ag181 sow.pdf

OVERHAUL DESCRIPTION

FOR OFFICIAL USE ONLY

ITEM NAME CRANE,JIB

STOCK NUMBER 3950-01-619-5772

PART NUMBER AMD-1881

USED ON

Items as received by the contractor must be complete and of the proper cited part number. Discrepancies shall be reported to the Coast Guard Contracting Officer.

OVERHAUL REQUIREMENTS:

ITEM NAME Crane Assembly

STOCK NUMBER 3950-01-619-5772

PART NUMBER AMD-1881

USED ON 270 WMEC

STATEMENT OF WORK (SOW)

1. Scope: The intent of this SOW covers the disassembly and inspection of the boat davit referenced in 1.1. Upon submission of condition found report and an estimate, possible follow on repairs/modifications may be authorized which include paint, preservation, packaging and marking as part of the davit refurbishment.

1.1 Government Furnished Property (GFP): The following crane assembly will be provided to the contractor for inspection and refurbishment services required by this statement of work.

a) Crane Assembly, Model AMD-1881, Original Equipment Manufacturer (OEM):

Appleton Marine Inc. NSN: 3950-01-619-5772.

1.2 Government Furnished Material (GFM):

a) Swivel Eye & Jaw under National Stock Number NSN 4030- 01-512-2113

b) Release Hook under NSN 4030- 01-467-1005.

1.2.1 One each eye & jaw swivel, and one each release hook referenced in section 1.2 shall be provided to the contractor to be used during the performance test and which shall remain with the davit. The contractor shall provide new wire rope and hardware necessary to complete the wire rope assembly. Contractor shall notify the Contracting Officer to arrange delivery of the swivel and release hook.

1.2.3 In order to attach the swivel to the release hook, one each stainless steel sleeve will need to be manufactured in accordance with Coast Guard drawing FL8201-093 rev G, sheet 2, detail 15A; sheet 4 is included as reference if needed.

1.3 Contractor shall be responsible for the safe handling and storage of the government furnished property or material while in possession.

1.4 The refurbishment and testing requirements described in this statement of work are intended to restore the davit to the operational standards and appearance equal to that of an identical new davit model FB20-21. These requirements are not intended to replace any procedures, controls, examinations or tests normally employed by the contractor to assure the

SHELF LIFE CD 0

quality of the product.

2. Applicable Documents:

a) Navsea Technical Publication T9074-AS-GIB-010/271 Requirements for Nondestructive Testing Methods.

b) TP-4924, Coast Guard Technical Publication for the Appleton Folding Boom Crane.

c) RR-W-410H, Federal Specification for Wire Rope. Dated 2015.12.22.

d) Military Specification, MIL-PRF-18458C Grease, Wire Rope-Exposed Gear.

Dated 2002.07.05

e) The Society for Protective Coatings, SSPC-SP 10, Near White Blast Cleaning. Dated 2007.01.01.

f) Society of Automotive Engineers SAE J1942-1 Hoses and Hose Assemblies for Marine Applications. Dated 2015.12.01.

g) Federal Standard, FED-STD-595C Colors Used In Government Procurement, Change Notice 1. Dated 2008.07.31.

h) ANSI/NCSL Z540-3 Calibration Laboratories and Measuring and Test Equipment. Dated 2006.08.03

i) U.S. Coast Guard Specification D-000-0100 REV. F, Dated 06/2000. Bar coding for U.S.C.G. SFLC material.

j) ISO 4406, Hydraulic Fluid Power - Fluids - Method for Coding the level of contamination by Solid Particles. Dated 1999.12.01.

k) MIL-STD 2035A Nondestructive Testing Acceptance Criteria. Dated 1995.05.15

l) Code of Federal Regulations 46 CFR 56.97-30, Hydrostatic Tests.

m) COMDINST M9000.6F Naval Engineering Manual, Chapter 505 Section B, paragraph 7.f

2.1 Precedence: In the event of a conflict between this statement of work and the referenced documents cited herein, this statement of work shall take precedence.

3.0 Requirements:

3.1 Upon receipt of material, the contractor shall inspect all items and shipping containers for damage. Any discrepancy shall be brought immediately to the attention of the contracting officer.

