-11, Dated 2011, Standard Specification for Wood Boxes

SSPC/NACE International (NACE), Joint Surface Preparation Standard SSPC-SP 10/NACE No 2, 2007, Near-White Blast Cleaning

ASTM A1011/ A1011M Rev A, 9/07 Edition, Standard Specification for Steel.

ANS/ISO/IEC 17025:2005, General requirements for the Competence of Testing and Calibration Laboratories

3. REQUIREMENTS

3.1 General. The Contractor shall provide storage for the GFP when not in use, and safe handling when in use.

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

3.1.2 Tech Rep. Not applicable.

3.2 Inspection. The Contractor shall carefully remove the rudder from the GFP wooden box and conduct a thorough inspection. A Condition Found Report (CFR) shall be submitted to the Coast Guard Contracting Officer (KO) within ten (10) days of receipt of GFP. The CFR shall include all inspection findings, test results as specified below, including any recommended repairs to return the rudder to serviceable “A” condition including repairs to or replacement of the wooden box. The CFR shall also include a breakdown of estimated cost of labor and materials for any repair work that is beyond the scope of work in this specification. No further work shall proceed until authorized by the KO.

NOTE

Serviceable “A” condition is defined as a reconditioned rudder meeting all required design specifications and design dimensions in accordance with Coast Guard drawing: 110C-WPB-562-001 and being capable of functioning and performing in the same manner as an identical new rudder although it may not have the appearance of a new rudder.

3.2.1 Visual inspection. While using Coast Guard drawing 110C WPB-562-001 and paragraph 3.5.1.1 of this requirement as guidance visually inspect the rudder for the following:

· Excessive wear on the stock bearing journal surfaces

· Straightness of stock and blade

· Key and Keyway excessive wear

· Any worn or damaged threats

· Corrosion and other mechanical defects

3.3 Paint removal. The Contractor shall abrasive grit blast all coated rudder surfaces to SSPC-SP 10/NACE No. 2 using grit conforming to MIL-A-22262 with a 3.0-4.0 mil profile. All pipe plugs shall be installed prior to grit blasting.

3.3.1 Rudder blade inspection. The Contractor shall:

3.3.1.1 Detection of previously applied double skin. Determine if any rudder delivered for repair has an existing double skin layer.

NOTE

An easy means of determining the existence of double skin is by Ultrasonic Test (UT) or by measuring the blade thickness at the trailing edge, which will measure approximately ¼” thicker than the drawing thickness dimension.

3.3.1.2 Ultrasonic test. Perform ultrasonic testing to the rudder to measure blade plate thickness. Take 20-30 UT shots on each side and log readings and location on CFR. Degradation in excess of 25% will render the rudder non-repairable.

3.3.1.3 Air pressure test. The Contractor shall conduct an air pressure test on the blade section after all the paint and primer are removed per section 3.3. Using a calibrated pressure gauge, test shall be performed at 1-1/2 PSI for a period of 30 minutes. If any pressure loss is noted, check porosity areas, plug threads, and all welds using a soapy water solution to expose leaky areas. The active formation of air bubbles on the blade surface indicates the presence of cavitation erosion damage. This condition needs to be repaired prior to acceptance. A second air test will need to be performed in order to ensure the void does not leak. All traces of soapy water solution shall be removed.

3.3.1.4 Rudders that show cavitation (erosion) damage, through double skin surface. Double skinning is considered a one-time process that shall not be repeated via a third skin layer. It is not considered cost effective or practical to strip off and replace the existing double skin layer.

· Any rudder showing cavitation damage through the double skin surface shall be determined as unserviceable with all further work discontinued on that rudder. This does not include leakage through welds addressed in 3.3.1.5

· Contractor shall cite all rudders that show the existence of porosity through the double skin layer in CFR.

3.3.1.5 Indicated leakage through welds. Rudders shall be serviceable if leakage is only found coming through welds but not through the skin surface. If air leaks are found through welds only, then the Contractor shall include the extent of weld leakage to the KO in the CFR with recommended repairs and cost. The Coast Guard shall determine if double skinned rudders having leaking welds should be repaired or scrapped based on the extent of leaks and cost to repair.

