ag092 od.pdf

OVERHAUL DESCRIPTION

FOR OFFICIAL USE ONLY

ITEM NAME PUMP, CENTRIFUGAL

STOCK NUMBER 4320-99-602-2262

PART NUMBER 2K6X4V-13RV-CD4M

USED ON WMEC 270 #1 AND #2 U/W ASW PUMP ASSEMBLY

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:

Descriptive Specification Data:

2K6X4V-13RV M3V FPD CD4

DURCO MK3 INLNE PUMP 2K6X4V-13

CASING CD4M/CD4MCUN

IMPELLER CD4M/ CD-4MCUN

COVER CD4M/CD-4MCUN

SHAFT 2205 DUPLEX STAINLESS, NO SLEEVE REQUIRED

BEARING HOUSING 316SS

BEARING HOUSING CARRIER CD4MCUN

BEARING HSG ADAPTER 316SS

MOTOR ADAPTER CI

COVER GASKET ? TM

IMPELLER GASKET ? TFR

CASING - STANDARD, 150# FF ANSI DRILLING, CASING DRAIN - 1/2" NPT THREADED

(TAP 1)

ISO 1940 G6.3 IMPELLER BALANCE, POWER END - STANDARD MK IIIA,

BEARINGS - REGREASEABLE (SINGLE SHIELD)

OIL SEALS - TSSR, FLOWSERVE SINGLE CARTRIDGE SEAL ISC PUSHER W/O PUMPING

RING SILCAR ROTARY VS. SILCAR SEAT VITON ELASTOMERS

316SS METAL PARTS

316SS LARGE BORE GLAND SEAL CHAMBER FML

WOODS SURE-FLEX PLUS SC W/STD SPACER [SC9] EPDM SPACER

STD. STEEL CPLG GUARD (SAFETY YELLOW)

PUMP STAND - 316SS

ABB BALDOR TEFC-XEX PREM EFF 30HP 1800RPM 286TSC 3/60/230-460V MOTOR

GENERAL REQUIREMENTS

1. SCOPE

1.1 Intent: This section describes the requirements which the Contractor shall follow applicable to all pump units inducted for overhaul under this Contract. Additional specific requirements applicable to a designated model / unit are addressed in the applicable individual Work Items (WI) within this specification package. These General Requirements in conjunction with the applicable WI make up the overall Contractor repair / overhaul requirements for each pump unit.

2. REFERENCES

Consolidated List of References:

The below-listed documents form a part of this specification to the extent specified herein. Approval / publication dates or revision dates / numbers are also identified, to ensure that same document versions are used at time of specification writing and during contract execution. All Coast Guard drawings, technical publications, and standard specifications will be provided to contractors by the Coast Guard at an appropriate time, or upon request, free of charge. Other Government documents may be accessed free of charge as follows:

MIL/DOD/CID Specifications:

http://www.assistdocs.com/search/search_basic.cfm Commandant Instruction Manuals: http://www.uscg.mil/directives/default.asp Public Laws, Code of Federal Regulations, U.S Codes, and other Federal Government laws: www.gpoaccess.gov

The Government is aware of the following internet web links where contractors may procure commercial specifications:

American Welding Society (AWS): http://www.awspubs.com/index.php ANSI, ASTM, IEEEE, NFPA, ASME, SAE Standards: http://www.techstreet.com/ NFPA: http://www.nfpa.org SSPC Standards and pictorial guides:

http://shopping.netsuite.com/sspcmarketplace

COAST GUARD DRAWINGS

None

COAST GUARD PUBLICATIONS

Coast Guard Technical Manual (TM) 4432, SWBS 312 A, Seawater Cooling Pump, Model Durco MK 3 ? Installation, Operation Maintenance & User Instructions Surface Forces Logistics Center Specification D-000-0100 Rev G Dated 06/2006, Bar Coding for USCG Surface Forces Logistics Center Material.

OTHER REFERENCES

Code of Federal Regulations (CFR), Title 40, Chapter I, 2008, Environmental Protection Agency.

National Conference of Standards Laboratories (NCSL) Z540-3-2006, dated 2006, Requirement for the Calibration of Measuring and Test Equipment.

MIL-PRF-81309F dated 05/16/2005, type 2, class 1 or 2, Corrosion preventive compounds, water displacing, ultra-thin film.

MIL-D-3464E dated 04/1987- Desiccants, Activated, Bagged, Packaging use and static dehumidification.

MIL-PRF-131K Type 1, dated 28 Aug 1998- Barrier materials, water vapor proof, greaseproof, flexible, heat sealable.

ASTM International (ASTM) D3951-18, Reapproved 2004, Standard Practice for Commercial Packaging.

American Society for Quality (ASQ) Q90001-2008, dated 2008, Quality Management Systems-Requirements.

SAE Standard, AMS-STD-595, Colors Used in Government Procurement.

International Standard Organization (ISO) 2953, 1999, Mechanical Vibration, Balancing Machines, Description and Evaluation.

MIL-STD-2073-1E, DOD Standard Practice for Military Packaging.

MIL-STD-129R, DOD Military Marking for Shipment and Storage.

The Society for Protective Coatings (SSPC) Surface Preparation Specification No.3 (SSPC-SP 11), 2004, Power Tool Cleaning to Bare Metal.

The Society for Protective Coatings (SSPC) Surface Preparation Specification No.3 (SSPC-SP 11), 2004, Power Tool Cleaning to Bare Metal.

American Society of Mechanical Engineers, ASME international - PTC 8.2 Centrifugal Pump, dated 1990.

American National Standards Institute (ANSI)/HI 3.6 Rotary Pump Tests, dated 2000.