3.2 Disassembly and inspection: Ensure all hydraulic fluid remaining in the system is drained and properly disposed of in accordance with all Federal, State and Local Laws for disposal of hazardous materials. Cap or plug all oil ports and openings. Remove and dispose of any existing wire rope and electrical cables. The contractor shall label/mark items and completely disassemble the davit and components per Section II of the OEM Technical Publication. Conduct inspections as addressed throughout reference 2.b and this SOW to determine all necessary repairs or need for replacement of components. Condition Found Reports (CFR) shall be prepared based on all findings either as a result of the inspection, conversion or service bulletins. The condition found reports and parts list (paragraph 3.3) shall be submitted which details all finding, recommendations and parts. A total refurbishment cost shall be submitted which includes all labor and material to assemble, test, paint, preserve, package and mark the davit as addressed throughput this SOW. The condition found report, part list and cost quote shall be submitted to the Coast Guard Contracting Officer for review. Upon submittal of this documentation, no additional work or cost shall be incurred unless authorized by the contracting officer. Upon review of all documents, the Coast Guard shall make a determination and advise the contractor as to the follow on disposition of the davit.

3.2.1 A separate condition found report (CFR), part list and quote shall be submitted for each davit offered under this contract identified separately by individual davit serial number.

3.3 Part list: An itemized part list shall be prepared utilizing chapter 7 of reference 2.b to accomplish the refurbishment of the davit. Each part listed shall include the nomenclature, part number, quantity of each part and include the unit and extended cost for each part.

3.3.1 Mandatory Replacement Parts: hydraulic motor and brake: service kits, seal kits and disc & bearing kits, CT winch assembly service kit, hydraulic cylinder service kit and bushings, and gear reducer service kit.

Miscellaneous valve service and seal kits, gasket, seals, o-rings, bearings, wire rope with fitting and retaining clip, cable packing glands and springs of the cable tension, down stop and anti-two block. Electrical cable, anti-two block wire rope and hardware, miscellaneous hardware, fasteners and hoses shall be replaced as part of the refurbishment, with the exception of the turntable bearing. The turntable bearing shall be evaluated and only renewed if findings deem it necessary. All replacement parts installed shall be new original equipment or equivalent. Reclaimed or serviced parts are not acceptable and shall not be used.

3.3.2 All miscellaneous non structural fasteners (i.e. nuts, bolts, washers, etc) shall be replaced with new grade 316 stainless steel fasteners with nylon inserted (ny-lock) lock nuts. All grease fittings shall be renewed with new monel fittings and shall have protective plastic caps installed.

3.4 All hydraulic hose assemblies shall be renewed and shall conform to the requirements of reference 2.f. Hose fittings shall be grade 316 stainless steel and shall be permanently swaged type. The hose material used shall not exceed one year from date of manufacture. Each hose assembly shall be hydrostatically tested IAW references 2.l and 2.m at 1.5 times its rated working pressure. Each hose assembly shall be tagged using a 1 1/4" x 5" x .032", Alloy 5052-H32 aluminum sheet metal with holes in each corner to band the tag to the hose by use of standard duty, UV black, nylon cable ties. Each tag shall by engraved, etched, or stamped with the hose part number; service life date- which is five years from the manufacture date and shall be identified as the quarter of year and last two digits of the year, example 1Q12, hydrostatic test pressure in (PSI), and hydrostatic test date in MM/DD/YY format.

3.5 Tube removal/reinstallation: Remove and inspect all hydraulic tubing from the davit, jib and swing system assemblies. Remove and inspect all hydraulic tube clamp sets and store clamps and tubes for reuse. Remove and inspect all tubes from the winch junction block to the hydraulic lid plate. Label all re-usable tubes and clamp for re-use. Tubes damaged or otherwise determined no longer suitable for reuse shall be renewed. All new tubing shall be grade 316 stainless steel materials.

3.6 Davit structure: Disassemble, clean and inspect the entire davit/jib structure, sheave assembly, pins, bearings, bushings, anti-two block, down stop, electrical junction box, and cable tension device in accordance with reference 2b. Visually inspect the weldments for twist, bulges and deformation. Inspect the sheave groove using a groove gage. Clean all parts of grease, oil and other contaminants in preparation for grit blast and weld examination covered separately. Submit a CFR of all findings and recommendations.

3.7 Swing drive components: Remove, disassemble and inspect the swing drive components in accordance with chapter 6 of reference 2.b. Inspect all components for wear or damage and repair as necessary. Reassemble the swing drive components in accordance with OEM specifications upon completion of all repairs.

3.8 Winch: The constant tension winch shall be refurbished in accordance with chapter 6 of reference 2.b and AMD Winch Assembly, AMD-1899 configuration if not to this configuration. This includes the use of Parker ORS series O-Ring seal fittings for all fluid interfaces. The mounting hole of the winch frame weldment shall be examined per paragraph 3.14. The mounting fasteners shall be renewed.

