Attachment 2 - Statement of Work.pdf

WBN_0619

WORK ITEM 1: 2040-01-461-1943, Rudder, Starboard, Repair

1. SCOPE

1.1 Intent. This work item sets forth the requirements for the Receipt, Inspection, Overhaul, Preservation, Packing, Marking, Bar-Coding and Shipping of Starboard Rudders used on US Coast Guard 87' Coastal Patrol Boats.

1.2 Government furnished property (GFP). The listed items are property of and managed by the USCG Surface Forces Logistics Center, Baltimore MD and will be issued to the Contractor as issuance of a contract or contract delivery order.

MTI ITEM DESCRIPTION NSN

P/N

CAGE

QTY

(EA.)

ESTIMATED COST

($/UNIT)

Y * Rudder NSN: 2040-01-461-1943

PN: 87WPB 561-001 STBD

CAGE: 81340

Y * Shipping Crate, Reusable

NSN: N/A

PN: N/A

CAGE: N/A

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

**New or refurbished equipment that the Government may provide for installation in place of existing equipment.

***Government-furnished property, which is to be supplied by the Coast Guard.2. REFERENCES

2. REFERENCES

COAST GUARD DRAWINGS

Coast Guard Drawing 87WPB 562-001 Rev. A, dated 3/10/2009 – 87FT Coastal Patrol Boat

Rudder Details Coast Guard Drawing 87WPB 561-001 Rev. K, dated 5/12/2017 – 87FT Coastal Patrol Boat

Steering System Details

COAST GUARD PUBLICATIONS

Surface Forces Logistics Center Standard Specification 0740 (SFLC Std Spec 0740), 2014, Welding and Allied Processes

OTHER REFERENCES

ANSI/ASQ Q9001, Dated 10/01/2015 – Quality Management Systems – Requirements – T860E ASME B17.1, Dated 1/1/1967, (Reaffirmed 2013) – Keys and Keyseats ASTM A276/A276M-17, Dated 3/15/2017 – Standard Work item for Stainless Steel Bars and

Shapes ASTM D6880/D6880M-11, Dated 2011 – Standard Work item for Wood Boxes

DODD 4140.01-M-1, Dated 7 Sep 2007 – Compliance for Defense Packaging: Phytosanitary Requirements for Wood Packaging Material (WPM)

ISO/IEC 16388:2007 (2014) Information Technology - Automatic identification and data capture techniques - Code 39 bar code symbology specification

ISO/IEC 17025:2017, Dated 11/2017 – General requirements for the Competence of Testing and Calibration Laboratories

MIL-A-22262, Dated 4/05/1993 – Abrasive Blasting Media Ship Hull Blast Cleaning MIL-STD-2073-1E, Dated 1/07/2011 – Department of Defense Standard Practice: Military

Packaging MIL-STD-129R, Dated 2/18/2014 – Department of Defense Standard Practice: Military Marking for Shipment and Storage SAE International, SAE J 448-2011 – Standard, Surface Texture SSPC/NACE International (NACE), Joint Surface Preparation Standard SSPC-SP 10/NACE No

2, 2007, Near-White Blast Cleaning

2.1 Document availability. The documents listed in this section are referenced in sections 3, 4 and 5 of this work item. Several references are listed on Coast Guard drawings 87WPB 562-001 Rev. A and 87WPB 561-001 Rev. K. To obtain the referenced documents see section 6.1.

2.2 Work item order of precedence. The Applicable Documents described are required to be adhered to in fulfilling the contract. In the event of a conflict between the text of this work item and the references cited herein, this work item shall take precedence. Nothing in this document, however, supersedes applicable laws and regulations unless a specific exemption has been obtained.

3. REQUIREMENTS

3.1 General. The Contractor shall provide storage for the GFP when not in use, and safe handling when in use.

3.1.1 Storage. The storage area shall at a minimum be closed on all sides, dry, and locked when unattended.

3.2 Inspection. The Contractor shall carefully remove the rudder from the GFP crate, clean and remove all paint and primer to facilitate a thorough inspection to determine all the necessary repairs to return the rudder to a serviceable “A” condition as defined below. A Condition Found Report (CFR) shall be submitted to the Coast Guard Contracting Officer (KO) within twenty (20) days of receipt of GFP. The CFR shall include all inspection findings and test results as specified below, including a breakdown of estimated cost of labor and materials for any repair work or testing outside of the standard rudder overhaul. This includes the repair or replacement of the shipping crate. The CFR shall also include a breakdown of estimated cost of labor and materials for any repair work that is beyond the scope of work in this work item. No further work shall proceed until authorized by the KO in writing.

