Appleton Marine Anchor Windlass Overhaul Specification WC.doc

BMD-478 Overhaul Spec

2/1/22

REVISION No:______

CHANGE No:______

INSPECTION AND OVERHAUL

OF THE APPLETON MARINE BMD-478 ANCHOR

WINDLASS USED ON 225 CLASS WLB COAST GUARD VESSELS

ORIGINATED BY: Andrew G Ollerman DATE: 14 May 2013 ORIGINATOR’S COMMAND: Surface Forces Logistics Center DEPARTMENT/DIVISION: Ice Breaker, Buoy and Construction Tender Product Line INTERNAL RE-VIEWER: Ernest Gaskins DATE: 20 May 2013

1.0 SCOPE:

1.1 This specification covers the requirements for the inspection, overhaul, testing, painting, preservation, packaging and marking of the anchor windlass used on WLB “B” Class Coast Guard vessels.

1.2 Government Furnished Property (GFP).

a) Anchor Windlass , Part Number: BMD-478

NATIONAL STOCK NUMBER: 3950-01-F12-2723

2.0 APPLICABLE DOCUMENT:

2.1 General-The following specifications and standards form a part of this specification to the extent specified herein. Unless otherwise specified, the documents listed here by number and date shall be those in the current Department of Defense Index of Specifications and Standards (DODISS) and supplements thereto.

2.2 GOVERNMENT DOCUMENTS:

a) MIL-C-104C (dtd. 06/93) Crates, Wood: Lumber or Plywood Sheathed.

b) United States Coast Guard USCG-SFLC Specification D-000-0100 Rev G Dated 06/2006, Bar Coding for USCG Surface Forces Logistics Center Material.

c) MIL-D-3464E dated 04/1987, Desiccants, Activated, Bagged, Packaging Use and Static Dehumidification.

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

e) MIL-PRF-169173E(SH) W/Int. Amendment 1, dated 09/07/2006, Corrosion preventive compounds, solvent cutback, cold-application.

f) MIL-PRF-131K, dated 08/18/2005, Barrier Materials, Water vapor proof, Greaseproof, Flexible, Heat-Sealable.

g) MIL-STD-2073-1E w/Change1, dated 01/07/2011, Standard Practice For Military Packaging.

2.3 OTHER GOVERNMENT DOCUMENTS- The following documents form a part of this specification to the extent specified herein. The documents listed shall be by title and effective date, unless otherwise documented.

a) U.S. Coast Guard specification D-000-0100. Bar coding for U.S.C.G. SFLC Material (latest revision).

b) Federal Standard 595B, Colors used in government procurement.

2.4 COMMERCIAL DOCUMENTS- The following documents form a part of this specification to the extent specified herein. The documents shall be the version listed by number and date from the referenced industry organization. Commercial documents may also be listed in the Department of Defense Index of Specifications and Standards (DODISS).

2.4.1 American National Standards Institute (ANSI)/ National Conference of Standards Laboratories (NCSL).

a) ANSI/NCSL Z540-3 (dtd. 8/2006) Requirements for the Calibration of Measuring and Test Equipment

b) ANSI/ASQC Q9003-1994 (dtd 1994) Quality Systems - Model for Quality Assurance in Final Inspection and Test.

2.4.2 American Society of Mechanical Engineers (ASME).

a) ASME B30.7 (dtd. 12/06) Base Mounted Drum Hoists.

2.4.3 Steel Structures Painting Council (SPCC).

a) SPCC SP10, (dtd. 01/07) Near-White Metal Blast Cleaning NACE No.2-2000 (Steel Structures Painting Manual, Ch 2 - Surface Preparation Specs.

2.4.4 American Society for Testing and Materials.

a) ASTM D-3951 (dtd 11/98) Standard Practice for Commercial Packaging.

2.5 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.

3.0 REQUIREMENTS:

3.1 GENERAL- The overhaul requirements described herein are the minimum necessary and are not intended to replace any procedures, controls, examinations or tests normally employed by the contractor to insure quality of the product. All work shall be performed in accordance with OEM standard procedures.

3.2 PRELIMINARY INSPECTION- Preliminary disassembly and inspection shall be conducted to evaluate the extent of repair required.

3.2.1 Upon receipt of the windlass, the contractor shall note the condition of the shipping container and contents. If the container as received does not conform to section 5.2.a packaging requirements, an estimate shall be provided for the manufacture of a new container. Any damage noted shall be included in an inspection report and immediately reported to the Contracting Officer.

3.2.2 The anchor windlass shall be completely disassembled. All components shall be cleaned and inspected to OEM specifications. All removed components that are listed in 3.3.4 for mandatory replacement shall be disposed of at the contractor’s discretion.

