Attachment 1- Repair Specification Carver Self-Priming Centrifugal Pumps.pdf

JMR 09/03/2024

Repair Specification Carver Self-Priming Centrifugal Pumps

1.0 SCOPE

1.1. This document sets forth the requirements for the receipt, disassembly, inspections, condition/test reports, repair, reassembly, testing, preservation, packaging, packing, and marking of the Carver Self Priming Centrifugal Pumps used on 418 ft WMSL U.S. Coast Guard Cutters.

1.2. Government Furnished Property (GFP)

1.2.1. 418 WMSL Carver Pump

Stock Number Description UI Part Number

4320 015497777 PUMP, CENT SW CLG EA 998-4213-H-04

4320 015618763 PUMP, CENTRIFUGAL EA 998-1110-F-02

4320 015618776 PUMP, CENTRIFUGAL EA 998-8004-A-01

4320 015618756 PUMP UNIT, CENTRIFUGAL EA 998-1110-E-14

3610 016079310 PUMP, S/W SSDG #3 EA 998-1110-E-12

4320 015617957 PUMP, FEEDWATER EA 998‐1107‐A‐60

4320 016055957 PUMP, CENTRIFUGAL EA 998-1107-B-06

4320 015619595 PUMP, CENTRIFUGAL EA 998-1107-A-41

4320 015619591 PUMP, CENTRIFUGAL EA 998-1107-B-13

4320 015628263 PUMP, CENTRIFUGAL EA 998-1111-A-01

4320 015619605 PUMP, CENTRIFUGAL EA 998-1107-A-58

4320 015619598 PUMP, CENTRIFUGAL EA 998-1107-A-42

4320-01-229-7711 PUMP UNIT,CENTRIFUGAL,W/MOTOR EA D-00J-0-98-012

1.3. The Contractor shall submit a Receiving Inspection Report to the Coast Guard Contracting Officer (KO), and Contracting Office’s Representative (COR) within 3 days of receiving a pump/pump unit. The report shall document that the make, part number, model and/or inlet/outlet size delivered for repair conform to the pump/pump unit cited. This report shall also include digital photographic documentation of the crate and its contents (see paragraph 3.5.a).

2.0 APPLICABLE DOCUMENTS

2.1. General. The documents listed in this section are specified in sections 3, 4, or 5 of this specification. This section does not include documents cited in other sections of this specification or recommended for additional information or 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 of documents cited in sections 3, 4, or 5 of this specification, whether or not they are listed.

2.2. Government Documents. 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 Single Stock Point of Specification and Standards (DODSSP) and supplements thereto.

2.2.1. Federal Standard, FED-STD-595C, dated 07/31/2008, Colors Used in Government Procurement

2.2.2. MIL-D-3464E dated 04/21/1987, Desiccants, Activated, Bagged, Packaging Use and Static Dehumidification.

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

2.2.4. United States Coast Guard Technical Manual TP: 3272A Section D Chilled Water Circulating Pump, 1-1/2JC6 (Carver)

2.2.5. United States Coast Guard Technical Manual TP: 7014 Section A End-Suction Pumps (Close Coupled), Fire Pump

2.2.6. United States Coast Guard USCG-SFLC Specification SP-PP&M-001 Dated 6/06/11 Revision 6/06/11 Preservation, Packaging & Marking

2.3. 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.

2.3.1. Carver Pump Company, Installation, Operation, Maintenance, and Repair Instructions with Parts List for Model 1 JC6, Hot Water Circulating Pump, June 1988

2.3.2. Carver Pump Company, In Installation, Operation, Maintenance, and Repair Instructions with Parts List for Model 4 x 3 x 10 ETN, AFT Auxiliary Sea Water Pump, July 1988

2.3.3. Carver Pump Company, Installation, Operation, Maintenance, and Repair Instructions with Parts List for Model 1 JC-8, Jacket Water Recirculating Pump and Model 1JC-8, Make-Up Feed Pump, June 1988

2.3.4. Carver Pump Company, (F998) I-780 M Series Installation, Operation and Maintenance Manual, Fall 2007

2.3.5. Steel Structure Painting Council, SSPC-SP 3, dated 11/01/1982, Power Tool Cleaning

2.3.6. Institute of Electrical and Electronics Engineers, IEEE 43 dated 03/06/2000 (R 2006) Recommended Practice for Testing Insulation Resistance of Rotating Machinery

2.3.7. National Electrical Manufacturers Association NEMA, MG1-2011, section 1, part 7, dated 01/01/2011

2.3.8. American Society of Mechanical Engineers, ASME international. PTC 8.2 Centrifugal Pump, dated 01/01/1990

2.3.9. National Conference of Standards Institute ANSI/NCSL Z540.3-2006, 03 Aug 2006, Requirements for the Calibration of Measuring and Test Equipment.