NOTE

Serviceable “A” condition is defined as a reconditioned rudder meeting all required design work items and design dimensions in accordance with Coast Guard drawing: 87WPB 562-001 Rev. A and being capable of functioning and performing in the same manner as an identical new rudder although it may not have the appearance of a new rudder.

3.2.1 CFR information. The CFR shall contain the following information as a minimum:

• Contractor name, address and telephone number

• Contract number and delivery order number as applicable

• Name of personnel conducting inspections

• Rudder serial number(s)

• Inspection sheets showing dimensional data and test results for rudder blades only (The entire stock will be cut down and welded back up per section 3.5.1 so initial measurements are not necessary)

• Estimated cost to complete rudder repairs including cost to repair or replace shipping container

3.2.2 Paint removal. The Contractor shall abrasive grit blast all coated rudder surfaces to SSPC-SP 10/NACE No. 2 using grit conforming to MIL-A-22262 with a 1.5-3.5 mil profile.

3.2.2.1 All pipe plugs shall be installed prior to grit blasting.

3.2.3 Visual inspection. Visually inspect the rudder for the following:

• Straightness of stock and blade

• Corrosion and other mechanical defects

3.2.4 Ultrasonic test. Perform ultrasonic testing to the rudder to measure blade plate thickness if there are signs of corrosion or wear. Take as many UT shots as necessary on each side, log readings and location on CFR.

3.2.5 Air pressure test. The Contractor shall conduct an air pressure test on the blade section after all the paint and primer are removed. Using a calibrated 0-5 PSI pressure gage, apply air pressure to the air cavity and hold at 2 PSI for 10 minutes. Any loss of air pressure will constitute test failure. If any pressure loss is noted, check porosity areas, plug threads, and all welds using a soapy water solution to expose leaky areas. The active formation of air bubbles on the blade surface indicates the presence of cavitation erosion damage. This condition needs to be repaired prior to acceptance. Subsequent air tests will need to be performed in order to ensure the void does not leak. All traces of soapy water solution shall be removed.

3.2.6 Indicated leakage through skin or welds. If air leaks are found through the skin or welds the Contractor shall include the extent of the leakage to the Contracting Officer in the CFR with recommended repairs and cost. The Coast Guard shall determine if excessive leaking should be repaired or scrapped based on the Contractor recommendation, extent of leaks and cost to repair per section 3.5.

• The air pressure test shall be repeated on rudders that undergo weld leakage repair work

• The cost of additional air test(s) if required shall be covered under the repair

• Weld repair increments for the blade section are listed in section 6.2

3.3 Rudder disposition. The Coast Guard will review the CFR and determine if rudder(s) will be repaired or scrapped due to the extent of necessary repairs and determine disposition. Disposition options are as follows:

• Contractor to scrap on site and provide credit to the Coast Guard based on current U.S.

stainless steel scrap prices

• Rudders to be re-packaged in the original shipping container, properly marked per section 5.5 and returned to SFLC Baltimore, MD at the address listed in section 5.7.

3.4 Welding certifications. The Contractor shall have welders qualified in accordance with Qualifications Standard for Welding and Brazing, also per SFLC STD Spec 0740. Certification documentation shall be maintained and available to the KO, Contracting Officer’s Representative (COR) or Coast Guard Quality Assurance personnel (QA) for review at any time during the contract period.

3.4.1 Penetrant testing. Liquid dye penetrant testing per SFLC Std Spec 0740 shall be completed in all areas in way of the keyways, tapers, bearing and seal areas, and welds from all welding and weld repairs.

All test results shall be recorded on the Final Inspection Report.

3.4.2 Surface finish. All surface finishes shall be in accordance with Coast Guard Drawing 87 WPB 562- 001, Rev A.

3.5 Rudder repairs. The Contractor shall:

3.5.1 Rudder stock. Starting where the stock meets the rudder blade above the knuckle, machine to undercut the entire stock diameter 0.1875”. Clad weld buildup with 316L stainless steel material to facilitate finish machining IAW drawing 87WPB 562-001 Rev. A. The surface finish indicated on the drawing shall be in accordance with SAE J 448-2011 Standard. Polish all machined surfaces above the knuckle to a 63 RMS or smoother.

3.5.2 Rudder blade. Leakage through skins or welds as identified in the initial inspection and approved for repair by the KO shall be repaired by welding per SFLC STD Spec 0740.