Flowserve Pump Construction Datasheet 2K6X4V-13RV-CD4

3. REQUIREMENTS

SHELF LIFE CD 0

Descriptive Specification Data:

2K6X4V-13RV M3V FPD CD4

DURCO MK3 INLNE PUMP 2K6X4V-13

CASING CD4M/CD4MCUN

IMPELLER CD4M/ CD-4MCUN

COVER CD4M/CD-4MCUN

SHAFT 2205 DUPLEX STAINLESS, NO SLEEVE REQUIRED

BEARING HOUSING 316SS

BEARING HOUSING CARRIER CD4MCUN

BEARING HSG ADAPTER 316SS

MOTOR ADAPTER CI

COVER GASKET ? TM

IMPELLER GASKET ? TFR

CASING - STANDARD, 150# FF ANSI DRILLING, CASING DRAIN - 1/2" NPT THREADED

(TAP 1)

ISO 1940 G6.3 IMPELLER BALANCE, POWER END - STANDARD MK IIIA,

BEARINGS - REGREASEABLE (SINGLE SHIELD)

OIL SEALS - TSSR, FLOWSERVE SINGLE CARTRIDGE SEAL ISC PUSHER W/O PUMPING

RING SILCAR ROTARY VS. SILCAR SEAT VITON ELASTOMERS

316SS METAL PARTS

316SS LARGE BORE GLAND SEAL CHAMBER FML

WOODS SURE-FLEX PLUS SC W/STD SPACER [SC9] EPDM SPACER

STD. STEEL CPLG GUARD (SAFETY YELLOW)

PUMP STAND - 316SS

ABB BALDOR TEFC-XEX PREM EFF 30HP 1800RPM 286TSC 3/60/230-460V MOTOR

GENERAL REQUIREMENTS

1. SCOPE

1.1 Intent: This section describes the requirements which the Contractor shall follow applicable to all pump units inducted for overhaul under this Contract. Additional specific requirements applicable to a designated model / unit are addressed in the applicable individual Work Items (WI) within this specification package. These General Requirements in conjunction with the applicable WI make up the overall Contractor repair / overhaul requirements for each pump unit.

2. REFERENCES

Consolidated List of References:

The below-listed documents form a part of this specification to the extent specified herein. Approval / publication dates or revision dates / numbers are also identified, to ensure that same document versions are used at time of specification writing and during contract execution. All Coast Guard drawings, technical publications, and standard specifications will be provided to contractors by the Coast Guard at an appropriate time, or upon request, free of charge. Other Government documents may be accessed free of charge as follows:

MIL/DOD/CID Specifications:

http://www.assistdocs.com/search/search_basic.cfm Commandant Instruction Manuals: http://www.uscg.mil/directives/default.asp Public Laws, Code of Federal Regulations, U.S Codes, and other Federal Government laws: www.gpoaccess.gov

The Government is aware of the following internet web links where contractors may procure commercial specifications:

American Welding Society (AWS): http://www.awspubs.com/index.php ANSI, ASTM, IEEEE, NFPA, ASME, SAE Standards: http://www.techstreet.com/ NFPA: http://www.nfpa.org SSPC Standards and pictorial guides:

http://shopping.netsuite.com/sspcmarketplace

COAST GUARD DRAWINGS

None

COAST GUARD PUBLICATIONS

Coast Guard Technical Manual (TM) 4432, SWBS 312 A, Seawater Cooling Pump, Model Durco MK 3 ? Installation, Operation Maintenance & User Instructions Surface Forces Logistics Center Specification D-000-0100 Rev G Dated 06/2006, Bar Coding for USCG Surface Forces Logistics Center Material.

OTHER REFERENCES

Code of Federal Regulations (CFR), Title 40, Chapter I, 2008, Environmental Protection Agency.

National Conference of Standards Laboratories (NCSL) Z540-3-2006, dated 2006, Requirement for the Calibration of Measuring and Test Equipment.

MIL-PRF-81309F dated 05/16/2005, type 2, class 1 or 2, Corrosion preventive compounds, water displacing, ultra-thin film.

MIL-D-3464E dated 04/1987- Desiccants, Activated, Bagged, Packaging use and static dehumidification.

MIL-PRF-131K Type 1, dated 28 Aug 1998- Barrier materials, water vapor proof, greaseproof, flexible, heat sealable.

ASTM International (ASTM) D3951-18, Reapproved 2004, Standard Practice for Commercial Packaging.

American Society for Quality (ASQ) Q90001-2008, dated 2008, Quality Management Systems-Requirements.

SAE Standard, AMS-STD-595, Colors Used in Government Procurement.

International Standard Organization (ISO) 2953, 1999, Mechanical Vibration, Balancing Machines, Description and Evaluation.

MIL-STD-2073-1E, DOD Standard Practice for Military Packaging.

MIL-STD-129R, DOD Military Marking for Shipment and Storage.

The Society for Protective Coatings (SSPC) Surface Preparation Specification No.3 (SSPC-SP 11), 2004, Power Tool Cleaning to Bare Metal.

The Society for Protective Coatings (SSPC) Surface Preparation Specification No.3 (SSPC-SP 11), 2004, Power Tool Cleaning to Bare Metal.

American Society of Mechanical Engineers, ASME international - PTC 8.2 Centrifugal Pump, dated 1990.

American National Standards Institute (ANSI)/HI 3.6 Rotary Pump Tests, dated 2000.

Flowserve Pump Construction Datasheet 2K6X4V-13RV-CD4

3. REQUIREMENTS

3.1 General:

3.1.1 Contractor Repair Process: The Contractor shall conform to all requirements specified throughout this specification during performance of this contract. In the event of a conflict between the text of this specification and the references cited herein, the text of this specification takes precedence. Nothing in this specification; however, supersedes applicable laws and regulations unless a specific exemption has been obtained.