3.2.3 Upon completion of all inspections, the contractor shall develop an individual written inspection report, which shall include, but not limited to the following information for each winch received:

a) Letterhead of Contractor.

b) Anchor Windlass model and serial number.

c) Shipping container condition.

d) Cost to repair or replace the existing shipping container, if required.

e) Signature of person performing inspections.

f) Disassembly and inspection summarized findings.

g) An itemized parts list including item name, quantity and cost of each part required for the overhaul.

h) Digital pictures showing any parts that need to be replaced that were not on the mandatory change out list.

i) Breakdown of labor costs.

j) Total overhaul cost.

3.2.4 Authority to Proceed: Upon completion of the winch disassembly, inspection, and submittal of an inspection report, the contractor shall not begin any repair or component/part replacement until authorized in writing by the Contracting Officer. The authorization will give specific guidance on the type of work to proceed with, which may include, but not limited to; (a) repair, reassembly, and testing of the winches as a ready to operate assembly as detailed in the contractor inspection report, or (b) disposal of any winch deemed non-repairable as determined by the Contracting Officer.

3.3 OVERHAUL REQUIREMENTS- Upon the approval of the inspection report and authorization to proceed by the Contracting Officer, the windlass shall be overhauled and tested in accordance with the Original Equipment Manufacturers (OEM) current design and requirements.

3.3.1 The windlass shall be restored to the performance standards of a like new condition winch.

3.3.2 Overhaul shall include a thorough cleaning of all parts. Renewal of parts worn beyond manufacturer’s tolerances or damaged shall be replaced. Overhaul procedure shall insure that all OEM specified clearances, procedures, calibrations, and torque values are applied.

3.3.3 Mandatory replacement parts: The following parts shall be replaced regardless of their condition.

Windlass Assembly AMD-1376

Brake Assembly AMD-1377

3.4 REPLACEMENT PARTS - Common hardware items such as bearings (i.e.: roller or ball type) lip seals may be purchased from local suppliers. Any common hardware part not purchased through the OEM shall be of the required type and of equal or better quality as the removed part. The OEM shall supply all gaskets.

3.5 WINCH TEST - Each winch shall be tested as follows or as to a mutually agreeable testing procedure:

3.5.1 The hydraulics supplied to test these winches shall be capable of producing a minimum of 3750 PSI at 28 GPM.

a) All preliminary pressure or relief valve adjustment shall be performed using calibrated gauges (see 4.5).

b) Run the windlass for 30 minutes in each direction using both the local and remote controls. Record the time of start and finish in each direction.

c) During the test the following observation shall be made.

a. Overheating of any part, smoking or discoloration of painted surfaces.

b. Excessive vibration.

c. Unusual Noises.

d. Failure of capstan to respond to control movements.

e. Metal dust of shavings around moving parts.

3.5.2 Rated Load Test: Each windlass shall perform a rated load line pull test of 6,900 LBS.

a) Hand tend the loose end of the test rope and raise a test load of 6,900 lbs. (30 Fathom Lift) at 36 FPM. Record test weight and line speeds.

b) Repeat test. Record test weight and line speed.

3.5.3 Dynamic Brake Test: Each windlass dynamic brake shall be tested to 13,180 LBS.

a) Lift rated load of 13,180 lbs. (100 Fathom Lift) shut off power unit while lowering the load. Hold the load for two minutes.

b) Record the test load, time held and brake drift.

3.5.4 Static Brake Test: Each windlass dynamic brake shall be tested to 13,180 LBS.

a) Lift the 13,180 lbs. load (100 Fathom Lift). Shut off the power unit. Hang additional weights to the raised load to increase the load to 21,985 lbs. Hold the load for two minutes.

b) Record the test load, time held and brake drift.

3.5.5 Manual Brake Release:

a) Demonstrate hand pump/manual release feature.

b) Verify that the brake release indicator light at the control stand is operating.

c) Record acceptance.

3.5.6 Hydro-test:

a) Disconnect windlass brake line. Raise power unit pump compensator to 3750 psi in order to hydraulically test the windlass piping to 150% of the rated pressure. Hold the pressure for 5 minutes.

b) Record the pressure from the control stand pressure gauge and check for leaks. Leaks can be repaired and the test repeated.

3.5.7 Brake Band Check:

a) Set pump compensator to 2500 psi. Operate windlass in “Payout Direction”. Apply the band brake to wear-in the lining.

CAUTION: ONLY ROTATE IN PAYOUT DIRECTION.

b) Check the lining and record the percentage of lining contact.

c) Stall the windlass on the band brake to verify the strength of the wildcat clutch.

d) Record acceptance.

