(01)_Specification_381,_Revision_F;_Buoy_Whistles_and_Whistle_Valves.pdf

UNITED STATES COAST GUARD

SHORE INFRASTRUCTURE LOGISTICS CENTER

WATERWAYS OPERATIONS PRODUCT LINE

JUNE 2018

SPECIFICATION FOR FABRICATION OF

BUOY WHISTLES, WHISTLE VALVE BODY, AND WHISTLE

RUBBER BALL

SPECIFICATION NO. 381

REVISION F

MJB_0618

WORK ITEM 1: 6350-01-034-1347, 120777 Whistle Buoy, Purchase

WORK ITEM 2: 4820-01-034-1348, 120777 Whistle Valve Body, Purchase

WORK ITEM 3: 2050-00-301-4067, 120777 Whistle Rubber Ball, Purchase

1. SCOPE

1.1 Intent. This specification defines the requirements for the fabrication of buoy whistle, whistle valve body, and whistle rubber ball for use on aids to navigation buoys. The items covered by this specification are as follows:

• NSN: 6350-01-034-1347, P/N: 120777 Whistle Buoy

• NSN: 4820-01-034-1348, P/N: 120777 Whistle Valve Body

• NSN: 2050-00-301-4067, P/N: 120777 Whistle Rubber Ball

1.2 Government-Furnished Property. The Coast Guard will provide the following items to the Contractor upon request as Government-Furnished Property (GFP). For information purposes, the applicable Accounting Control Number (ACN) for each item set is listed below.

PATTERN

DESCRIPTION

ACN/PN PATTERN

NO.

# OF

PIECES

ESTIMATED

COST

($/UNIT)

Whistle Valve Body

(Mold - 2 pieces)

NSN: 6350-01-F83-0116

PN: 945-1 MOLD WHISTLE VALVE

BODY

945-1 2 1,324.00

Whistle Valve Cover

(Mold - 2 pieces, Pattern - 1 piece)

NSN: 6350-01-F83-0117

PN: 945-2 MOLD & PATTERN

WHISTLE VALVE COVER

945-2 3 1,322.00

Whistle Valve Gland

(Pattern - 2 pieces)

NSN: 6350-01-F83-0118

PN: 945-3 PATTERN WHISTLE

VALVE GLAND

945-3 2 1,322.00

Whistle Body (Mold -2 pieces; Pattern – 2 pieces)

NSN: 6350-01-F83-0119

PN: 945-4 MOLD & PATTERN

WHISTLE BODY

945-4 4 1,328.00

Whistle Bell (Mold – 2 pieces; Pattern - 1 piece)

NSN: 6350-01-F83-0120

PN: 945-5 PATTERN WHISTLE BELL

945-5 3

1,326.00

Whistle Spindle (Mold

– 2 pieces; Pattern - 2 piece)

NSN: 6350-01-F83-0121

PN: 945-6 PATTERN WHISTLE

SPINDLE

945-6 4 500.00

Whistle Cap Nut (Mold

- 2 pieces; Pattern - 2 pieces)

NSN: 6350-01-F83-0122

PN: 945-7 MOLD & PATTERN

WHISTLE CAP NUT

945-7 4 1,326.00

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

1.2.1 Maintenance of Molds. The Government will ship the above listed GFP to the Contractor's facility after award of contract for manufacture of Buoy Whistles, Whistle Valve Bodies, and Whistle Rubber

Balls. The Contractor shall be responsible for any necessary maintenance/reconditioning of the GFP for the duration of the contract. The Contractor shall make the GFP available for inspection by Government personnel for the duration of the contract. Upon completion of the contract, the Contractor shall return the above listed GFP in usable condition. The Contractor will package, label and ship the above listed GFP from the Contractor's facility back to the Coast Guard address per Section 5 of this specification.

2. REFERENCES

COAST GUARD DRAWINGS

Coast Guard Drawing 120777 Rev E, Buoy Whistle & Valve Whistle Assembly & Details

COAST GUARD PUBLICATIONS

None

OTHER REFERENCES

ANSI/ASQ Q9001, 1 Oct 2015 Quality Management Systems – Requirements – T860E

ANSI/NCSL Z540-3.2006, 1 Mar 2006 Requirements for the Calibration of Measuring and Test

Equipment

ANSI/ASQ Z1.4-2008, R2013 Sampling Procedures and Table for Inspection by Attributes

(Table IIA, based on General Inspection Level II from Table I)

ASTM B96/B96M-16, 1 Apr 2016 Standard Specification for Copper-Silicon Alloy Plate, Sheet, Strip, and Rolled Bar for General Purposes and Pressure Vessels1