2.3.10. American Society for Quality (ASQ) Q9001-2008, dated 01/01/2008, Quality Management Systems-Requirements-T860E

2.3.11. Specification Packaging and Labeling SP-PP&M Rev D dated 6/6/11

2.3.12. American Society for Testing & Materials (ASTM) D3951-98, dated 08/15/2010, Standard Practice for Commercial Packaging

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

3.0 REQUIREMENTS

3.1. General. Inspections, repair and testing of the pump/pump unit shall be accomplished in accordance with the Original Equipment Manufacturer (OEM) procedures, specifications, references and standard practices. 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. Vendor shall upon receipt of pump task orders open, inspect, and report before doing any repairs.

3.1.1. The repair requirements described herein are considered the minimum necessary and are not intended to replace any procedures, controls, examinations, or tests normally employed by the Contractor to assure the quality of the product. The repair of the pump/pump unit is intended to return the pump/pump unit’s performance and appearance to a like new condition.

3.2. Repair - The Contractor shall provide all labor and materials to perform the repair services as described below for the pump/pump unit.

3.2.1. Preliminary disassembly and inspection of the pump/pump unit shall be conducted in accordance with pump/pump unit OEM procedures, specifications, references and standard practices to determine the total estimated cost to repair including material, labor, testing, Preservation, Packing and Marking (PP&M) costs. A Condition Found Report (CFR) shall be submitted to the KO, and COR within 10 days of the completion of the Receiving Inspection Report? detailing the repair parts recommended for replacement and a total repair cost.

a. It is assumed that the pump/pump unit will arrive in a re-usable container. In the event the container is deemed unusable the contractor shall state so as part of the inspection report and provide photo documentation.

3.2.2. The CFR shall be submitted to the KO and COR for review and approval prior to the start of any repair or order of any material. The Contractor shall also provide the replacement cost of an identical new pump/pump unit for comparison to the repair cost. At a minimum, mandatory replacement parts shall include all bearings, bushings, seals and gaskets. All parts that are worn, have an improper fit and or damaged beyond the OEM tolerances, shall be repaired or replaced as determined by the COR.

a. The detailed cost estimate shall contain the following as a minimum:

1. The part number, NSN and serial number of the pump/pump unit

2. The contract number and delivery order number for the pump/pump unit

3. A listing of individual parts by part number, cost and quantity

4. A listing of labor hours and labor rate to perform the repair, testing, and PP&M

5. The cost of an identical new pump/pump unit (see section 3.2.3. b. of this specification)

b. Upon acceptance of the cost estimate and authorization to proceed by the KO, the Contractor shall repair the pump/pump unit in accordance with the OEM procedures, specifications, references, standard practices and the references cited in section 2.0 of this specification.

3.2.3. The government reserves the right to dispose of the pump/pump unit if the pump/pump unit is Beyond Economic Repair (BER). The contractor will dispose of the unit at a predetermined cost to the government. The contractor shall provide a scrap credit to the government or a price to discard any pump/pump unit BER.

a. The Coast Guard KO will determine the disposition of any pump/pump unit delivered for repair that is Beyond Economical Repair (BER).

b. If the pump/pump unit is BER, the government reserves the right to purchase an identical new pump/pump unit from the Contractor.

3.2.4. All replacement parts used in the repair 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.

3.2.5. The motor shall be disassembled, and all parts thoroughly cleaned and inspected.

Inspection findings shall be included in the CFR submitted to the COR. As a minimum, mandatory replacement parts shall include all bearings, bushings, seals and gaskets. All parts that are worn, have an improper fit and or damaged beyond the OEM tolerances shall be repaired or replaced as determined by the COR.