3.9 Hydraulic cylinder: Remove, disassemble, clean and inspect the cylinder.

Inspect all components for wear or damage. Inspect, overhaul and set counterbalance valve for operation at 3,000 PSI. After metal preparation, conduct non-destructive test of clevis pins, rod eye and clevis end welds per paragraph 3.14. Take and record dimensional readings of the cylinder bore and piston. Cylinder rod shall receive double chrome plating as part of the overall cylinder repair.

3.10 Wire Rope: New wire rope assemblies AMI P/N: YMD-10400 shall be provided and tested see paragraph

3.10.1. The wire rope shall be pressure lubricated with lead free grease conforming to MIL-G-18458C.

3.11.1 Wire Rope Certification & marking: Wire rope and socket shall be pull test to 40% of wire ropes breaking strength and include a pull test certificate from the wire rope manufacture. Certificate shall be packed with the overhauled crane at the time of packaging. A copy of the certificate shall be provided to the Coast Guard Quality Assurance Representative (QAR).

Additionally, the wire rope shall have a metal information tag attached to the wire that included test information (i.e. OSHA Pull Tested), the test load and date of test.

3.12 Electrical components: All components such as solenoids, various type switches and control valves shall be cleaned, resistance tested and actuated to confirm their performance and a condition found report submitted.

3.13 Surface preparation: Abrasive grit blast all steel painted surfaces to white metal in accordance with reference 2.e. Prior to blasting protect all bearing surfaces and threads by blank or cover. Remove all label plates and replace them at the conclusion of painting. Soft metal surfaces such as aluminum and such shall be clean by alternate methods suitable for such metals as not to damage the surface.

3.14 Non-destructive examination (NDE): Inspection shall be performed by a nondestructive examination method in accordance with reference 2.a or commercially equivalent inspection method. Inspections shall be performed as indicated throughout this SOW and as determined where the need exist. An appropriate and most cost effective method of examination shall be chosen based on the type of material being inspected. The results of each examination shall be interrupted based on acceptance criteria in accordance with reference 2.k. The result of each test shall be reported in the CFR as pass or fail.

3.14.1 The following areas/items shall be inspected by NDE: davit structural welds, structural pins, bushings, CT winch frame mounting holes, hydraulic cylinder rod eye and clevis end welds. Other areas that visually show signs of fatigue, bulging, cracks or other indications of concern.

3.15 Paint: All surfaces intended for paint shall be clean, dry and free of contamination. The paint system shall include a primer coat shall be a zinc rich primer, compatible with polysiloxane system (3-4) mils dry film thickness (dft). The intermediate coat shall be (1-2) mils dft of polysiloxane. The top coat shall be (5-6) mils dft of polysiloxane. Color of intermediate and top coat shall be "spar" in accordance with Federal Standard 595B color number 10371. Total paint thickness shall be 9 to 12 mil minimum dry film.

3.15.1 Paint application shall be applied in accordance with the paint manufactures recommendations. Managing and disposal of paints shall be in accordance with federal, state and local requirements.

3.16 Hydraulic system cleanliness shall be maintained to a level of 17/14 cleanliness or better per reference 2.j. Water content shall not exceed 500 PPM by volume.

3.17 Upon authorization to proceed with refurbishment, the davit shall be reassembled in accordance with reference 2.b. During assembly, fasteners shall be torque in accordance with reference 2.b.The davit shall be lubricated in accordance with reference 2.b.

3.18 After davit refurbishment, the contractor shall perform a weight test in accordance with OEM test practices to ensure maximum design performance in the presence of a Coast Guard, QAR. Contractor shall provide certification of conformance at the conclusion of successful weight testing.

3.19 Test preparation: Hydraulic Test Equipment (Power Unit) used for testing boat davits shall be capable of producing a minimum of 3,400 PSI pressure at a 34 GPM flow rate. Test fluid shall be certified to a cleanliness level per paragraph 3.16. Adjust the system pressure to 2500 PSI with exceptions as noted for the static and dynamic test. A suitable hook shall be provided by the contractor to conduct the static and dynamic overload test.

3.20 Performance Test: The refurbished davit shall be required to successfully pass the following tests prior to acceptance by the Coast Guard.

Any sign of oil leakage or otherwise defective operation observed shall be cause for rejection. A davit that does not pass any segment of testing shall be corrected and retested. The following tests are required traceable to the davit serial number, type of test, date of test and test personnel description and names.

a) Make all necessary system start up inspections and adjustments. Make all necessary hydraulic and mechanical adjustments per reference 2.b.

b) Rated Load Test: Document each test as a pass or fail.