ASTM B584-14, 1 Apr 2016 Standard Specification for Copper Alloy Sand Castings for General

Applications1

ASTM D7478/D7478M-11, 1 Nov 2011 Standard Specification for Heavy Duty Sheathed Wood

Crates1

ASTM D3953-15, 1 May 2015 Standard Specification for Strapping, Flat Steel Seals1

ASTM D4675-14a, 1 May 2014 Standard Guide for Selection and Use of Flat Strapping

Materials

ASTM D4727-17, 1 Apr 2017 Standard Specification for Corrugated and Solid Fiberboard Sheet

Stock (Container Grade) and Cut Shapes1

ASTM D5118/D5118M-15, 1 Oct 2015 Standard Practice for Fabrication of Fiberboard Shipping

Boxes1

ASTM D1974/D1974M-16, 22 Dec 2010 Standard Practice for Methods of Closing, Sealing, and

Reinforcing Fiberboard Boxes1

ASTM D5486D/5486M-06 (Reapproved 2012), 31 May 2012 Standard Specification for

Pressure-Sensitive Tape for Packaging, Box Closure, and Sealing 1,2

MIL-STD-2073-1E w/Change 1, 7 Jan 2011 Department of Defense Standard Practice for

Military Packaging

MIL-STD-129R, 18 Feb 2014 Department of Defense Standard Practice Military Marking for

Shipment and Storage

ISO/IEC 16388:2007, 15 May 2007 Information Technology - Automatic identification and data capture techniques - Code 39 bar code symbology specification

2.1 General. The documents listed in this section are referenced in sections 3, 4, and 5 of this specification. This section does not include documents cited in other sections of this specification, which are recommended for additional information or used as examples. While every effort has been made to ensure the completeness of this list, document users are cautioned that they must meet all specified requirements cited in sections 3, 4, and 5 of this specification, whether or not the referenced documents are listed here. Suffixes denoting the specific issue of each document are omitted from future references to the documents in this specification.

2.2 Specification order of precedence. In the event of a conflict between the text of this specification and the references cited herein, this specification shall take precedence. Nothing in this document, however, supersedes applicable laws and regulations unless a specific exemption has been obtained.

3. REQUIREMENTS

3.1 Materials.

3.1.1 Copper Alloy Castings. All cast items shall meet the requirements of ASTM B584, Copper Alloy

UNS Number C87600.

3.1.2 Copper Alloy Sheet. The whistle bell shall be fabricated from Copper Alloy C65500 sheet that meets the requirements of ASTM B96/B96M.

3.1.3 Brass. All brass items shall be a standard commercial grade of brass.

3.1.4 Whistle Ball. Shall be manufactured as follows.

3.1.4.1 Whistle Ball Material.

• Core shall be made of cork or balsa wood (foam or synthetic material of equal resiliency is acceptable).

• Rubber coating shall be made of rubber gum containing 55-65 percent rubber by volume, compounded with lamp black and zinc oxide, without barytes or lead to yield an elastic product having a specific gravity of 1.2 to 1.3 at 15 degrees to 50 degrees Celsius. The sum of organic acetone, chloroform and alcohol-alkali extracts shall not exceed 18 percent with a total sulfur content approximately 2 percent.

3.1.4.2 Whistle Ball Dimensions.

• Core diameter shall be: minimum diameter 3.875 inches, maximum diameter 4.000 inches

• Rubber coating thickness shall be: minimum thickness 0.063 inches, maximum thickness

0.125 inches

• Overall dimensions shall be: minimum diameter: 4.000 inches, maximum diameter 4.063 inches

3.1.4.3 Whistle Ball Finish.

• Core shall be smooth, true to shape, and of uniform diameter so that excess rubber will not be required to fill depressions and voids

• Rubber surface shall be smooth and true to shape

• The finished ball shape shall be smooth, of uniform diameter, and true to shape

• Weight of the finished ball shall not exceed 7.5 ounces each

3.2 Surface Finish - Metal. Where indicated on the drawing, surfaces shall be finished to the designated maximum roughness height of 125 micro-inches. Surfaces shall remain with their natural finish and shall not have a protective coating. All castings shall be free of adhering sand, visual cracks, surface porosity, burrs, and sub-surface defects.

3.3 Marking.

3.3.1 Identification Marking. For tracking purposes, each item (except for the ball) shall be identified by an identification marking. The marking shall be stamped, engraved, or otherwise permanently affixed to each item. The marking shall consist of ½-inch tall block alphanumeric characters and be clearly visible.

