Overhaul Requirements.pdf

OVERHAUL DESCRIPTION

ITEM NAME PUMP,HYDRAULIC

STOCK NUMBER 4320-01-470-8803

PART NUMBER AA11VLO260LRDS/11RNTD62K07

USED ON 225' WLB

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:

INSPECTION AND OVERHAUL DESCRIPTION

1. Scope: This description covers the requirements for contractor inspection, estimate and overhaul of the following cited hydraulic pump.

Stock No: 4320 01-470-8803 Name: PUMP, HYDRAULIC Part No: AA11VLO260LRDS/11RNTD62K07

1.2 General Description Displacement 15.87 CU. IN., Clockwise Rotation, Spline Shaft 17 Tooth, 8/16 Pitch, 30 deg Pressure Angle. Mounting Flange SAE E, 4 Bolt, Through Drive SAE C, 2 Bolt, Suction Port SAE 4" , Pressure Port SAE 1-1/2", Drain Port #16 SAE O-Ring. Control Device Constant Power/Pressure Cut-Off/Load Sensing Control. This hydraulic pump is used for the the forward bouy deck HPU onboard the 225' WLB B and 240' WLBB Cutters.

1.3 The assembly delivered for overhaul services is intended to be a complete Rexroth Corp pump part number AA11VLO260LRDS/11RNTD62K07 configuration.

Contractor shall notify the Coast Guard Contract Administrator of any missing components or, otherwise, questionable condition that may hinder the overhaul process.

1.4 The overhaul requirements described herein are considered minimum and are not intended to replace any procedures, controls, examinations or tests normally employed by the contractor to assure the quality of the product.

Overhaul is intended to return the pump to a condition equal to that of an identical new pump.

2. Applicable Documents:

a) ANSI/NCSL Z540-1-1994 (dtd. 1994) Calibration laboratories and Measuring and Test Equipment- General Requirements.

b) The Society for Protective Coatings, SSPC-SP 10, Near White Blast Cleaning Dtd. Sept. 2000.

c) TP-3798, Coast Guard Technical Publication CRANE AND BUOY DECK Hydraulic power unit for 240' WLBB.

d) SAE, AMS-STD-595 Colors Used In Government Procurement.

e) MIL-STD-129R, Marking

f) ISO/IEC-16388-2007, Code 39 Symbology

3. Requirements: The contractor shall provide all labor and materials to perform overhaul services on the pump.

3.1 Preliminary disassembly and Cleaning. Disassembly and thorough cleaning of all parts is required. Removal of all existing paint in accordance with part 3.6 herein shall also be included as part of the cleaning process.

3.2 Inspection and Estimated Cost for Overhaul. Inspection shall be conducted to determine estimated cost of overhaul including material, labor, testing, preservation, packing and marking cost. A detailed estimate shall be submitted to the Coast Guard Contracting Officer for approval prior to the start of overhaul work. Estimate shall include a breakdown of the replacement parts, materials and processes with costs for each item needed to accomplish the overhaul.

3.3 Replacement Parts: All replacement parts used in overhaul shall only be new original equipment replacement parts or equal new parts. Reclaimed or recycled parts are not acceptable and shall not be used.

3.3.1 Each newly-repaired pump shall be equipped the original Falk (Taylor- Newcomb) servo control and potentiometer. If the pump is not equipped with the servo and potentiometer upon receipt by the contractor, the contractor shall notify the USCG Contracting Officer on the initial inspection report.

If necessary, the contractor shall procure one for each pump, install it, and adjust/calibrate as required to have the pump perform as new.

3.4 Special Instructions: Any pump delivered for overhaul having packing glands shall be converted to mechanical seal assemblies as part of the overall work performed. Contractor shall include conversion work and parts in the overhaul estimate as necessary.

3.5 Disposition. The Coast Guard shall determine the disposition of any pump delivered for repair that is found to be not suitable for repair for whatever reason.