· The air pressure test shall be repeated on rudders that undergo weld leakage repair work (see 3.3.1.3). The cost of additional air test if required shall be covered under the repair

3.3.2 Rudder disposition. The Contractor shall secure, repackage and return any rudder the KO deems not repairable to the Coast Guard at the address listed in 5.7.1 unless otherwise directed. The wooden box shall be marked “H” condition as described in 5.5.2.

3.4 Welding certifications. The Contractor shall have welders qualified in accordance with Qualifications Standard for Welding and Brazing, and Welding and Brazing Operators per SFLC STD Spec 0740. Certification documentation shall be maintained and available to the KO, Contracting Officer’s Representative (COR) or Quality Assurance (QA) for review at any time during the contract period.

3.5 Rudder repairs. The Contractor shall:

3.5.1 Rudder stock. Starting at the top of the .750” radius where the stock meets the rudder blade, machine to undercut the stock diameter ¼”. Clad weld buildup ¼” with 309 stainless steel material. Undercut the 309 stainless steel clad weld 1/8” and clad weld back up with 308 stainless steel material to facilitate finish machining IAW drawing 110C WPB-562-001 Rev. G. The surface finish indicated on the drawing shall be in accordance with SAE J 448-2011 Standard. Polish all machined surfaces to a 32 RMS or smoother.

3.5.1.1 The allowed length tolerance for each segment of stock diameter shall be +/- 1/64” (.0156”).

3.5.2 Blade selection requirements for single skinned rudders.

3.5.2.1 Rudders delivered without double skin application shall be double skinned as part of the Contractors overall repair work.

3.5.2.2 Rudder blade shall be double skinned with new 1/8” thick ASTM A1011 steel plate.

· The new skin shall be formed tight against the original blade skin to follow the exact contour and curves of the rudder blade

· The double skin layer shall be attached through the use of continuous fillet and plug welds to form a watertight seal

3.5.2.3 The contractor shall perform Non-Destructive Testing (NDI) as required by SFLC STD Spec 0740 for all welds.

3.5.2.4 The contractor shall conduct an air pressure test of newly double skinned rudders in accordance with that as described in 3.3.1.3, paying particular attention to welded areas. Any leakage found during the air pressure test shall be corrected by welding with an additional air pressure test conducted after weld repairs are complete. This process shall be repeated until all leakage has been corrected.

3.5.2.5 The contractor shall abrasive grit blast the new double skinned surfaces to SSPC-SP 10/NACE No. 2 using grit conforming to MIL-A-22262 with a 3.0-4.0 mil profile. All pipe plugs shall be installed prior to grit blasting.

3.6 Rudder blade coating and painting. The Contractor shall:

3.6.1 Flow coating (interior). The rudder internal cavity shall be filled and drained (flow coated) with corrosion preventative compound that conforms to MIL-PRF-16173 Grade 3. Replace pipe plugs with new stainless steel plugs in accordance with drawing 110C WPB 562-001 Rev. G Rudder Details upon completion of flow coating. Flow coating of the internal rudder blade section shall be accomplished after all other repairs are complete.

3.6.2 Exterior painting. The Contractor shall:

3.6.2.1 Surface preparation. All rudders shall be cleaned and readied for painting as described below.

· Inspect the previously blasted surfaces to assure they still meet the SSPC-SP10 standard. If not, sandsweep or blast the surfaces again with abrasive grit to meet SSPC-SP 10/NACE No. 2 using grit conforming to MIL-A-22262 with a 3.0-4.0 mil profile. All pipe plugs shall be installed prior to grit blasting.

· Clean entire substrate surface free of chlorides and test until satisfactory results are achieved IAW SFLC Standard Spec 6310, section 3.1.8.5.

· Document chloride test results on paint report.