a. The winding resistance shall be inspected in accordance with the Institute of Electrical and Electronics Engineers, IEEE 43 Recommended Practice for Testing Insulation Resistance of Rotating Machinery. Windings that do not meet the standard of IEEE 43 section 12.3, shall be reinsulated in a qualified insulation material recommended by the motor OEM. Reinsulated windings shall be subjected to a follow up resistance test once thoroughly dry. This process shall be repeated until acceptable resistance readings are achieved. If acceptable insulation resistance cannot be achieved by re-insulating the Contractor shall submit a CFR and separate cost to rewind or renew the motor.

b. The motor rotating element shall be balanced in accordance with National Electrical Manufactures Association NEMA, MG1-2011, section 1, part 7. The final result of imbalance shall be documented.

c. The Contractor shall provide written certification to the KO that the motor was reconditioned to the same standards as a new motor and a copy shall be turned over to the Coast Guard Quality Assurance Representative (QAR). All test results shall be made available for review by the QAR upon his request.

3.2.6. Where any carbon steel zerc fittings or pipe plugs exist, all items shall be replaced with a non-magnetic grade of stainless steel. Pipe plugs shall be installed with a non-hardening thread sealer and protective plastic caps shall be installed on each zerc fitting.

a. A decal or permanent type label shall be affixed to the side of the pump/pump unit informing the user of the manufacturer’s recommended amount and type of grease to be used.

3.2.7. Any existing paint shall be removed in accordance with Steel Structure Painting Council, SSPC-SP3, Power Tool Cleaning, where practicable. An equal method of paint removal is acceptable where power tool cleaning may pose a risk of damage to internal components.

3.2.8. The entire pump/pump unit shall be painted with primer and finish coats of paint. The primer coat shall be any rust preventive metal primer suitable for use with the finish coat. The finish coat shall be Silicone Alkyd Enamel Type III Class I. The color shall be Machinery Gray, color number 16376, with the exception of pump PN: 998-1110-F-02 which shall have a topcoat of Red, color number 11105, in accordance with the Federal Standards, FED-STD-595C, dated 01/16/2008, Colors Used in Government Procurement. Total paint thickness shall be a minimum of 3-6 mil dry film thickness.

3.2.9. Renew all original data or label plates after completing pump external preservation. A separate label plate made of similar material as the original label plate shall be attached to the pump stating the Contractor’s name, contract number and date of repair.

3.3. Pump/Pump Unit Tests

3.3.1. To ensure the pump 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 QA representative shall inspect for smoothness of rotation and check for signs of binding, dragging, or unusual noises. The Contractor shall investigate any questionable test results and correct as necessary.

3.3.2. The Contractor shall conduct an energized test of the repaired motor using IEEE Std 112- 2004. The test shall be conducted to certify, document and report all parameters found on the Annex B Typical report of test form found in IEEE Std 112-2004. The Contractor shall investigate and correct any fault, failure or deviation from the OEM performance characteristics for the motor and retest the motor until satisfactory motor performance and function are achieved.

3.3.3. The Contractor shall conduct a hydrostatic test of the repaired pump 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 maximum working pressure or mechanical seal rating whichever is less. The test shall be conducted for a period of thirty (30) minutes and discontinued at any sign of leakage. The Contractor shall investigate and correct any leakage and retest the pump/pump unit.

3.3.4. The pump/pump unit shall be operationally tested by the use of a test tank of compatible OEM recommended test fluid. The pump unit shall be able to meet the original performance shown on the OEM pump data sheet. Each operational pump test shall be conducted, recorded and reported in accordance with Type B of ASME International PTC 8.2 Centrifugal Pump Tests, dated 1990.

3.3.5. The test results shall be documented on a report and provided to the Contracting Officer. A copy of the test report shall be packed with each pump/pump unit and a copy shall be provided to the QAR. The report shall contain the following information as a minimum:

a. Contractor’s name

b. Contract number and delivery order number

c. Pump/pump unit model number, part number and serial number

d. Date of test

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

f. Name of the person conducting the testing

3.4. Pump/Pump Unit Configuration - The repaired pump/pump unit shall be delivered to the Coast Guard completely assembled and in a ready to operate condition and configuration.

3.5. Photo Documentation - The Contractor shall provide digital photo documentation to the Contracting Officer as follows:

a. During initial opening of the pump/pump unit after receipt.

b. When significant findings that will affect cost of repair or time are discovered.

c. When other significant or unusual findings such as failed parts or damages are discovered.

d. When the pump/pump unit is tested to document configuration.

e. When the shipping container integrity is questionable.

f. When is the pump/pump unit prepared for shipment to document as shipped configuration to include images of the PP&M. (minimum one photo of motor packed and one of outside of container)

g. The photo documentation shall be color digital with a minimum 300 dpi and shall be sent to the KO and the COR via email.