3.1.2 Repair to Original Equipment Manufacturer (OEM) Specifications:

Unless otherwise specified in the individual WI, the inspection, repair/overhaul, and testing of each pump unit shall be accomplished in accordance with the OEM procedures, specifications, references and standard practices.

3.2 Repair Parts: All replacement parts utilized in each overhaul shall be new OEM parts. Reclaimed, recycled or aftermarket parts are not acceptable and shall not be used. Commercial parts such as seals and ball / roller type bearings and couplings which are not manufactured by the pump or motor manufacturer shall be identified by their marking or through the use of the technical manual for identification purposes. Commercially available items such as these are generally interchangeable between different manufacturers and may be substituted as long as they are equal in all respects. Only in the case where the part cannot be identified shall it be ordered directly through the pump manufacturer and by their part number.

3.2.1 Gaskets: All new gaskets shall be made of non-asbestos materials.

3.2.2 Zerc Fittings: All ferrous metal zerc fittings or pipe plugs called out in the bill of material shall be substituted with like items made of nonmagnetic grade stainless steel. All pipe plugs shall be installed with a non hardening thread sealer. Zerc fittings shall have a protective plastic cap installed on each fitting.

3.2.3 Label Plates: Renew all original data or label plates after completing pump unit external preservation. A separate label plate made of similar material as the original label plate shall be attached to the pump unit stating the Contractor's name, contract number and date of overhaul.

3.3 Billable Costs: The Contractor shall provide all labor and materials to perform the overhaul services as described in the WI for each pump unit.

3.4 Inspections:

3.4.1 Receiving Inspection: The Contractor shall immediately notify the Coast Guard Contracting Officer (CG KO) if the make, part number, model and/or inlet/outlet size delivered for overhaul do not conform to the pump unit cited. A Government Furnished Property Discrepancy Report shall be submitted to the CG KO within 10 business days.

3.4.2 Preliminary Inspection: The Contractor shall conduct a preliminary disassembly and inspection of the pump unit and its shipping container in accordance with pump unit OEM procedures, specifications, references and standard practices addressed in each WI. A Condition Found Report (CFR) shall be submitted within three days of the completion of the inspection pump/pump unit inducted for overhaul.

3.4.3 Open and Inspection Report: An Open and Inspection Report (OIR), also known as a Condition Found Report and Cost Proposal shall be provided to the Coast Guard Contracting Officer within 30 days from receipt of each pump unit, which shall include: the required repairs needed for each pump unit, new replacement parts and materials required individually priced, labor rate, labor hours required, and a total estimate for all required services which shall also include any charges for labor in the repair and building of a new shipping container if needed.

The CFR shall provide a detailed cost estimate and lead time for any additional work and replacement parts that are determined to be required beyond the scope of this specification and the standard practice for overhaul as detailed in the manufacturer's technical manual. The Contractor shall provide the pump replacement cost and lead time for comparison to the overhaul cost. The CG KO will make the determination as to the disposition of any pump unit delivered for overhaul to be Beyond Economical Repair (BER).

3.4.4 Beyond Economical Repair: If the pump unit is BER, the government reserves the right to dispose of the pump unit.

3.5 Status Report: The Contractor shall submit a status report via email to the CG KO and the COR upon request. All pump assemblies shall be listed with the current repair status. The status report shall contain the following information:

a. Delivery order number

b. Work Item number

c. Part number

d. Serial number

e. National Stock Number (NSN)

f. Date pump received

g. Date pump detailed cost estimate

h. Date material ordered.

i. Date material received.

j. Date of Quality Assurance final inspection

k. Date pump shipped

l. Comments/remarks

3.6 Quality Assurance: The Contractor shall maintain an inspection system per American Society for Quality (ASQ) Q90001-2008 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 and available for review by the Coast Guard.

3.7 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

3.1 General:

3.1.1 Contractor Repair Process: The Contractor shall conform to all requirements specified throughout this specification during performance of this contract. In the event of a conflict between the text of this specification and the references cited herein, the text of this specification takes precedence. Nothing in this specification; however, supersedes applicable laws and regulations unless a specific exemption has been obtained.

3.1.2 Repair to Original Equipment Manufacturer (OEM) Specifications:

Unless otherwise specified in the individual WI, the inspection, repair/overhaul, and testing of each pump unit shall be accomplished in accordance with the OEM procedures, specifications, references and standard practices.

3.2 Repair Parts: All replacement parts utilized in each overhaul shall be new OEM parts. Reclaimed, recycled or aftermarket parts are not acceptable and shall not be used. Commercial parts such as seals and ball / roller type bearings and couplings which are not manufactured by the pump or motor manufacturer shall be identified by their marking or through the use of the technical manual for identification purposes. Commercially available items such as these are generally interchangeable between different manufacturers and may be substituted as long as they are equal in all respects. Only in the case where the part cannot be identified shall it be ordered directly through the pump manufacturer and by their part number.

3.2.1 Gaskets: All new gaskets shall be made of non-asbestos materials.

3.2.2 Zerc Fittings: All ferrous metal zerc fittings or pipe plugs called out in the bill of material shall be substituted with like items made of nonmagnetic grade stainless steel. All pipe plugs shall be installed with a non hardening thread sealer. Zerc fittings shall have a protective plastic cap installed on each fitting.

3.2.3 Label Plates: Renew all original data or label plates after completing pump unit external preservation. A separate label plate made of similar material as the original label plate shall be attached to the pump unit stating the Contractor's name, contract number and date of overhaul.