The marking shall be of the form 18-XX. The first two digits are the last two digits of the calendar year built and the last two letters are the Contractor’s designation, which will be furnished by the Contracting Officer after contract award.

3.3.2 Serial Number. For inspection purposes, the Contractor shall assign each item (except for the ball) a unique serial number of two (2), three (3) or four (4) digits depending on the quantities of the production run. The serial number shall be stamped, engraved, or otherwise permanently affixed to each item. The serial number shall consist of ½-inch tall block alphanumeric characters and be clearly visible.

3.4 Documentation.

3.4.1 Quality Assurance Inspection Form. The Contractor shall develop and provide a Quality Assurance Inspection Form (QAIF). The QAIF shall be used to document the inspections and tests performed on every item throughout its fabrication process. The form shall be printed on standard (i.e., 8½ x 11 inch) white paper. Inspection results may be handwritten on the form. The form shall be prepared in the Contractor's format and shall be legible, in English, and suitable for reproduction. The form shall be made available to the Contracting Officer’s Representative (COR) for review.

3.4.1.1 QAIF Content. At a minimum the QAIF shall include:

• Item serial number

• Date of test or inspection

• Test or inspection to be performed (list every test and inspection required by section 4.0)

• Result of test or inspection

• Accept/Reject criteria for each test or inspection

• Corrective action taken (if any)

• Notes

• Initials or signatures of Contractor’s test personnel

3.4.2 Material Certifications. When requested by the COR, the Contractor shall furnish material certifications, either from the material manufacturers or an independent testing laboratory, to the effect that the material described in paragraph 3.1.1 through 3.1.3, and 3.1.4.1 has been tested and found to meet the requirements of the applicable section of this specification. The material certifications shall be stored by the Contractor for the life of the contract.

3.4.3 Material Inspection and Receiving Report (DHS Form 700-21). A form DHS-700-21 shall be used as a certification of product quality assurance, as a packing list, and as a certification of acceptance. The Contractor shall prepare a separate DHS-700-21 for each shipping lot. Prior to shipment, the DHS-700-21 must be signed by the COR.

4. QUALITY ASSURANCE

4.1 General. The Contractor's quality assurance program shall meet the requirements of ASQ Q9001.

However, the Contractor does not have to be Q9001 certified.

4.1.1 Contractor’s calibration system. The contractor shall maintain a calibration and maintenance system to control the accuracy of measurement and test equipment used in the fulfillment of this specification.

The system shall include, as a minimum, prescribed calibration intervals and the source of calibration. A monitoring system to this requirement shall be readily available to the Coast Guard Inspector. Calibration shall be traceable to the National Institute of Standards and Technology in accordance with ANSI/NCSL

Z540-3.2006. At the time of CG inspection, documentation in support of this requirement shall be made available to the COR.

4.2 Classification of Inspections. The inspection requirements specified herein are classified as follows:

• First article inspection (paragraph 4.3)

• Contractor production inspection (paragraph 4.4)

• Coast Guard production inspection (paragraph 4.5)

4.3. First Article Inspection. When first article samples are required, the Contractor shall perform a first article inspection in accordance with paragraph 4.6. A first article inspection shall be performed by the

Contractor and at the Contractor’s facility. The first articles shall meet the requirements of this specification and shall pass all the tests and inspections listed in this section.

4.3.1 First Article Tests and Inspections Notification. The Contractor shall notify the Contracting Officer in writing at least seven (7) business days prior to the scheduled commencement of any inspections and tests required by this specification.

4.3.2 Waiver of First Article Requirements. The Contracting Officer reserves the right to waive all or part of the first article requirements specified herein.

4.3.3 Rejection Criteria. The results of the first article inspection will be reviewed by the Contracting

Officer to determine compliance with the requirements of this specification. Failure of any of the tests or inspections described herein will be cause for rejection of the first article. If the first article is rejected, the

Contractor will be notified in writing by the Contracting Officer and allowed fourteen (14) calendar days to fix or resubmit a new first article. Repair or replacement of the first article shall be by the Contractor at the Contractor's expense.

4.3.4 Authorization to Proceed. Upon successful completion of the first article inspection, the Contracting

Officer will provide the Contractor with written authorization to begin fabricating production quantities.

4.3.5 Standardization. Materials, parts, design, and fabrication methods used in the production quantities shall be identical to those used in the first articles, unless otherwise authorized in writing by the

Contracting Officer.