3.6.2.2 Painting/coating. The Contractor shall paint the rudder blade exterior surfaces by applying a high turbulence paint/coating system per SFLC Standard Specification 6310, Appendix C:

· The painting/coating system shall be applied with proper environmental, ventilation, humidity and temperature controls as specified by the pertinent OEM. The paint Contractor shall have a minimum of 5 years' experience dealing with the paint/coating application. Observe all the OEM safety precautions.

· Inspect blasted substrate, recording and keeping Testex tape readings in a project logbook. Apply two coats of high turbulence paint/coating (black), 10-11 mils dry film thickness each, to achieve a total of not less than 20 mils dry film thickness. Observe the curing time of recoating before application of the second coat.

3.6.2.3 Painting/coating of the exterior blade section shall be accomplished after all other repair work and interior flow coating is complete.

3.6.2.4 Paint data sheet. Paint data sheets shall be prepared to certify the paint type and mil thickness used on the rudder blade. The paint data sheet shall be packed with each overhauled rudder and a copy provided to the KO.

3.7 Final inspection and test report. A detailed Final Inspection and Test Report shall be submitted to the KO for approval prior to scheduling Coast Guard SFLC Quality Assurance personnel. The report shall depict the final condition of the rudder after all work has been completed. A copy of the inspection and test report shall be turned over to the Coast Guard Quality Assurance representative upon arrival for final inspection and testing. The inspection and test report shall contain the following information as a minimum:

· Contractor name, address and telephone number

· Contract number and delivery order number as applicable

· Rudder serial number(s)

· Written dimensional survey showing the rudder measurements and test results are within tolerance for each dimension shown on the drawing or per this requirement

· Name of the person conducting the testing

· Test equipment used, nomenclature, serial number, and calibration date

· Pressure test certification

· Float coat application

· All required documentation concerning preparation and application of all paint and coatings

3.8 Workmanship. Rudders shall have a professional appearance and be free of dirt, grease, burrs or sharp edges.

3.9 Notifications and inspections. The Contractor shall be responsible for notifying the Contracting Officer at least ten (10) calendar days prior the Contractor being ready for any Quality Assurance inspections or testing as required herein. The rudders require a one hundred percent Coast Guard Quality Assurance inspection.

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 in accordance with ANSI/ASQC Q9001, documented 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 ANS/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 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 that are deemed necessary to assure that supplies and services conform to the prescribed requirements.

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 Tests and inspections. The inspections/tests required here and in section 3.0 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.

4.6.1 The following are required and will be witnessed by Coast Guard SFLC Quality Assurance Representative(s):

· Overall dimensional tolerances are in accordance with the drawing

· Surface texture (stock section)

· Weld inspection

· Air pressure test

· Paint thickness check

· Paint data sheets (Including Chloride checks)

· Float coat application

· Blade straightness in reference to the centerline on the drawing

· Rudder seal kit secured and marked in crate

· Rudder nuts (2) tested for thread fit, secured and marked in crate

· Preservation, packing, marking and bar-coding of rudder prior to shipping

4.7 Failure responsibility. If a rudder 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 Tests and inspection reports. One copy of any required inspection, test or tolerance check done on each delivery order shall be sent to the KO.

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 3.9 of this specification.

5. PRESERVATION, PACKING, MARKING, AND SHIPPING

5.1 Preservation. Rudder stock is stainless steel so additional preservation is not necessary. The rudder blade interior cavity is flow coated per section 3.6.1 so additional preservation is not necessary.

5.2 Packing. Each rudder shall be individually packaged in its own reusable wood box, or a new reusable wood box if approved.

5.2.1 The rudder stock shall be supported in the box by use of cradles and blocking that will not allow shifting of the rudder within the box. The rudder stock shall be protected with PVC pipe, plastic mesh or similar protection. The lower blade end shall be supported with 2” x 6” wood planks covered in ½” minimum thickness resilient rubber or foam to prevent blade paint/coating damage.

5.2.2 Pack one (1) Rudder Sealing Kit (GFP) with installation tool, Ref. 1.2, in the box with each rudder. The seal kit shall be secured to prevent movement during handling and multiple shipments. The seal kit shall be clearly marked in permanent ink with NSN and description.