3.5.8 Clutch Demonstration:

a) With no load on the capstan head, test rope removed, demonstrate clutching the wildcat “IN” and “OUT” of the drive train.

b) Record acceptance.

3.5.9 Brake Demonstration:

a) Demonstrate band brake operation from the remote hand wheel stand. Check if the linkage is free and not binding. Check if the hand wheel spins freely in both directions.

b) Record acceptance.

3.5.10 Chain Fit:

a) Wrap the chain sample around the wildcat to demonstrate proper fit of the chain.

b) Record Acceptance.

3.5.11 Burn in Test:

a) Demonstrate the ability of the windlass to raise and lower various loads up to the rated load for at least a three (03) hour time period.

b) Record the starting time and completion time. Record the hoist pressure for various loads.

c) During the test the following observations shall be made.

a. Overheating of any part, smoking or discoloration of painted surfaces.

b. Excessive vibration.

c. Unusual Noises.

d. Failure of capstan to respond to control movements.

e. Metal dust of shavings around moving parts.

3.5.12 Test certification: Contractor shall provide a test certificate for each winch upon successful completion of all testing. Certificate shall include the following information as a minimum:

a) Contractors name and address.

b) Contract number.

c) Test date.

d) Model and serial numbers of the tested winch.

e) A detailed description (i.e.: system pressure, test pressure in PSI, Test time, etc.) of each test performed with results of the test.

f) Signature of the contractor official conducting or overseeing the testing.

3.5.6.1 Test certificate for each winch shall be turned over to the Coast Guard Quality Assurance Representative upon his arrival at the contractor’s facility. A second copy shall be packed with the tested winch.

3.6 SURFACE PREPARATION: Removal of existing paint shall be accomplished by abrasive blast to near white metal in accordance with SSPC SP-10/NACE No.2 using grit conforming to Mil-A-22262/ (1.5.-2.5). 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 PAINT APPLICATION:

3.7.1 All non- painted surfaces or openings shall be protected by masking or capping to protection during paint application.

a) The internal surface of the winch drum, where the cable rides, shall not be painted. It will only have one coat of "Zinc-Rich Primer-Polysiloxane System", at 3.0 to 4.0 mils DFT.

3.7.2 Paint application:

a) Abrasive-blast all steel surfaces to "Near White", in accordance with the Society of Protective Coatings (SSPC) Specification SSPC-SP 10, with angular abrasive to achieve a 1.5 to 2.5 mil anchor profile.

b) Prime all surfaces (the same day they are cleaned or before flash-rusting occurs), with one coat of "Zinc-Rich Primer-Polysiloxane System", at 3.0 to 4.0 mils DFT.

c) Apply a thin coat of "Polysiloxane" top coating, at 1.0 to 2.0 mils DFT.

d) Apply a full coat of "Polysiloxane" top coating, at 5.0 to 6.0 mils DFT.

3.7.3 Authorized Polysiloxane System suppliers are as provided in COMDTINST M10360.3C, Change 1, with Interim change ALCOAST 427/09 (COMDT COGARD R241408Z JUL 09), as follows:

a) PPG polysiloxane system: Dimetcote 302H / PSX-700 b. Sherwin-Williams polysiloxane system: Fast Clad Zinc HS / XLE-80. Color: SPAR (10371) per FED STD 595b.

3.8 WINCH DATA PLATES: Contractor shall apply two (2) plastic engraved data plates on the winch. Plates shall have a black face with minimum 3/16-inch high white engraved characters. Plates shall be applied to the winch using whether proof adhesive. Plates shall be located on opposite sides of the winch in areas that offer reasonable protection to the plate. Each plate shall contain the following information:

a) Model Number.

b) Serial Number.

c) Load Rating.

d) Rope Size.

e) Rope Speed in feet per minute.

f) Date of overhaul and contractors company name.

3.9 Warranty- Standard manufactures warranty.

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

4.0 QUALITY ASSURANCE:

4.1 RESPONSIBILITY FOR INSPECTION- The contractor shall be responsible for the performance of all inspection requirements specified herein. The contractor shall provide space, personnel and test equipment for the conduct of all inspection requirements. All inspection and testing shall be performed at the contractor’s plant or at other facilities acceptable to the Coast Guard. The Coast Guard reserves the right to verify any of the inspections set forth in this specification where such inspections are deemed necessary to assure that supplies and services conform to the prescribed requirements.