3.3 Billable Costs: The Contractor shall provide all labor and materials to perform the overhaul services as described in the WI for each pump unit.

3.4 Inspections:

3.4.1 Receiving Inspection: The Contractor shall immediately notify the Coast Guard Contracting Officer (CG KO) if the make, part number, model and/or inlet/outlet size delivered for overhaul do not conform to the pump unit cited. A Government Furnished Property Discrepancy Report shall be submitted to the CG KO within 10 business days.

3.4.2 Preliminary Inspection: The Contractor shall conduct a preliminary disassembly and inspection of the pump unit and its shipping container in accordance with pump unit OEM procedures, specifications, references and standard practices addressed in each WI. A Condition Found Report (CFR) shall be submitted within three days of the completion of the inspection pump/pump unit inducted for overhaul.

3.4.3 Open and Inspection Report: An Open and Inspection Report (OIR), also known as a Condition Found Report and Cost Proposal shall be provided to the Coast Guard Contracting Officer within 30 days from receipt of each pump unit, which shall include: the required repairs needed for each pump unit, new replacement parts and materials required individually priced, labor rate, labor hours required, and a total estimate for all required services which shall also include any charges for labor in the repair and building of a new shipping container if needed.

The CFR shall provide a detailed cost estimate and lead time for any additional work and replacement parts that are determined to be required beyond the scope of this specification and the standard practice for overhaul as detailed in the manufacturer's technical manual. The Contractor shall provide the pump replacement cost and lead time for comparison to the overhaul cost. The CG KO will make the determination as to the disposition of any pump unit delivered for overhaul to be Beyond Economical Repair (BER).

3.4.4 Beyond Economical Repair: If the pump unit is BER, the government reserves the right to dispose of the pump unit.

3.5 Status Report: The Contractor shall submit a status report via email to the CG KO and the COR upon request. All pump assemblies shall be listed with the current repair status. The status report shall contain the following information:

a. Delivery order number

b. Work Item number

c. Part number

d. Serial number

e. National Stock Number (NSN)

f. Date pump received

g. Date pump detailed cost estimate

h. Date material ordered.

i. Date material received.

j. Date of Quality Assurance final inspection

k. Date pump shipped

l. Comments/remarks

3.6 Quality Assurance: The Contractor shall maintain an inspection system per American Society for Quality (ASQ) Q90001-2008 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 and available for review by the Coast Guard.

3.7 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.

3.8 Calibration System: The Contractor, as well as any sub-contractors, shall be required to maintain a measuring and test equipment calibration program in compliance with the National Conference of Standards Laboratories (NCSL) Z540-3. The program shall be documented and traceable to the National Institute of Standards (NIST).

3.9 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 to conduct all required inspections. 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 or tests that are deemed necessary to assure that supplies and services conform to the prescribed requirements. It is the Coast Guard's intent for the Coast Guard Quality Assurance Representative (QAR) to have the discretion to witness and or verify inspections and tests of all pump units overhauled by the Contractor. Any inspection scheduling issues that may occur that would impede progress may only be waived by the CG KO.

3.10 Responsibility for Compliance: The Contractor shall meet the provisions of section 3 of this specification. The inspections set forth in this specification shall become part of the Contractor's overall inspection system and 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.

3.11 Quality System: The Contractor shall maintain an inspection system for tools and equipment which shall ensure that each item performs in accordance with the National Conference of Standards Laboratories (NCSL) Z540-3. The inspection system shall be documented and available for review by the Coast Guard.

3.12 Tests & Inspections: The inspections / tests required, here and in the appropriate subsection in the individual WI 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. The Contractor shall submit a written CFR for each test and inspection.

3.13 Notifications of Inspections / Tests: The Contractor shall notify the Contracting Officer at least ten calendar days prior to accomplishing the following inspections and tests:

a. WFT/DFT readings

b. Motor winding resistance check

c. Motor certification

d. Pump rotation and impeller direction verification

e. Hydrostatic test

f. Operational test (note results including meter and gauge readings in CFR)

g. OEM installation / alignment, parts and service manuals verified packed with the pump

h. Verify Preservation, Packaging & Marking requirement

i. Replacement and disposal of used mandatory replacement parts.

3.14 Warranty: Contractor's standard pump unit warranty shall apply.

3.15 Assembly: The overhauled pump unit shall be delivered to the Coast Guard completely assembled and in a ready to operate condition and configuration.

3.16 Documentation: The contractor shall supply a copy of the inspection and test report to the Coast Guard Q.A. representative upon his arrival at the contractor's plant. The material and dimensional inspection report shall be sent to the Contracting Officer prior to requesting a Q.A. inspection. A final inspection or test report shall be packed with each pump.

3.17 Recommended Grease: A decal or permanent type label shall be affixed to the side of the pump informing the user of the manufacturer's recommended amount and type of grease to be used.

3.19 Preservation, Packing and Marking (PP&M): Each pump unit shall be preserved, packaged in accordance with MIL-STD-2073-1E Standard Practice for Military Packaging and marked in accordance with MIL-STD-129R Standard Practice for Military Marking.

3.18.1 Preservation: An overhauled pump unit is typically intended for warehouse storage and not for immediate installation. Therefore, the Contractor shall ensure that the overhauled pump undergoes the following preservation requirements.

3.18.2 The pump shall be drained and completely dried of all test fluid. The pump shaft, flange faces and all unpainted surfaces shall be coated with a thin film of anti-corrosive rust inhibitor. The inlet and outlet openings shall have plastic plugs or blanks which are secured using the bolt holes.

Any sharp edges or protruding parts shall be covered to protect the packaging bag from tears.

3.18.3 Any ferrous metal surface and all unpainted surfaces shall have a thin coat of rust inhibitor per MIL-PRF-81309F applied.