4.3.6 Production Lot Sampling. A random sample of items shall be selected from each production lot. The minimum sample size shall be specified by ASQ Z1.4-2008, R2013 Table IIA, based on General

Inspection Level II from Table I, Normal, Acceptance Quality Limit (AQL) = 1.0. A production lot shall be all the items from an identifiable production period from one manufacturer and one plant and submitted for acceptance at one time. Each lot sample shall be examined to verify conformance to requirements stated in applicable specifications and drawings. Samples that fail to comply with any production test requirements of this specification, have any defects that will interfere with a sample item’s use, or will decrease its reliability shall be rejected. Entire lots shall be rejected when the percent of nonconformance exceeds ASQ Z1.4-2008, R2013, Level II, Normal, AQL = 1.0.

4.4 Contractor Production Inspection. The tests and inspections required by this specification are not intended to supplant any controls, examinations, inspections, or tests normally employed by the

Contractor to assure product quality. The Contractor shall perform the tests and inspections specified in paragraph 4.6 to ensure conformance to this specification. The Contractor shall provide space, personnel, and test equipment to conduct all inspections and test requirements.

4.5 Coast Guard Production Inspection. The Coast Guard reserves the right to observe, verify, or perform the tests and inspections outlined in paragraph 4.6.

4.6 Tests and Inspections. The following tests and inspections shall be conducted for each first article unit and subsequent production units:

• Visual inspection

• Documentation review

4.6.1 Visual Inspection. Each item shall be visually inspected for quality of workmanship and conformance to this specification and the drawing. The inspection shall include checks of dimensional conformance, mechanical fit, alignment of parts, and marking.

4.6.2 Documentation Review. The documentation required by paragraph 3.4 shall be reviewed for conformance with this specification and provided to the COR upon request.

4.7 Rejection for Defects. The Coast Guard will reject all items which do not conform to the requirements of this specification. Repair or replacement of the rejected items shall be by the Contractor at the

Contractor's expense. All rejected items shall be resubmitted for inspection only when they conform to the requirements of this specification. Resubmitted items shall be identified as such and shall be kept separate from new items. If defective items are found, no further items will be accepted by the Coast

Guard until the Contractor has demonstrated that the defects have been corrected and that the cause of the defects has been eliminated from the production process.

5. PRESERVATION, PACKING, MARKING, AND SHIPPING

5.1 Preservation. Per MIL-SPEC-2073-1E, Method 10.

5.2 Packing. Shall be in accordance with MIL-SPEC-2073-1E Level B, to protect these assemblies and items during moderate worldwide shipment, handling, and storage conditions.

5.2.1 Whistle Buoy (Assembly) and Whistle Valve Body (Assembly). Shall be individually packed and packaged in accordance with ASTM D7478/D7478M, Type 1 (nailed or screwed), Class 2 (plywood sheathed), Style A (skid base). Cushioning materials, dunnage, blocking, bracing and strapping shall be applied as required to protect the item and restrict the movement of the item within the container. The materials selected for all blocking and bracing, and the design and application thereof, shall be compatible with the item and its bearing load limitations. Materials shall be as clean and as dry as practicable. The top sheathing shall be attached with screws. Ventilation is not necessary. The crate shall be reinforced with metal strapping manufactured in accordance with ASTM D3953 and applied in accordance with

ASTM D4675, Figure S1.3 and Table S1.3.

5.2.2 Whistle Rubber Ball - When Purchased Separately (Not Within Whistle Buoy Assembly or Whistle

Valve Body (Assembly). Shall be individually packaged in a single-wall (SW) corrugated fiberboard (CF)

Regular Slotted box (0201), Class Weather Resistant (WR) in accordance with ASTM D5118/D5118M-

15. The box shall be manufactured with fiberboard in accordance with ASTM D4727.

5.2.2.1 Closure of Regular Slotted Boxes. Shall be in accordance with ASTM D1974/D1974M, Closure

Method 2B6. The tape shall comply with Specification D5486/D5486M, Type V.

5.3 Marking. Each packaged item shall have a waterproof label securely attached or waterproof stencil on wood crates in the upper left-hand corner of the two longest sides (two opposite sides if square) of each box or crate in accordance with MIL-STD-129R. The stencil marking shall be ¾ - 1 inch in height.

5.3.1 Marking Layout. The following information shall be on the label attached to each box or crate. See

6.2 for label example and placement.