3.6. Notifications & Inspections. The Contractor shall be responsible for notifying the KO at least ten (10) calendar days prior to said Contractor being ready for any inspections or testing.

4.0 QUALITY ASSURANCE

4.1. General. The Contractor shall maintain an inspection system 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.

4.2. 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.

4.3. Calibration System. The Contractor, as well as any subcontractors, shall be required to maintain a test equipment calibration program in compliance with the National Conference of Standards Laboratories ANSI/NCSL Z540.3-2006, 03 Aug 2006, Requirements for the Calibration of Measuring and Test Equipment. The program shall be documented and traceable to the National Institute of Standards (NIST).

4.4. 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 intention for the QAR to witness the testing of all pumps repaired by the Contractor.

4.5. Responsibility for Compliance. All items shall meet the provisions of sections 3 & 5 of this specification. 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 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.

4.6. Quality System. The Contractor shall maintain an inspection system which shall insure that each item offered to the Coast Guard for acceptance or approval conforms to the contract requirements in accordance with the American Society for Quality (ASQ) Q9001-2008, dated 2008, Quality Management System-Requirements. The inspection system shall be documented and available for review by the Coast Guard.

4.7. Tests & Inspections. The inspections/tests required here and in the appropriate subsection in section 3.0. of this specification, 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.

4.7.1. The Contractor shall notify the KO at least ten calendar days prior to accomplishing the following inspections and tests:

a. Motor certification

b. Pump rotation and impeller direction verification

c. Proper pump orientation as per the OEM tech pub

d. Hydrostatic test

e. Operational test (note results including meter and gauge readings in Test Report)

f. Verify PP&M requirements

4.8. Packing Inspection. The KO shall be notified prior to the packaging and marking of the completed units in accordance with section 3.6 of this specification.

5.0 PRESERVATION, PACKING, & MARKING

5.1. Preservation. An repaired pump/pump unit is typically intended for long term warehouse storage and not for immediate installation. Therefore, it is critical that the Contractor ensure that the repaired pump/pump unit undergoes the following preservation requirements in accordance with the Specification Packaging and Labeling SP-PP&M Rev D dated 6/11.

5.1.1. The pump shall be drained and completely dried of all test fluid.

5.1.2. Intake and discharge ports shall have plastic caps installed. 64 units of desiccant shall be placed inside the sealed bag in accordance with MIL-D-3464E dated 04/1987, Desiccants, Activated, Bagged, Packaging Use and Static Dehumidification.

5.1.3. The pump shaft, flanges and all unpainted surfaces shall be sprayed with a thin film of rust inhibitor in accordance with MIL-PRF-81309F, dated 05/16/2005, type 2, class 1 or 2, Corrosion preventive compounds, water displacing, ultra-thin film. Any exposed threads shall be protected by a cardboard sleeve.

5.1.4. Each pump/pump unit shall be placed into an 8 mil minimum thickness translucent polyethylene bag. The bag opening shall be secured with an appropriately sized doubled nylon tie wrap. The areas where the skid mount bolts penetrate the polyethylene bag a gasket or silicone sealant shall be used to seal the bag from the entrance of moisture.

5.2. Packing . Each pump/pump unit shall be individually packed in its own enclosed reusable wooden container. The pump/pump unit shall be securely bolted (NO BLIND BOLTS) to a skid base and the lid or cover shall be attached using stainless steel Phillips head screws.

The container shall be framed (either on the inside or outside) using solid wood as framing material. Wood screws directly into plywood will not be acceptable. The container shall be capable of protecting the pump/pump unit from damage during multiple shipments by commercial carrier in accordance with the American Society for Testing & Materials (ASTM) D3951-98, dated 2004, Standard Practice for Commercial Packaging.

5.3. Marking. Each preserved and packed pump/pump unit shall be stenciled in the upper left-hand side of the two longest sides (two opposite sides if square) of each box. The stenciling shall be 4 inches minimum height black characters on a white painted background. NOTE: ALL

PREVIOUS MARKINGS AND QUALITY ASSURANCE DECALS SHALL BE REMOVED FROM A

REUSABLE SHIPPING CONTAINER PRIOR TO THE APPLICATION OF ANY NEW MARKINGS.