3.18.4 Each pump unit shall be placed into a protective heat sealable bag per MIL-PRF-131K, Type 1. The pump base shall be fastened to the shipping container. Areas where the fasteners penetrate the sealing bag, either a rubber gasket or 100% silicone rubber shall be used to seal the bag from moisture.

3.18.5 Prior to sealing the bag opening, a minimum of 24-28 ounces of self contained dehydrated desiccant per MIL-D-3464E shall be placed inside the corrective action taken.

3.8 Calibration System: The Contractor, as well as any sub-contractors, shall be required to maintain a measuring and test equipment calibration program in compliance with the National Conference of Standards Laboratories (NCSL) Z540-3. The program shall be documented and traceable to the National Institute of Standards (NIST).

3.9 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 to conduct all required inspections. 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 or tests that are deemed necessary to assure that supplies and services conform to the prescribed requirements. It is the Coast Guard's intent for the Coast Guard Quality Assurance Representative (QAR) to have the discretion to witness and or verify inspections and tests of all pump units overhauled by the Contractor. Any inspection scheduling issues that may occur that would impede progress may only be waived by the CG KO.

3.10 Responsibility for Compliance: The Contractor shall meet the provisions of section 3 of this specification. The inspections set forth in this specification shall become part of the Contractor's overall inspection system and 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.

3.11 Quality System: The Contractor shall maintain an inspection system for tools and equipment which shall ensure that each item performs in accordance with the National Conference of Standards Laboratories (NCSL) Z540-3. The inspection system shall be documented and available for review by the Coast Guard.

3.12 Tests & Inspections: The inspections / tests required, here and in the appropriate subsection in the individual WI 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. The Contractor shall submit a written CFR for each test and inspection.

3.13 Notifications of Inspections / Tests: The Contractor shall notify the Contracting Officer at least ten calendar days prior to accomplishing the following inspections and tests:

a. WFT/DFT readings

b. Motor winding resistance check

c. Motor certification

d. Pump rotation and impeller direction verification

e. Hydrostatic test

f. Operational test (note results including meter and gauge readings in CFR)

g. OEM installation / alignment, parts and service manuals verified packed with the pump

h. Verify Preservation, Packaging & Marking requirement

i. Replacement and disposal of used mandatory replacement parts.

3.14 Warranty: Contractor's standard pump unit warranty shall apply.

3.15 Assembly: The overhauled pump unit shall be delivered to the Coast Guard completely assembled and in a ready to operate condition and configuration.

3.16 Documentation: The contractor shall supply a copy of the inspection and test report to the Coast Guard Q.A. representative upon his arrival at the contractor's plant. The material and dimensional inspection report shall be sent to the Contracting Officer prior to requesting a Q.A. inspection. A final inspection or test report shall be packed with each pump.

3.17 Recommended Grease: A decal or permanent type label shall be affixed to the side of the pump informing the user of the manufacturer's recommended amount and type of grease to be used.

3.19 Preservation, Packing and Marking (PP&M): Each pump unit shall be preserved, packaged in accordance with MIL-STD-2073-1E Standard Practice for Military Packaging and marked in accordance with MIL-STD-129R Standard Practice for Military Marking.

3.18.1 Preservation: An overhauled pump unit is typically intended for warehouse storage and not for immediate installation. Therefore, the Contractor shall ensure that the overhauled pump undergoes the following preservation requirements.

3.18.2 The pump shall be drained and completely dried of all test fluid. The pump shaft, flange faces and all unpainted surfaces shall be coated with a thin film of anti-corrosive rust inhibitor. The inlet and outlet openings shall have plastic plugs or blanks which are secured using the bolt holes.

Any sharp edges or protruding parts shall be covered to protect the packaging bag from tears.

3.18.3 Any ferrous metal surface and all unpainted surfaces shall have a thin coat of rust inhibitor per MIL-PRF-81309F applied.

3.18.4 Each pump unit shall be placed into a protective heat sealable bag per MIL-PRF-131K, Type 1. The pump base shall be fastened to the shipping container. Areas where the fasteners penetrate the sealing bag, either a rubber gasket or 100% silicone rubber shall be used to seal the bag from moisture.

3.18.5 Prior to sealing the bag opening, a minimum of 24-28 ounces of self contained dehydrated desiccant per MIL-D-3464E shall be placed inside the bag. Remove as much air as possible and heat seal the bag opening.

3.19 Packing: Each pump unit shall be individually packed in its own enclosed wooden container. The pump unit shall be securely bolted to a skid base and the lid or cover shall be attached using stainless steel crosshead screws.

The container shall be framed (either on the inside or outside) using solid wood as framing material. The container shall be capable of protecting the pump unit from damage during multiple shipments by commercial carrier per

ASTM D-3951.

At a minimum, the shipping container shall consist of a box constructed of ?

inch plywood, totally enclosed, with internal or external bracing with a skid mounted base to facilitate handling by a fork lift. Each pump unit shall be secured within the shipping container with cross bracing. The use of flakeboard, particle board, OSB is not authorized. The crate lid shall be secured with corrosion resistant Phillips head screws for ease of inspection.

The use of nails, staples, brads or other securing hardware is not authorized.

3.20 Marking: Each preserved and packed pump unit crate shall be stenciled in the upper left-hand corner of the two longest sides (two opposite sides if square). The stencil marking shall be 3/4" -1" inch in height. Markings shall be black characters on white enamel painted background. All previous markings and quality assurance decals shall be removed from a reusable shipping container prior to the application of any new markings. The container markings shall consist of the following:

STOCK NUMBER 4320-99-602-2262

ITEM NAME Pump, Centrifugal

PART NUMBER 2K6X4V-13RV-CD4M

CONTRACT NUMBER See Contract DELIVERY ORDER NUMBER See Contract SHIPPING WEIGHT 2,000 Lbs, As determined by Contractor (includes container).