5.2.3 Pack two (2) Rudder Lock Nuts (GFP), Ref. 1.2, in the box with each rudder. The nuts shall be packaged separately and secured to prevent movement during handling and multiple shipments. The nuts shall be clearly marked in permanent ink with NSN and description.

5.2.4 Once the rudder is secured and all items are in the crate as required, the box lid shall be screwed in place and banded in a minimum of two locations.

5.3 New reusable wood box. When a change request is authorized by the KO, the Contractor shall construct a new reusable wood box manufactured IAW ASTM D6880/D6880M-11.

5.3.1 The wood box shall be constructed using 2” x 8” framing and ¾” plywood top and bottom. Particleboard, flake board, OSB etc. will not be acceptable. The wood box shall be skid mounted and constructed with a removable lid secured with corrosion resistant wood screws to allow easy access and removal of the rudder without damage to the box.

5.3.2 Wood Packing Material (WPM) requirements. New reusable wood boxes shall meet the Phytosanitary Requirements for WPM in accordance with DOD 4140.01-M-1, Compliance for Defense Packaging Ref. 2 paragraph C2.1.1. WPM is defined as wood pallets, skids, load boards, pallet collars, wooden boxes, reels, dunnage, crates, frames and cleats. Packaging material exempt from the requirements are materials that have undergone a manufacturing process such as corrugated fiberboard, plywood, particleboard, veneer and oriented strand board (OSB). All new purchases of WPM shall be constructed from heat treated (treated to 56° C. core temperature for 30 Minutes) lumber and certified by an accredited agency recognized by the American Lumber Standard Committee (ALSC).

5.3.3 WPM markings. All new wood boxes shall have the appropriate markings in accordance with DOD 4140.01-M-1, Compliance for Defense Packaging Ref. 2 paragraph C2.5.

5.3.4 Newly manufactured wood boxes shall be secured and stored per section 3.1.

5.4 Unit packaged cube data. 13 in x 32 in x 65 in – 15.6 cubic feet Unit Packaged Weight: approximately - 540 lbs.

5.5 Marking. Each preserved and packed rudder shall have a water proof stencil in the upper left-hand corner of the two longest sides (two opposite sides if square) of each wood box IAW MIL-STD-129. The stencil marking shall be ½” – 3/4" inch in height on a highly contracting painted background. Bare plywood behind stencil will not be acceptable. Laminated paper stencils will not be acceptable.

5.5.1 Marking layout (ready for issue) “A” condition.

5.5.2 Marking layout (scrap) “H” condition.

5.6 Bar coding. U.S. Coast Guard requires bar coding of the NSN, IAW MIL-STD-129P w/Change 4. See paragraph 4.4, page 47 of MIL-STD-129P w/Change 4 for identification linear (Code 39) and 2D (PDF417) bar code markings and locations.

5.6.1 The Bar Code Label can be applied separately or as part of the marking required in 5.5.

5.7 Shipping. Unless otherwise directed, the Contractor shall ship and deliver the parts and components to the government address specified in paragraph 5.7.1. Notify the COR and KO about the shipment (07) days in advance. Provide timely shipping information to KO and 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 KO.

5.7.1 Address. Unless otherwise specified, the Contractor shall ship, and deliver all parts to the following government addresses:

US Coast Guard

Surface Forces Logistics Center

2401 Hawkins Point RD, Receiving Room - Bldg. 88

Curtis Bay, 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

· USCG Surface Forces Logistics Center

2401 Hawkins Point Road

Baltimore, MD. 21226-5000

Phone: 410-762-6649

ATTN: Contracting Branch, CPD1

6.1.2 Commercial document sources.

· ASTM International

1916 Race Street

Philadelphia, PA 19103-1187

Phone: 215-299-5585

Fax: 215-977-9679

· American National Standards Institute (ANSI)

1430 Broadway

New York, NY 10018

Phone: 212-642-4900

· 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

RFQ 70Z08014002B00

Attachment (3)