5.3.1. This marking shall consist of the STOCK NUMBER, ITEM NAME, PART NUMBER, CONTRACT NUMBER, DELIVERY ORDER NUMBER, GROSS WEIGHT (in lbs.), condition code CONDITION (A), unit of issue with quantity (i.e. 1-EA), and the words COAST GUARD SFLC

MATERIAL.

STOCK NUMBER SEE CONTRACT

ITEM NAME SEE CONTRACT

PART NUMBER SEE CONTRACT

CONTRACT NUMBER SEE CONTRACT

DELIVERY ORDER NUMBER SEE CONTRACT

SHIPPING WEIGHT AS DETERMINED BY CONTRACTOR

CONDITION CODE CODITION (A)

QUANTITY & UNIT OF ISSUE 1 - EACH

U.S. COAST GUARD SFLC MATERIAL

5.4. Bar Coding. The Contractor shall supply bar code labels on all CLIN?s except for those that require data submissions only.

5.4.1. All bar code labels shall be in accordance with SFLC specification SP-PP&M-001.

a. The actual labels shall be for porous surfaces and consist of paper without plastic laminate.

b. The stock number or numbers, and purchase order/ contract number shall be bar coded with Human Readable Interpretation (HRI) immediately below the bar coding on unit and unitized packs.

6.0 SHIPPING

6.1. General- Unless otherwise directed by the KO, the contractor shall return repaired pumps/pump units to:

US Coast Guard

Surface Forces Logistics Center

2401 Hawkins Point RD, Bldg 88

Baltimore, MD 21226

7.0 HAZARDOUS WASTE DISPOSAL

7.1. The Contractor shall be responsible for proper disposal of all hazardous wastes 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.

8.0 NOTES

8.1. Terms and definitions

a. The word “pump” does not include an electric motor and/or primary drive unit.

b. The word “pump” unit? includes an electric motor and/or primary drive unit.

c. BER - Beyond Economical Repair.

d. HRI - Human Readable Interpretation

e. PP&M - Preservation, Packing, & Marking.

f. KO - Contracting Officer.

g. NA - Not Available.

h. QAR - Quality Assurance Representative

i. COR - Coast Guard Contracting Officer’s Representative

j. QA - Quality Assurance

8.2. Government & Commercial Document Sources

8.2.1. Government Documents

a. Department of Defense Single Stock Point (DODSSP Documents)

700 Robbins Avenue

Building #4, Section D

Philadelphia, PA 19111-5098

FAX (215) 697-9398

http://dodssp.daps.dla.mil/

b. DOD & Navy Publications and Forms (Other Than DODISS)

Naval Publication and Forms Center

5801 Tabor Ave.

Philadelphia, PA. 19120

215-697-2197

c. USCG Surface Forces Logistics Center

Long Range Enforcer Product Line

Mail Stop 26, Bldg. 3, 2nd Floor, CPD-2

2401 Hawkins Point Road

Baltimore, MD 21226-5000

410-762-6039

8.2.2. Commercial Documents

a. American Society of Mechanical Engineers, ASME international

Three Park Avenue

Ney York, NY 10016-5990

800-843-2763 www.asme.org

b. American Society for Testing & Materials (ASTM)

1916 Race Street

Philadelphia PA. 19103-1187

215-299-5585

FAX 215-977-9679

www.astm.org

c. American Society for Quality (ASQ)

P.O. Box 3005

Milwaukee, WI 53201-3005

800-248-1946 www.asq,org

d. Carver Pump Company

2415 Park Avenue

Muscatine, Iowa 52761-5691

563-263-3410

Fax 563-262-0510 www.carverpump.com

e. IEEE-USA

2001 L Street, NW. Suite 700

Washington, DC 20036-4910 USA

202-785-0017

Fax: 202-785-0835 www.ieee.org

f. National Conference of Standards Laboratories (NCSL)

2995 Wilderness Place, Suite 107

Boulder, CO 80301

303-440-3339

Fax: 303-440-3384 www.ncsli.org

g. National Electrical Manufacturers Association (NEMA)

1300 North 17th Street

Suite 1752

Rosslyn, VA 22209

703-841-3200 www.nema.org

h. Steel Structure Painting Council

40 24th Street

Pittsburgh, PA 15222

412-281-4331 www.sspc.org