3.5.2.1 The Contractor shall conduct an air pressure test (section 3.2.5) after repairs paying particular attention to welded areas. Any leakage found during the air pressure test shall be corrected by welding with an additional air pressure test conducted after weld repairs are complete. This process shall be repeated until all leakage has been corrected and rudder passes air pressure testing.

3.5.3 Workmanship. Rudders shall have a professional appearance and be free of dirt, grease, burrs or sharp edges.

3.6 Rudder key stock. The Contractor shall provide a rudder key stock as part of each repaired rudder.

3.6.1 Dimensions. The rudder key stock dimensions shall be in accordance with Coast Guard drawing 87WPB 561-001 Rev. K, piece 19.

3.6.2 Manufacturing. The rudder key stock shall be manufactured from 316 key stock meeting ASTM A276/A276M-17.

3.6.3 Keyway fit. The key to keyway fit shall be Class 1 per ASME B17.1.

3.6.4 Packaging. The Rudder Key shall be secured in the shipping container to prevent movement and be clearly marked “RUDDER KEY” with black waterproof markings.

3.7 Rudder nuts. The Contractor shall provide (1) each of the following nuts and washer for each repaired rudder per drawing 87WPB 561-001 Rev. K.

• Nut, Steel 2 ½” x 4 TPI, piece 05

• Washer, ½” Thick x 89mm I.D. x 127mm O.D., piece 06

• Nut, Locking, Steel M90 x 2, piece 07

3.7.1 Welding. Nut, Steel 2 ½” x 4 TPI, piece 05 and Washer, ½” Thick x 89mm I.D. x 127mm O.D., piece 06 shall be welded together IAW drawing 87WPB 561-001 Rev. K, sheet 3, detail 21 D.

3.7.2 Fitting. The rudder nuts shall screw on the rudder stock threads with a Class 2A/2B fit in accordance with ANSI/ASME B1.1-2003.

3.7.3 Packaging. The rudder nuts shall be secured and cushioned individually to prevent movement or damage to the threads during shipping and handling.

3.7.4 Marking. The rudder nuts shall be clearly marked “RUDDER NUT” with black waterproof markings.

3.8 Serial numbers. All repaired rudders with no serial numbers shall be marked on the stock end face with a stamped-in serial number at least 1/8” high. The Contracting Officer (KO) will provide rudder stock serial numbers as required.

3.9 Final inspection and test report. A detailed Final Inspection and Test Report shall be submitted to the KO for approval prior to scheduling QA personnel. The report shall depict the final condition of the rudder after all work has been completed. A copy of the inspection and test report shall be turned over to the QA representative upon arrival for final inspection and testing. The inspection and test report shall contain the following information as a minimum:

• Contractor name, address and telephone number

• Contract number and delivery order number as applicable

• Rudder serial number(s)

• Written dimensional survey showing the rudder measurements and test results are within tolerance for each dimension shown on the drawing or per this work item.

• Name of the person conducting the testing

• Test equipment used, nomenclature, serial number, and calibration date

• Pressure test certification

• NDT test results

3.9.1 Rudder measurement form. The Contractor shall use the rudder measurement form in section 6.3 as part of the Final Inspection and Test Report.

3.10 Warranty. Standard manufacturer’s warranty applies to items manufactured or repaired under this work item.

3.11 Notifications and inspections. The Contractor shall be responsible for notifying the KO at least ten

(10) calendar days prior the Contractor being ready for any Quality Assurance inspections or testing as required herein. The rudders require a one hundred percent Coast Guard Quality Assurance inspection.

4. QUALITY ASSURANCE

4.1 General. The Contractor shall maintain an inspection system, which shall insure each item offered to the Coast Guard for acceptance or approval conforms to the contract requirements. The inspection system shall be in accordance with ANSI/ASQC Q9001, 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 ISO/IEC 17025. 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 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 or have performed any of the inspections that are deemed necessary to assure that supplies and services conform to the prescribed requirements.

4.5 Responsibility for compliance. All items shall meet the provisions of sections 3 & 5. The inspections set forth in this work item shall become part of the Contractor’s overall inspection system or quality program. The absence of any inspection requirements in the work item 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 Tests and inspections. The inspections/tests required here and in section 3.0 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.

4.6.1 The following are required and will be witnessed by Coast Guard SFLC Quality Assurance Representative(s):

• Overall dimensions and dimensional tolerances are in accordance with the drawings

• Surface texture (stock section), per section 3.5.1

• Weld inspection per section 3.5.2

• Air pressure test per section 3.5.2

• Blade straightness in reference to the centerline on the drawing

• Rudder Key per section 3.6

• Rudder nuts (2) tested for thread fit, secured and marked in crate per section 3.7

• Preservation, packing, marking and bar-coding of rudder prior to shipping per section 5

4.6.2 The Rudder inspection requires 100% verification to assure compliance with the applicable drawings and this work item.