NATIONAL STOCK NUMBER

(Of the item)

CAGE CODE

(Contractor’s)

PART NUMBER

(Of the item)

QUANTITY & UNIT OF ISSUE

1 EA

CONTRACT NUMBER

(See Contract Page 1)

DELIVERY ORDER NUMBER

(See Contract Page 1)

MANUFACTURED DATE

MFD 05/18

SHIPPING WEIGHT (LBS)

WT (As Determined by Contractor)

SERIAL NUMBER

SER NO (Of item within) (Omit for Whistle Rubber Ball)

CONDITION CODE

CONDITION A

OTHER DATA as Directed

USCG SILC-WOPL MATERIAL

5.4 Bar coding. U.S. Coast Guard requires bar coding of the NSN, IAW ISO/IEC 16388-2007 Code 39

Symbology. See 6.2 for label placement and 6.3 for Bar Code examples.

5.4.1 Bar Code Label. Can be applied separately or as part of the marking required in 5.3.

5.5 Shipping. The Contractor shall deliver the contracted items/delivery order to the Coast Guard address specified in paragraph 5.5.3, unless directed otherwise per the contract.

5.5.1 Shipment Details. The Contractor shall notify the COR and Contracting Officer within three (3) business days of:

• date of shipment the contracted items/delivery order leaves the Contractor's facility

• name of the shipping company

• tracking number(s) of shipment

• expected arrival date and time at the Coast Guard facility

5.5.1.1 Normal delivery hours at the warehouse (Curtis Bay, MD) are Monday through Friday 0730-1300

(excluding Federal Holidays). Deliveries outside this window shall require prior written approval by the

Contracting Officer.

5.5.2 All items shall be shipped FOB Destination.

5.5.3 Address. Unless otherwise specified, the Contractor shall ship, and deliver all parts to the following

Coast Guard address:

US Coast Guard

Surface Forces Logistics Center

2401 Hawkins Point RD

Receiving Room - Building 88

Curtis Bay, MD 21226

6. NOTES

6.1 Document sources.

6.1.1 Coast Guard documents.

United States Coast Guard Shore Infrastructure Logistics Center

Waterways Operations Product Line

300 East Main Street

Norfolk, VA 23510-9104 http://www.dcms.uscg.mil/Our-Organization/Assistant-Commandant-to-Engineering-Logistics-

CG-4-/Logistic-Centers/Waterways-Operation-Product-Line/

6.1.2 Industry Publications.

(ANSI/AIM) American National Standards Institute USA

25 West 43rd Street, 4th floor

New York, NY 10036

Office 212-642-4900 Fax 212-398-0023

Customer Service or Document Sales 212-642-4980 0830-1800

(ANSI/ASQ) American Society for Quality Control

310 West Wisconsin Avenue

Milwaukee, Wisconsin 53203 http://asq.org/index.aspx

(ASTM) American Society for Testing & Materials

100 Barr Harbor Drive

P.O. Box C700

West Conshohocken, PA 19428-2959

Office 610-832-9500 Fax 610-832-9555 http://www.dcms.uscg.mil/Our-Organization/Assistant-Commandant-to-Engineering-Logistics-CG-4-/Logistic-Centers/Waterways-Operation-Product-Line/ http://www.dcms.uscg.mil/Our-Organization/Assistant-Commandant-to-Engineering-Logistics-CG-4-/Logistic-Centers/Waterways-Operation-Product-Line/ http://asq.org/index.aspx

(ISO) International Organization for Standardization BIBC II

Chemin de Blandonnet 8, CP 401

1214 Vernier, Geneva, Switzerland

Phone +41 22 749 01 11 Fax: +41 22 733 34 30

Email: central@iso.org

6.1.3 Military Standards and Specifications.

Defense Printing Service Detachment Office

Bldg. 4D (NPM-DODSSP)

700 Robbins Avenue

Philadelphia, PA 19111-5094

215-697-2667 or -2179 Fax 215-697-1462

DOD & Navy Publications & Forms (Other Than DODSSP)

Naval Publication and Forms Center

5801 Tabor Avenue

Philadelphia, PA 19120

215-697-2000

6.2 Military Marking Example.

Placement of identification and address marking on boxes and crates.

Example of unit pack, intermediate and exterior container identification markings (including an example of bar code markings).

6.3 Bar coding example.

SPECIFICATION NO. 381 REV F – FABRICATION OF BUOY

WHISTLE, WHISTLE VALVE BODY, AND WHISTLE RUBBER

BALL

Prepared by: Reviewed by:

Mr. M. J. Beimel LT. Rudy Bowis

Equipment Specialist, Waterways Operations Asset Line Manager, Waterways Operations

Product Line Product Line

Approved by: Date:

Mr. Wayne Danzik

Deputy Manager, Waterways Operations

Product Line