3.6 Paint Removal: Removal of existing paint shall be accomplished by abrasive blast to near white metal in accordance with SSPC SP-10 where practicable. Equal means of paint removal is acceptable where grit blast poses a risk of damage to internal components and cannot be properly protected from blasting operation. Remove any label plates and replace at the conclusion of painting.

3.7 Painting: Entire pump shall be painted with primer and finish coats.

Primer coat shall be any rust preventive metal primer suitable for use with the finish coat. Finish coat shall be Silicone Alkyd Enamel. Color shall be Machinery Gray in accordance with Federal Standard 595B color number 16376.

Total paint thickness shall be a minimum of 3 mil dry film.

3.8 Testing: In order to assure maximum design performance, after completion of overhaul the contractor shall conduct an operational test to the pumps rated capacity. Contractor shall provide test certification for each pump upon determination of satisfactory operation. One certification shall be placed in the box with each pump unit and a copy for each unit shall be provided to the Coast Guard Quality Assurance Representative. All testing shall be accomplished on Contractor supplied test equipment. Contractor shall ensure all test fluid is drained from the pump casing at the conclusion of testing.

3.8.1 Rotational Test: To ensure the pump turns freely and without bind, the pump rotor assembly shall be rotated 10-20 times by the use of a strap wrench or other non-damaging tool. The QAR shall inspect for smoothness of rotation and check for signs of binding. Contractor shall investigate any questionable test results and correct as necessary.

INSPECTION AND OVERHAUL DESCRIPTION

1. Scope: This description covers the requirements for contractor inspection, estimate and overhaul of the following cited hydraulic pump.

Stock No: 4320 01-470-8803 Name: PUMP, HYDRAULIC Part No: AA11VLO260LRDS/11RNTD62K07

1.2 General Description Displacement 15.87 CU. IN., Clockwise Rotation, Spline Shaft 17 Tooth, 8/16 Pitch, 30 deg Pressure Angle. Mounting Flange SAE E, 4 Bolt, Through Drive SAE C, 2 Bolt, Suction Port SAE 4" , Pressure Port SAE 1-1/2", Drain Port #16 SAE O-Ring. Control Device Constant Power/Pressure Cut-Off/Load Sensing Control. This hydraulic pump is used for the the forward bouy deck HPU onboard the 225' WLB B and 240' WLBB Cutters.

1.3 The assembly delivered for overhaul services is intended to be a complete Rexroth Corp pump part number AA11VLO260LRDS/11RNTD62K07 configuration.

Contractor shall notify the Coast Guard Contract Administrator of any missing components or, otherwise, questionable condition that may hinder the overhaul process.

1.4 The overhaul requirements described herein are considered minimum and are not intended to replace any procedures, controls, examinations or tests normally employed by the contractor to assure the quality of the product.

Overhaul is intended to return the pump to a condition equal to that of an identical new pump.

2. Applicable Documents:

a) ANSI/NCSL Z540-1-1994 (dtd. 1994) Calibration laboratories and Measuring and Test Equipment- General Requirements.

b) The Society for Protective Coatings, SSPC-SP 10, Near White Blast Cleaning Dtd. Sept. 2000.

c) TP-3798, Coast Guard Technical Publication CRANE AND BUOY DECK Hydraulic power unit for 240' WLBB.

d) SAE, AMS-STD-595 Colors Used In Government Procurement.

e) MIL-STD-129R, Marking

f) ISO/IEC-16388-2007, Code 39 Symbology

3. Requirements: The contractor shall provide all labor and materials to perform overhaul services on the pump.

3.1 Preliminary disassembly and Cleaning. Disassembly and thorough cleaning of all parts is required. Removal of all existing paint in accordance with part 3.6 herein shall also be included as part of the cleaning process.