Using the GFM swivel and hook, attach 5,000 lbs + 25 lbs - 0 lbs test weight to the hook of the davit and operate the davit through three (3) up and down cycles at full operating speed. Observe the operation of each cycle for unusual operation or sounds which shall be investigated and corrected. With the boom stationary, operate the winch up and down over a 60 inch distance while documenting the following data while in operation: system pressure and operating oil and ambient air temperature; start and finish position (inches); Elapsed time (seconds); system flow (GPM); system pressure (PSI) and calculate performance to meet or exceed 60 (ft/min).

c) Constant tension test: Document each test as a pass or fail.

Demonstrate that the wire rope tension in the C.T. mode is adjusted to 50lbs +/-10 lbs. Attach a 2,500 lb weight and momentarily raise the load. Select CT function and then lower the load to the deck until the wire goes slack.

Observe that the system switches from the lowering mode to CT Mode once the wire rope goes slack.

Using a fork truck to move the 2500 lb weight rapidly up and down to simulate wave motion. Demonstrate that the CT mode can be cancelled and the load can be hoisted up while the forks are moving up and down.

d ) Dynamic overload test: Document each test as a pass or fail.

Increase the system pressure to 4300 PSI. Using a contractor furnished hook, attach 7,500 lbs + 25 - 0 lbs test weight (150% of rated load) to a suitable contractor furnished hook. Winch the load up within proximity of the anti-two block without activating, stop and hold the load for 5-10 seconds. The winch shall operate smoothly and there shall be no brake slippage. Lower and stop the load to within 2-3 inches of the deck and wait for 5-10 seconds, The winch shall operate smoothly and there shall be no brake slippage. Conduct this test through three (3) cycles in both directions at a fast controlled speed.

e) Static overload Test: Document this test as a pass or fail.

Using a suitable contractor furnished hook, attach the hook to an 10,000 lbs + 25 lbs, - 0 lbs test weight (150% of rated load) and raise the load 3-4 inches using a fork truck. Slowly winch up and remove any slack from the wire rope. Slowly lower the load from the fork truck onto the hook so that the entire load rest on the davit and hold load for 5 minutes. There shall be no brake slippage during this test. Reverse the procedure to remove the load.

Document actual load and clear flange distance between the last wrap and outer flange. Observe the structure for signs of bulging or bending of the weldments.

f) No load test: Davit shall be operated at maximum speed through all cycles of operation with no load for a minimum of 5 minutes. These cycles shall include: hoisting and lowering, articulation of jib in and out, and slewing.

During this test all safety devices and functions, switches, emergency stop shall be verified to operate properly. Hydraulic and mechanical adjustment shall be made during this test. Observe the operation of each cycle for unusual operation or sounds which shall be investigated and corrected. With the boom stationary, operate the winch up and down over a 60 inch distance while documenting the following: system pressure and operating oil and ambient air temperature; start and finish position (inches); Elapsed time (seconds); system flow (GPM); system pressure (PSI) and calculated performance (ft/min).

g) Upon a successful performance test a copy of the test results shall be placed in a zip lock pouch and attached to the davit.

4. Quality Assurance:

4.1 Notifications : The contractor shall be responsible for notifying the Contracting Officer no less then seven (7) calendar days prior to the contractor being ready for any Quality Assurance (Q.A.) inspections or testing required herein.

4.2 Calibration System: All equipment used for testing overhauled davit shall be calibrated. The Contractor shall maintain a test equipment calibration program in compliance with reference 2.h. The program shall be documented and traceable to the National Institute of Standards (NIST). The calibration system records shall be maintained for inspection for the duration of any contract referencing this specification. All test equipment shall have a current calibration sticker of less than 1 year from date of last calibration. The Coast Guard reserves the right to conduct its own inspections at any time during the course of the contract.

4.3 Records and certifications: The contractor shall submit all records, certifications and performance test to the Contracting Officer prior to the Coast Guard QAR visit. A copy of the certifications and performance test shall be placed in a zip lock pouch and attached to the davit.

4.4 Quality Assurance Inspections: All inspections 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 following are required to be reviewed and or inspected by the Coast Guard QAR Inspector.

a) Disassembly inspection reports.

b) Material certifications and hose tags.

c) Wire rope assembly certification

d) Paint type and thickness.

e) Performance test.

f) Preservation, Package, Packaging and Marking.