CONDITION CODE Condition "A"

QUANTITY & UNIT OF ISSUE 1 - EACH

COAST GUARD SFLC MATERIAL

3.21 Bar Coding: The Contractor shall attach bar code labels on all shipping containers for each pump returned to the Coast Guard. Bar code labels shall be in accordance with USCG-SFLC Specification D-000-0100 Rev G Dated 03/2006, Bar Coding for USCG Surface Forces Logistics Center Material.

3.22 Shipping: Unless otherwise directed by the KO, the contractor shall return repaired pump unit to:

US Coast Guard Surface Forces Logistics Center 2401 Hawkins Point RD, Bldg 88 Curtis Bay, MD 21226

3.23 Hazardous Waste Disposal: The Contractor shall be responsible for proper disposal of all hazardous waste generated by work under this contract, i.e. asbestos gaskets, test fluids. Label and package all hazardous wastes in accordance with all applicable Federal, state, and local laws and regulations. In addition, comply with CFR title 40 part 262, applicable to handling and disposal of hazardous waste.

4. NOTES

None

5. Vendor Information:

a. OEM: Ohio Transmission LLC, (Cage 1HNS1), 1900 Jetway Blvd. Columbus, OH 43219-1681

b. OEM: OTC Industrial Technologies, 3948 Townsfair Way, Suite 200, Columbus, OH 43219

c. Distributor: Cummins-Wagner Company, Inc. (Cage 4G363)10901 Pump House Rd, Annapolis Junction, MD 20701-1206

d. Distributor: Pump Parts & Service (PP&S), 3149 Dublin Lane, Bessemer, AL 35022

WORK ITEM 1: 270' Sea Water Pump Overhaul NSN 4320-99-602-2262 Flowserve Durco MK3 Inline Pump, P/N 2K6X4V-13RV-CD4M

1. Scope

1.1 Intent: The Contractor shall disassemble, overhaul, assemble, paint, test, prepare for delivery, and ship the designated auxiliary sea water pump unit. This WI shall be used in conjunction with the General Requirements included in this specification package.

Overhaul in accordance with the Repair Specification is contingent upon receipt, review and approval of the Open and Inspect Report and authorization to proceed from the Coast Guard Contracting Officer. Each Pump Unit shall be overhauled to a condition which shall restore the operating and performance characteristics to the OEM's like new current design and technical specifications.

1.2. Government-Furnished Material: None.

1.3. Mandatory Replacement Parts: To be Determined. Mandatory replacement parts shall be identified and documented as per manufacturer?s recommendation with a description, part number and quantity per assembly.

1.3.1 Contingency Replacement Parts: To be Determined. Contingency replacement parts shall be identified and documented as per manfacturer?s recommendation with a description, part number and quantity per assembly.

2. REFERENCES

COAST GUARD DRAWINGS: Not applicable.

COAST GUARD PUBLICATIONS:

Coast Guard Technical Manual (TM) 4432, SWBS 312 A, Sea Water Cooling Pump.

OTHER REFERENCES:

The Society for Protective Coatings (SSPC) Surface Preparation Specification bag. Remove as much air as possible and heat seal the bag opening.

3.19 Packing: Each pump unit shall be individually packed in its own enclosed wooden container. The pump unit shall be securely bolted to a skid base and the lid or cover shall be attached using stainless steel crosshead screws.

The container shall be framed (either on the inside or outside) using solid wood as framing material. The container shall be capable of protecting the pump unit from damage during multiple shipments by commercial carrier per

ASTM D-3951.

At a minimum, the shipping container shall consist of a box constructed of ?

inch plywood, totally enclosed, with internal or external bracing with a skid mounted base to facilitate handling by a fork lift. Each pump unit shall be secured within the shipping container with cross bracing. The use of flakeboard, particle board, OSB is not authorized. The crate lid shall be secured with corrosion resistant Phillips head screws for ease of inspection.

The use of nails, staples, brads or other securing hardware is not authorized.

3.20 Marking: Each preserved and packed pump unit crate shall be stenciled in the upper left-hand corner of the two longest sides (two opposite sides if square). The stencil marking shall be 3/4" -1" inch in height. Markings shall be black characters on white enamel painted background. All previous markings and quality assurance decals shall be removed from a reusable shipping container prior to the application of any new markings. The container markings shall consist of the following:

STOCK NUMBER 4320-99-602-2262

ITEM NAME Pump, Centrifugal

PART NUMBER 2K6X4V-13RV-CD4M

CONTRACT NUMBER See Contract DELIVERY ORDER NUMBER See Contract SHIPPING WEIGHT 2,000 Lbs, As determined by Contractor (includes container).

CONDITION CODE Condition "A"

QUANTITY & UNIT OF ISSUE 1 - EACH

COAST GUARD SFLC MATERIAL

3.21 Bar Coding: The Contractor shall attach bar code labels on all shipping containers for each pump returned to the Coast Guard. Bar code labels shall be in accordance with USCG-SFLC Specification D-000-0100 Rev G Dated 03/2006, Bar Coding for USCG Surface Forces Logistics Center Material.

3.22 Shipping: Unless otherwise directed by the KO, the contractor shall return repaired pump unit to:

US Coast Guard Surface Forces Logistics Center 2401 Hawkins Point RD, Bldg 88 Curtis Bay, MD 21226

3.23 Hazardous Waste Disposal: The Contractor shall be responsible for proper disposal of all hazardous waste generated by work under this contract, i.e. asbestos gaskets, test fluids. Label and package all hazardous wastes in accordance with all applicable Federal, state, and local laws and regulations. In addition, comply with CFR title 40 part 262, applicable to handling and disposal of hazardous waste.