3.2 Inspection and Estimated Cost for Overhaul. Inspection shall be conducted to determine estimated cost of overhaul including material, labor, testing, preservation, packing and marking cost. A detailed estimate shall be submitted to the Coast Guard Contracting Officer for approval prior to the start of overhaul work. Estimate shall include a breakdown of the replacement parts, materials and processes with costs for each item needed to accomplish the overhaul.

3.3 Replacement Parts: All replacement parts used in overhaul shall only be new original equipment replacement parts or equal new parts. Reclaimed or recycled parts are not acceptable and shall not be used.

3.3.1 Each newly-repaired pump shall be equipped the original Falk (Taylor- Newcomb) servo control and potentiometer. If the pump is not equipped with the servo and potentiometer upon receipt by the contractor, the contractor shall notify the USCG Contracting Officer on the initial inspection report.

If necessary, the contractor shall procure one for each pump, install it, and adjust/calibrate as required to have the pump perform as new.

3.4 Special Instructions: Any pump delivered for overhaul having packing glands shall be converted to mechanical seal assemblies as part of the overall work performed. Contractor shall include conversion work and parts in the overhaul estimate as necessary.

3.5 Disposition. The Coast Guard shall determine the disposition of any pump delivered for repair that is found to be not suitable for repair for whatever reason.

3.6 Paint Removal: Removal of existing paint shall be accomplished by abrasive blast to near white metal in accordance with SSPC SP-10 where practicable. Equal means of paint removal is acceptable where grit blast poses a risk of damage to internal components and cannot be properly protected from blasting operation. Remove any label plates and replace at the conclusion of painting.

3.7 Painting: Entire pump shall be painted with primer and finish coats.

Primer coat shall be any rust preventive metal primer suitable for use with the finish coat. Finish coat shall be Silicone Alkyd Enamel. Color shall be Machinery Gray in accordance with Federal Standard 595B color number 16376.

Total paint thickness shall be a minimum of 3 mil dry film.

3.8 Testing: In order to assure maximum design performance, after completion of overhaul the contractor shall conduct an operational test to the pumps rated capacity. Contractor shall provide test certification for each pump upon determination of satisfactory operation. One certification shall be placed in the box with each pump unit and a copy for each unit shall be provided to the Coast Guard Quality Assurance Representative. All testing shall be accomplished on Contractor supplied test equipment. Contractor shall ensure all test fluid is drained from the pump casing at the conclusion of testing.

3.8.1 Rotational Test: To ensure the pump turns freely and without bind, the pump rotor assembly shall be rotated 10-20 times by the use of a strap wrench or other non-damaging tool. The QAR shall inspect for smoothness of rotation and check for signs of binding. Contractor shall investigate any questionable test results and correct as necessary.

3.8.2 Hydrostatic Test: Contractor shall conduct a hydrostatic test on the overhauled pump using clean fresh tap water or, otherwise OEM specified test fluid. Test shall be conducted to certify the integrity of the pump case and seal areas. Testing shall be witnessed by a Coast Guard Quality Assurance Representative. Test shall be conducted at 4500 PSIG (based on approximately 150% of the MAX System Pressure (3000 PSIG) for a ten (10) minute time period. Test shall be discontinued at any sign of leakage for repairs and re-test.

3.8.3 Test Report: Test results shall be documented on a report. A copy of the test report shall be packed with the tested cylinder and a copy shall be turned over to the Coast Guard Quality Assurance Representative. Report shall contain the following information as a minimum:

a. Contractor Name

b. Contract Number

c. Pump Unit Model & Serial Number

d. Date Tested

e. Description of each test conducted and results of each test

f. Name of person conducting tests

3.9 Calibration: All test equipment and attached gages shall be calibrated and have a current calibration sticker. Calibration shall be traceable to National standards. (See paragraph 4.4).

3.10 Assembly: Overhauled pump shall be delivered to the Coast Guard completely assembled and ready for installation. Contractor shall preserve, package and mark each pump in accordance with part 5 below.