4.5 Warranty: Contractors standard new davit warranty shall apply.

5.0 Preservation "Marking" & Packaging:

5.1 Preservation: Overhauled davit assembly shall be preserved in accordance with OEM standard practice for new davit to ensure protection against corrosion of all internal and external parts. Preservation shall ensure the Davit assembly will be ready for installation and usage at any time during a warehouse storage period of up to 5 years.

5.2 Marking: An information tag shall be attached to the davit assembly.

Tag shall contain the information as laid out in 5.4 parts (a) through (f).

5.3 Packaging: Davit assembly shall be secured together on a skid mounted shipping platform and completely enclosed with a plywood cover. Plywood shall be construction grade,19/32 in thickness and the cover shall be assembled with screws. Davit shall be supported by cradles placed at points as determined by the contractor to ensure proper support. The shipping platform shall be capable of supporting the davit during multiple shipping and handling by commercial carriers.

(Note: CG owned steel skid mount shall be used with the plywood cover unless unservicable)

5.4 Marking (Container): A waterproof label shall be attached or applied to the shipping container on each of the two long sides. The label shall be capable to withstand sunlight without fading. Label shall contain the information as laid out below in 1 inch minimum height legible black figures on white background. The label shall be attached in such a way to protect it from damage or lose. The following information shall be included:

(a) National Stock Number (NSN): 3950-01-619-5772

(b) Item Name: CRANE, ASSEMBLY

(c) Part Number: AMD-1881

(d) Shipping Weight: (fill in).

(e) Government Contract No.: (fill in).

(f) The statement: COAST GUARD SFLC MATERIAL CONDITION "A", 1 each.

5.5 Bar Coding: A bar coded label, in accordance with ELC specification D- 000-0100, Rev. F shall also be applied. The Bar Code Label can be applied separately or as part of the marking required in this specification.

a) The actual labels shall be Type "V", Grade "C" Style "2", Composition "a" with or without plastic laminate.

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

6.0 NOTES:

Source of Documents:

Government:

Standardization Document Order Desk 700 Robbins Avenue Building #4, Section D Philadelphia, PA 19111

(215) 697-1187

Commercial:

American Petroleum Institute (API) 1220 L Street NW Washington DC 20005

(202) 682-8000 www.api.org

Steel Structures Painting Council (SSPC) 40 24th Street, 6th floor, Pittsburgh, PA 15222

(412) 281-2331

SAE (Society of Automotive Engineers) SAE Washington Office 1200 G St., NW, Suite 800 Washington, DC 20005 1-877-606-7323

ANSI (American National Standards Institute) 11 west, 42nd street, 13th floor New York NY, 10036

(212) 642-4900

ISO (International Organization for Standardization) 1, ch. de la Voie-Creuse

CP 56

CH-1211 Geneva 20 Switzerland +41 22 749 01 11

Military Standards (various) WWW.Everyspec.com

WARRANTY:

X A. Standard Manufacturer's Warranty

B. Item being repaired as an "onboard repair" or a "system stock" item and will be put into inventory. NOT FOR IMMEDIATE INSTALLATION.

Contractor must guarantee item against defects that lead to failure for days after installation for a period of up to two (2) years after delivery to Coast Guard.

GOVERNMENT ACCEPTANCE:

Acceptance will be made at destination by a Government representative.

Acceptance will be contingent upon the representative's verification of no damage in transit, correctness and completeness of order and contractor's conformance to preservation/packaging, packing and marking requirements.

PACKAGING AND MARKING FOR SHIPMENT:

X

A. Each unit shall be packed individually in it's own wooden box which shall be capable of providing adequate protection to the item during multiple shipments. Mark each box in legible black print lettering with the following information:

NATIONAL STOCK NUMBER

ITEM NAME

PART NUMBER

GOVERNMENT ORDER NUMBER

3950-01-619-5772

CRANE,JIB

AMD-1881

PRESERVATION / PACKAGING:

A. Each unit shall be individually preserved and wrapped for protection against deterioration for a period of two (2) years minimum.

X B. See Attachments

B. See Attachments

And the words: "Coast Guard SFLC Material, Condition "A"

RECOMMENDED SOURCES:

APPLETON MARINE INC

3030 EAST PERSHING STREET

P.O. BOX 6007

APPLETON, WI. 54915-6007

STEVE.ZAHRINGER@APPLETONMARINE.COM

WRITTEN BY:

DATE :

STEPHEN TWOMEY

20 FEB 20

Cost Estimate for Overhaul NOT TO EXCEED: $158,900