4. NOTES

None

5. Vendor Information:

a. OEM: Ohio Transmission LLC, (Cage 1HNS1), 1900 Jetway Blvd. Columbus, OH 43219-1681

b. OEM: OTC Industrial Technologies, 3948 Townsfair Way, Suite 200, Columbus, OH 43219

c. Distributor: Cummins-Wagner Company, Inc. (Cage 4G363)10901 Pump House Rd, Annapolis Junction, MD 20701-1206

d. Distributor: Pump Parts & Service (PP&S), 3149 Dublin Lane, Bessemer, AL 35022

WORK ITEM 1: 270' Sea Water Pump Overhaul NSN 4320-99-602-2262 Flowserve Durco MK3 Inline Pump, P/N 2K6X4V-13RV-CD4M

1. Scope

1.1 Intent: The Contractor shall disassemble, overhaul, assemble, paint, test, prepare for delivery, and ship the designated auxiliary sea water pump unit. This WI shall be used in conjunction with the General Requirements included in this specification package.

Overhaul in accordance with the Repair Specification is contingent upon receipt, review and approval of the Open and Inspect Report and authorization to proceed from the Coast Guard Contracting Officer. Each Pump Unit shall be overhauled to a condition which shall restore the operating and performance characteristics to the OEM's like new current design and technical specifications.

1.2. Government-Furnished Material: None.

1.3. Mandatory Replacement Parts: To be Determined. Mandatory replacement parts shall be identified and documented as per manufacturer?s recommendation with a description, part number and quantity per assembly.

1.3.1 Contingency Replacement Parts: To be Determined. Contingency replacement parts shall be identified and documented as per manfacturer?s recommendation with a description, part number and quantity per assembly.

2. REFERENCES

COAST GUARD DRAWINGS: Not applicable.

COAST GUARD PUBLICATIONS:

Coast Guard Technical Manual (TM) 4432, SWBS 312 A, Sea Water Cooling Pump.

OTHER REFERENCES:

The Society for Protective Coatings (SSPC) Surface Preparation Specification

No.3 (SSPC-SP 3), 2004, Power Tool Cleaning.

Federal Standard, FED-STD-595C, dated 01/16/2008, Colors Used in Government Procurement.

American Society of Mechanical Engineers, ASME international - PTC 8.2 Centrifugal Pump, dated 1990.

Flowserve Pump Construction Datasheet 2K6X4V-13RV-CD4

3. OVERHAUL DESCRIPTION

3.1 General: The Contractor shall disassemble, overhaul, assemble, paint, test, prepare for delivery, and ship the designated auxiliary sea water pump unit. The Contractor shall accomplish the specified requirements of this WI in conjunction with the "General Requirements" included in this specification package for each designated pump unit. The Contractor shall refer to applicable OEM overhaul procedures for the FLOWSERVE pump and BALDOR motor and to the Coast Guard TM 4432 for guidance in accomplishing this WI.

3.2 Quality Product: The overhaul requirements described herein are considered to be the minimum acceptable and are not intended to replace any procedures, controls, examinations or tests normally conducted by the Contractor to assure the quality of the product.

3.3 Inspection Reports: The Contractor shall receive, open and inspect each pump in accordance with TM 4432, and adhere to the "General Requirements" in this specification package regarding any required inspection reports.

3.4 Motor Overhaul: The Baldor AC Motor, Spec #10-0004541 is included in this repair specification and shall be overhauled to a like new condition. This also includes restoration of the pump mount, coupling and supporting frame.

3.5 Replacement Parts: The Contractor shall renew all pump unit parts listed in this work item with Contractor provided replacement parts, regardless of their condition.

3.6 Pump: Pump Assembly

3.7 Pump Assembly: The Contractor shall assemble the pump unit in accordance with section four of TM 4432.

3.8 Pump QA Tests: After assembly of the pump unit, the Contractor shall accomplish the tests listed below for each designated pump unit. At the Coast Guard's discretion, a QAR will witness and or verify inspections and tests conducted by the Contractor to prove satisfactory operating condition.

The Contractor shall provide all labor, material and place of service to conduct the tests.

3.9 Rotation Test: To ensure the pump unit turns freely, the pump shaft shall be rotated a minimum of five revolutions by the use of a strap wrench or other non-damaging tool. The Contractor's QA Representative shall inspect for smoothness of rotation and check for signs of binding or dragging. Pump units which have reversible impellers shall be inspected to confirm proper rotation. The Contractor shall investigate any questionable test results and correct as necessary.

3.10 Hydrostatic Test: The Contractor shall conduct a hydrostatic test of the overhauled pump unit using the OEM specified test fluid. The test shall be conducted to certify the integrity of the pump and seal area. The test shall be conducted at 150 percent of the rated working pressure or mechanical seal rating whichever is less. The test shall be conducted for a period of ten minutes and discontinued at any sign of leakage. The Contractor shall investigate and correct any leakage and retest the pump unit.

3.11 Operational Test: In addition to the hydrostatic test, the pump unit shall be operationally tested by the use of a test tank of compatible OEM recommended test fluid. Each operational pump unit test shall be conducted, recorded and reported in accordance with Type B of ASME International PTC 8.2.

3.12 QA Test Documentation: The test results shall be documented on a report in accordance with ASME International PTC 8.2 and provided to the KO. A copy of the test report shall be packed with each pump unit and a copy shall be available to the QAR for review.