4.6.3 For the safety of Coast Guard personnel and shop workers, QA inspections shall be completed indoors away from Normal shop work, operating machinery, loud noise, welding (arching) and grinding operations if permissible.

4.7 Failure responsibility. If a rudder fails to pass any inspection/test, the Contractor shall report the failure and the recommended fix to the Contracting Officer. If approved, the corrective action on the materials or processes shall be taken in accordance with this section.

• The Contracting Officer reserves the right to totally reject any failed item without considering any suggested corrective action

• The inspection/testing shall be discontinued until all corrective action has been taken

• After all corrective actions have been taken the inspection/tests shall be continued or repeated at the option of the Contracting Officer

• Acceptance shall be withheld until re-inspection has been shown that the corrective action was successful and the item satisfactorily passes all inspections and tests

• All corrective actions shall be documented as part of the Contractor's inspection system and submitted for approval to the Contracting Officer

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

4.8 Tests and inspection reports. One copy of any required inspection, test or tolerance check done on each delivery order shall be sent to the KO.

4.8.1 Quality assurance representative. A copy of any test, inspection or tolerance report shall be turned over to the SFLC QA Representative upon arrival at the Contractor’s plant.

4.9 Packing inspection. The KO shall be notified prior to the packaging and marking of the completed units in accordance with section 3.11 of this work item.

5. PRESERVATION, PACKING, MARKING, AND SHIPPING

5.1 General. Each rudder shall be individually preserved, packed, marked and bar-coded in its own reusable wood box, or a new reusable wood box if approved. Preservation, packaging, packing, marking and bar-coding will be inspected by Coast Guard SFLC QA personnel at Contractor’s facility.

5.2 Preservation. Each rudder manufactured under this contract shall be preserved in accordance with MIL-STD-2073-1E, Method 10. The rudder stock shall be supported in the box by use of cradles and blocking that will not allow shifting of the rudder within the box. The entire rudder stock shall be protected with PVC pipe or a heavy plastic mesh.

5.3 Packaging. Each preserved and packed rudder shall be packaged in its own completely enclosed shipping container. The container shall be constructed of 1/2” minimum thickness plywood sheathing with 2” X 3” minimum wood framing for strength. Particleboard, flake board, OSB etc. will not be acceptable. The container shall be skid mounted using 4”x4” wooden posts and constructed with a removable lid secured with corrosion resistant self-tapping wood screws to allow for easy access and removal in accordance with ASTM D6880/D6880M.

5.4 New reusable shipping container. When authorized by the KO, the Contractor shall construct a new reusable wood box manufactured IAW 5.3 and ASTM D6880/D6880M.

5.4.1 Wood Packing Material (WPM) requirements. New reusable wood boxes shall meet the Phytosanitary Requirements for WPM in accordance with paragraph C2.1.1 of DODD 4140.01-M-1, Compliance for Defense Packaging. WPM is defined as wood pallets, skids, load boards, pallet collars, wooden boxes, reels, dunnage, crates, frames and cleats. Packaging material exempt from the requirements are materials that have undergone a manufacturing process such as corrugated fiberboard, plywood, particleboard, veneer and oriented strand board (OSB). All new purchases of WPM shall be constructed from heat treated (treated to 56° C. core temperature for 30 Minutes) lumber and certified by an accredited agency recognized by the American Lumber Standard Committee (ALSC).

5.4.2 WPM markings. All new wood boxes shall have the appropriate markings in accordance with DODD 4140.01-M-1, Compliance for Defense Packaging Ref. 2 paragraph C2.5.

5.4.3 Newly manufactured wood boxes shall be secured and stored per section 3.1.

5.5 Marking. Each wooden box shall be stenciled with the information as laid out below. Markings shall be placed on each side of the two longest sides of the container so it will be visible to a forklift driver during storage and shipment. Stencil shall be applied directly on the container and a minimum of 3/4 inch height black block characters on a highly contrasting painted white background, using permanent waterproof ink or enamel paint. Laminated paper stencils will not be acceptable.