3.11 Notifications & Inspections: The contractor is responsible for notifying the Contracting Officer no less than seven (7) calendar days prior to the contractor being ready for any Quality Assurance (Q.A.) inspections or testing required herein.

4.0 Quality Assurance:

4.1 Responsibility for Inspection: The contractor is responsible for all inspections and testing as required herein or otherwise necessary to ensure that the pump undergoing service is returned to the same operational standards as an identical new pump. The Coast Guard reserves the right to perform any of the inspections and tests set forth in this statement of work at any time.

4.2 Responsibility for Compliance: All items shall meet the provisions of sections 3 & 5 of this statement of work. The inspections set forth in this statement of work shall become part of the contractor's overall inspection system or quality program. The absence of any inspection requirements 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.

4.3 Calibration System: All equipment used for testing overhauled pumps shall be calibrated. The contractor shall maintain a test equipment calibration program that's in compliance with ANSI/NCSL Z540-1. 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 statement of work. All test equipment shall have a valid calibration test sticker.

4.4 INSPECTIONS/TESTS - The inspections, and tests required herein are the minimum necessary and are not intended to replace any controls, examinations or tests normally employed by the contractor to assure the quality of the product. The following are required and shall be witnessed by a government Quality Assurance representative.

a) Test requirements described in part 3.8.

b) Visual inspection of the paint coating.

c) Inspection of packaging and markings.

4.5 Warranty: Contractors standard warranty applies. A copy of the contractors warrenty shall be packed with the pump with an additional copy provided to the Coast Guard QA Representative.

4.6 Tests and Inspection Reports: Contractor shall supply a copy of any standard inspection and test report to the Coast Guard QA Representative regardless of its being specified by this statement of work or not. A copy of all test reports shall also be packed with the pump unit.

5.0 Preservation, Packaging and Marking:

5.1 Preservation: The overhauled pump is intended for warehouse storage and not for immediate installation. Therefore, it is critical that the contractor shall ensure that the overhauled pump undergo all standard preservation practices normally applicable to new pumps.

5.2 Packaging (Shipping Container): Each pump shall be individually packed in its own shipping container constructed of lumber or plywood. Container shall be skid mounted to allow handling by fork truck. The pump shall be mounted in its container with thru bolts and suitable blocking to maintain stable containment. The container shall be capable of rotection to the pump during multiple shipments and handling by commercial carriers.

5.3 Marking - Each shipping container shall be marked on two (2) sides in legible waterproof print with the following information:

NSN: 4320-01-470-8803

Name: PUMP,HYDRAULIC Part No: AA11VLO260LRDS/11RNTD62K07 Serial No: As Determined By Contractor Contract Number: See Contract Shipping Weight: As Determined By Contractor Condition Code: Condition "A" Quantity & Unit of Issue: 1 EA

3.8.2 Hydrostatic Test: Contractor shall conduct a hydrostatic test on the overhauled pump using clean fresh tap water or, otherwise OEM specified test fluid. Test shall be conducted to certify the integrity of the pump case and seal areas. Testing shall be witnessed by a Coast Guard Quality Assurance Representative. Test shall be conducted at 4500 PSIG (based on approximately 150% of the MAX System Pressure (3000 PSIG) for a ten (10) minute time period. Test shall be discontinued at any sign of leakage for repairs and re-test.

3.8.3 Test Report: Test results shall be documented on a report. A copy of the test report shall be packed with the tested cylinder and a copy shall be turned over to the Coast Guard Quality Assurance Representative. Report shall contain the following information as a minimum:

a. Contractor Name

b. Contract Number

c. Pump Unit Model & Serial Number

d. Date Tested

e. Description of each test conducted and results of each test

f. Name of person conducting tests

3.9 Calibration: All test equipment and attached gages shall be calibrated and have a current calibration sticker. Calibration shall be traceable to National standards. (See paragraph 4.4).

3.10 Assembly: Overhauled pump shall be delivered to the Coast Guard completely assembled and ready for installation. Contractor shall preserve, package and mark each pump in accordance with part 5 below.