4.2 RESPONSIBILITY FOR COMPLIANCE- All items shall meet the requirements of sections 3 and 5. The inspections set forth in this specification shall become part of the contractor’s overall inspection system or quality program. The absence of any inspection requirements in this specification shall not relieve the contractor of the responsibility of assuring that all products or services submitted to the government for acceptance comply with all requirements of the contract. Sampling for quality conformance does not authorize submission of known defective material (either indicated or actual) nor does it commit the government to acceptance of defective material.

4.3 RECORDS- The Contractor shall maintain a record of all inspections and tests. At a minimum the records shall indicate the nature and number of observations made the number and type of deficiencies found, and the corrective action taken.

4.4 INSPECTIONS & TESTS: The inspections & 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:

a) All testing as required by section 3.5.

b) Paint thickness.

c) Data plate requirements in section 3.8.

d) Preservation, packaging and marking requirements.

4.5 CALIBRATION SYSTEM - The Contractor, as well as any subcontractors, shall be required to maintain a test equipment calibration program in compliance with reference 2.4.1a during the existence of this contract. The program shall be documented and traceable to the National Institute of Standards (NIST).

4.5.1 The calibration system records shall be maintained for inspection for the duration of any contract referencing this specification. These records shall be available for review by any Coast Guard government representative.

4.6 FAILURE RESPONSIBILITY- If a winch fails to pass any inspection or test, the Contractor shall report the failure and their recommended corrective action to the Contracting Officer. If approved, the corrective action on the materials or processes shall be taken in accordance with this section.

a) The Contracting Officer reserves the right to totally reject any failed anchor windlass without considering any suggested corrective action.

4.6.1 The inspection/test shall be discontinued until all corrective action has been taken.

4.6.2 After all corrective action has been taken; the inspection/test shall be continued or repeated, at the option of the Contracting Officer.

4.6.3 Acceptance shall be withheld until re-inspection/testing has shown that the corrective action was successful and the item satisfactorily passes all inspections and tests.

4.6.4 All corrective actions shall be documented as part of the Contractor’s inspection system, and submitted for approval of the Contracting Officer.

a) Each corrective action report shall include, but not be limited to, the cause of each defect, corrective action suggested, and steps taken to prevent a recurrence of each defect.

5.0 PRESERVATION, PACKAGING AND MARKING

5.1 PRESERVATION:

a) After final test acceptance, each winch shall be completely drained of all oil and drain plugs reinstalled.

b) A red warning tag shall be attached to the winch stating that the anchor windlass has been drained of lubricants.

c) All openings not previously plugged, shall be sealed with shipping plugs or caps.

5.2 PACKAGING

a) The anchor windlass shall be individually packaged in its own skid mounted, plywood sheathed container per section 2.4.4. Each shall be lag bolted through the mounting feet into skid base to prevent it from shifting within the crate.

b) A copy of the manufactures start up procedures shall be placed in the shipping container of each winch.

5.3 MARKING- The marking described herein shall be placed and/or verified to be on the longest two sides of each box on opposite ends.

a) Each container shall be marked in legible ½-inch to ¾-inch high black waterproof print and marked as shown in bold text:

Stock Number: 3950-01-F12-2723 Item Name: Anchor Windlass Part Number: BMD-478 Serial No: as determined Contract Number: as determined Shipping Weight: as determined The Following Statement: USCG SFLC MATERIAL, CONDITION “A”, 1- EA, REUSABLE CONTAINER.

5.4 BAR CODING: Bar coding shall be supplied on all CLIN’s except for those that require data submissions only.

5.4.1 All bar coded labels shall be in accordance with reference 2.3a.

a) The actual labels shall be Type “V”, Grade “A”, Style “2”, Composition “B” with plastic laminate.

b) Each label shall contain encoded data for the Stock Number, part number, and the Contract and Delivery Order Number.

c) The marking required in 5.3 of this specification can be applied separately or as part of the bar code label.

5.5 PRESERVATION/PACKAGING INSPECTION: The Coast Guard reserves the right to witness the units prior to and after packaging. The Contracting Officer shall be notified in accordance with section 3.10 of this specification and prior to the final packaging of the completed units.

6.0 DOCUMENTS:

6.1 Government documents:

a) Department of Defense Single Stock Point (DoDSSP) Building 4, Section D 700 Robbins Ave.

Philadelphia, PA 19111-5094 215-697-2667/2179

215-697-1462 FAX

a) DOD & navy Publications and Forms (other then DODISS)

Naval Publication and Forms Center

5801 Tabor Avenue

Philadelphia, PA 19120

215-697-2000

6.2 Commercial documents:

a) Steel Structures Painting Council

40 24th Street

Pittsburgh, PA 15222

(412) 281-2331

a) American Society of Mechanical Engineers

United Engineering Center

345 East 47th Street

New York, New York 10017

(212) 705-7739

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