3.13 Paint: The Contractor shall prepare the exterior pump housing for preservation in accordance with SSPC-SP-3. The Contractor shall apply primer and finish coats of paint to the entire pump unit external housing (excluding flange faces). The primer coat shall be 5-6 mils dry film thickness (DFT) of any rust preventive metal primer suitable for use with the finish coat. The finish coat shall be 3-6 mils DFT of silicone alkyd enamel, Type II or III, Class I or II. The color shall be dark green, color number 14062 per SAE Standard, AMS-STD-595. Total paint thickness shall be a minimum of 8-12 mils DFT. The pump shall be painted after all tests are complete.

3.14 Quality Assurance: See General Requirements.

3.15 Preservation, Packaging & Marking: See section 3.19 of the General Requirements. The shipping container shall be marked as follows:

STOCK NUMBER 4320-99-602-2262

ITEM NAME Pump, Centrifugal

PART NUMBER 2K6X4V-13RV-CD4M

CONTRACT NUMBER See Contract DELIVERY ORDER NUMBER See Contract SHIPPING WEIGHT 2,000 Lbs, As determined by Contractor (includes container).

CONDITION CODE Condition "A"

QUANTITY & UNIT OF ISSUE 1 - EACH

COAST GUARD SFLC MATERIAL

4. NOTES

The Flowserve Pump 2K6X4V-13RV-CD4 Construction data sheet by PP&S is available upon request.

No.3 (SSPC-SP 3), 2004, Power Tool Cleaning.

Federal Standard, FED-STD-595C, dated 01/16/2008, Colors Used in Government Procurement.

American Society of Mechanical Engineers, ASME international - PTC 8.2 Centrifugal Pump, dated 1990.

Flowserve Pump Construction Datasheet 2K6X4V-13RV-CD4

3. OVERHAUL DESCRIPTION

3.1 General: The Contractor shall disassemble, overhaul, assemble, paint, test, prepare for delivery, and ship the designated auxiliary sea water pump unit. The Contractor shall accomplish the specified requirements of this WI in conjunction with the "General Requirements" included in this specification package for each designated pump unit. The Contractor shall refer to applicable OEM overhaul procedures for the FLOWSERVE pump and BALDOR motor and to the Coast Guard TM 4432 for guidance in accomplishing this WI.

3.2 Quality Product: The overhaul requirements described herein are considered to be the minimum acceptable and are not intended to replace any procedures, controls, examinations or tests normally conducted by the Contractor to assure the quality of the product.

3.3 Inspection Reports: The Contractor shall receive, open and inspect each pump in accordance with TM 4432, and adhere to the "General Requirements" in this specification package regarding any required inspection reports.

3.4 Motor Overhaul: The Baldor AC Motor, Spec #10-0004541 is included in this repair specification and shall be overhauled to a like new condition. This also includes restoration of the pump mount, coupling and supporting frame.

3.5 Replacement Parts: The Contractor shall renew all pump unit parts listed in this work item with Contractor provided replacement parts, regardless of their condition.

3.6 Pump: Pump Assembly

3.7 Pump Assembly: The Contractor shall assemble the pump unit in accordance with section four of TM 4432.

3.8 Pump QA Tests: After assembly of the pump unit, the Contractor shall accomplish the tests listed below for each designated pump unit. At the Coast Guard's discretion, a QAR will witness and or verify inspections and tests conducted by the Contractor to prove satisfactory operating condition.

The Contractor shall provide all labor, material and place of service to conduct the tests.

3.9 Rotation Test: To ensure the pump unit turns freely, the pump shaft shall be rotated a minimum of five revolutions by the use of a strap wrench or other non-damaging tool. The Contractor's QA Representative shall inspect for smoothness of rotation and check for signs of binding or dragging. Pump units which have reversible impellers shall be inspected to confirm proper rotation. The Contractor shall investigate any questionable test results and correct as necessary.

3.10 Hydrostatic Test: The Contractor shall conduct a hydrostatic test of the overhauled pump unit using the OEM specified test fluid. The test shall be conducted to certify the integrity of the pump and seal area. The test shall be conducted at 150 percent of the rated working pressure or mechanical seal rating whichever is less. The test shall be conducted for a period of ten minutes and discontinued at any sign of leakage. The Contractor shall investigate and correct any leakage and retest the pump unit.

3.11 Operational Test: In addition to the hydrostatic test, the pump unit shall be operationally tested by the use of a test tank of compatible OEM recommended test fluid. Each operational pump unit test shall be conducted, recorded and reported in accordance with Type B of ASME International PTC 8.2.

3.12 QA Test Documentation: The test results shall be documented on a report in accordance with ASME International PTC 8.2 and provided to the KO. A copy of the test report shall be packed with each pump unit and a copy shall be available to the QAR for review.

3.13 Paint: The Contractor shall prepare the exterior pump housing for preservation in accordance with SSPC-SP-3. The Contractor shall apply primer and finish coats of paint to the entire pump unit external housing (excluding flange faces). The primer coat shall be 5-6 mils dry film thickness (DFT) of any rust preventive metal primer suitable for use with the finish coat. The finish coat shall be 3-6 mils DFT of silicone alkyd enamel, Type II or III, Class I or II. The color shall be dark green, color number 14062 per SAE Standard, AMS-STD-595. Total paint thickness shall be a minimum of 8-12 mils DFT. The pump shall be painted after all tests are complete.

3.14 Quality Assurance: See General Requirements.

3.15 Preservation, Packaging & Marking: See section 3.19 of the General Requirements. The shipping container shall be marked as follows:

STOCK NUMBER 4320-99-602-2262

ITEM NAME Pump, Centrifugal

PART NUMBER 2K6X4V-13RV-CD4M

CONTRA…