3.11 Notifications & Inspections: The contractor is responsible for notifying the Contracting Officer no less than seven (7) calendar days prior to the contractor being ready for any Quality Assurance (Q.A.) inspections or testing required herein.

4.0 Quality Assurance:

4.1 Responsibility for Inspection: The contractor is responsible for all inspections and testing as required herein or otherwise necessary to ensure that the pump undergoing service is returned to the same operational standards as an identical new pump. The Coast Guard reserves the right to perform any of the inspections and tests set forth in this statement of work at any time.

4.2 Responsibility for Compliance: All items shall meet the provisions of sections 3 & 5 of this statement of work. The inspections set forth in this statement of work shall become part of the contractor's overall inspection system or quality program. The absence of any inspection requirements 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.

4.3 Calibration System: All equipment used for testing overhauled pumps shall be calibrated. The contractor shall maintain a test equipment calibration program that's in compliance with ANSI/NCSL Z540-1. 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 statement of work. All test equipment shall have a valid calibration test sticker.

4.4 INSPECTIONS/TESTS - The inspections, and tests required herein are the minimum necessary and are not intended to replace any controls, examinations or tests normally employed by the contractor to assure the quality of the product. The following are required and shall be witnessed by a government Quality Assurance representative.

a) Test requirements described in part 3.8.

b) Visual inspection of the paint coating.

c) Inspection of packaging and markings.

4.5 Warranty: Contractors standard warranty applies. A copy of the contractors warrenty shall be packed with the pump with an additional copy provided to the Coast Guard QA Representative.

4.6 Tests and Inspection Reports: Contractor shall supply a copy of any standard inspection and test report to the Coast Guard QA Representative regardless of its being specified by this statement of work or not. A copy of all test reports shall also be packed with the pump unit.

5.0 Preservation, Packaging and Marking:

5.1 Preservation: The overhauled pump is intended for warehouse storage and not for immediate installation. Therefore, it is critical that the contractor shall ensure that the overhauled pump undergo all standard preservation practices normally applicable to new pumps.

5.2 Packaging (Shipping Container): Each pump shall be individually packed in its own shipping container constructed of lumber or plywood. Container shall be skid mounted to allow handling by fork truck. The pump shall be mounted in its container with thru bolts and suitable blocking to maintain stable containment. The container shall be capable of rotection to the pump during multiple shipments and handling by commercial carriers.

5.3 Marking - Each shipping container shall be marked on two (2) sides in legible waterproof print with the following information:

NSN: 4320-01-470-8803

Name: PUMP,HYDRAULIC Part No: AA11VLO260LRDS/11RNTD62K07 Serial No: As Determined By Contractor Contract Number: See Contract Shipping Weight: As Determined By Contractor Condition Code: Condition "A" Quantity & Unit of Issue: 1 EA

The following statement: Coast Guard SFLC Material Reusable Container Do Not Destroy

5.4 BAR CODING: The stock number shall also be bar coded in addition to the numerical marking.

a. All bar coded labels shall be in accordance with ISO/IEC-16388-2007, Code 39 Symbology.

1. The actual labels shall be Type "V", Grade "C", Style "2", Composition "a".

2. The Bar Code Label can be applied separately or as part of the marking required in 5.3.

5.5 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.

6.0 Notes:

Source of Documents: Commercial:

Steel Structures Painting Council 40 24th Street Pittsburgh, PA 15222

(412) 281-2331

American Society of Mechanical Engineers United Engineering Center 345 East 47th Street New York, New York 10017

(212) 705-7739

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

90 days after installation for a period of up to two (2) years after delivery to Coast Guard.

GOVERNMENT ACCEPTANCE:

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

4320-01-470-8803

PUMP,HYDRAULIC

AA11VLO260LRDS/11RNTD62K07

PRESERVATION / PACKAGING:

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

B. See Attachments

B. See Attachments

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