5.5.1 Marking layout (ready for issue) “A” condition Starboard Rudder.

NATIONAL STOCK

NUMBER

2040-01-461-1943

ITEM NAME RUDDER

PART NUMBER 87 WPB 561-001 STBD

CONTRACT NUMBER (See Contract)

SHIPPING WEIGHT (LBS) As Determined by Contractor

QUANTITY & UNIT OF

ISSUE

1 - EA

CONDITION CONDITION A

OTHER DATA AS

DIRECTED

U.S. COAST GUARD SFLC

MATERIAL

5.5.2 Marking layout (scrap) “H” condition Starboard rudder.

2040-01-461-1943

ITEM NAME RUDDER

PART NUMBER 87 WPB 561-001 STBD

CONTRACT NUMBER (See Contract)

SHIPPING WEIGHT (LBS) As Determined by Contractor

QUANTITY & UNIT OF

ISSUE

1 - EA

CONDITION CONDITION H

OTHER DATA AS

DIRECTED

5.6 Bar coding. U.S. Coast Guard requires bar coding of the NSN, IAW MIL-STD-129R. See paragraph 5.4.1.2.1, page 51 of MIL-STD-129R for identification linear (Code 39) and 2D (PDF417) bar code markings and locations.

5.6.1 The Bar Code Label can be applied separately or as part of the marking required in 5.5.

5.7 Shipping. Unless otherwise directed, the Contractor shall ship and deliver the parts and components to the government address specified in paragraph 5.7.1. Notify the COR and KO about the shipment (07) days in advance. Provide timely shipping information to KO and COR including the name of the shipping company, date of shipment leaving Contractor’s facility, and expecting arrival date and time at the government facility. No shipment shall arrive outside of government normal business hours as determined by the KO.

5.7.1 Address. Unless otherwise specified, the Contractor shall ship, and deliver all parts to the following government addresses:

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

6 NOTES

6.1 Document sources.

6.1.1 Government document sources.

• Department of Defense Single Stock Point (DODSSP)

Building 4, Section D 700 Robbins Avenue Philadelphia, PA 19111-5094 215-697-2667/2179

FAX 215-697-1462

• DOD & Navy Publications & Forms (Other Than DODSSP) Naval Publication and Forms Center 5801 Tabor Ave.

Philadelphia, PA 19120 215-697-2000

• USCG Surface Forces Logistics Center 2401 Hawkins Point Road Baltimore, MD. 21226-5000 Phone: 410-762-6649 ATTN: Contracting Branch, CPD1

6.1.2 Commercial document sources.

• ASTM International

1916 Race Street Philadelphia, PA 19103-1187 Phone: 215-299-5585 Fax: 215-977-9679

• American National Standards Institute (ANSI) 1430 Broadway New York, NY 10018 Phone: 212-642-4900

• International Standard Organization (ISO) 1, ch. De la Voie-Creuse CP 56 - CH-1211 Geneva 20 Switzerland Phone: +41 22 749 01 11 Fax: +41 22 733 34 30

• American Society of Mechanical Engineers (ASME) Two Park Avenue New York, NY 10016-5990 Phone: 800-843-2763

• The Society for Protective Coatings (SSPC) 800 Trumbull Drive Pittsburg, PA 15205 Phone: 1-877-281-7772 Fax: 412-444-3591

Society of Automotive Engineers (SAE) 400 Commonwealth Drive Warrendale, PA 15096 Phone: 724-776-4841 Fax: 724-776-0790

6.2 Weld Repair Increments: The Coast Guard has derived weld repair increments for rudder repair. They are as follows:

6.2.1 General - Rudder blade: 4 square inch of blade skin removed, replaced, welded and tested.

6.2.2 Blade welds, 3 inch – based on welding a 3 inch length to repair leakage and test.

6.3 Rudder Measurement Form:

WBN_0619

WORK ITEM 1: 2040-01-461-1944, Rudder, Port, Repair

1. SCOPE

1.1 Intent. This work item sets forth the requirements for the Receipt, Inspection, Overhaul, Preservation, Packing, Marking, Bar-Coding and Shipping of Port Rudders used on US Coast Guard 87' Coastal Patrol Boats.

1.2 Government furnished property (GFP). The listed items are property of and managed by the USCG Surface Forces Logistics Center, Baltimore MD and will be issued to the Contractor as issuance of a contract or contract delivery order.

MTI ITEM DESCRIPTION NSN

P/N

CAGE

QTY

(EA.)

ESTIMATED COST

($/UNIT)

Y * Rudder NSN: 2040-01-461-1944

PN: 87WPB 561-001 PORT

CAGE: 81340

Y * Shipping Crate, Reusable

NSN: N/A

PN: N/A

CAGE: N/A

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

**New or refurbished equipment that the Government may provide for installation in place of existing equipment.

***Government-furnished property, which is to be supplied by the Coast Guard.2. REFERENCES

2. REFERENCES

COAST GUARD DRAWINGS

Coast Guard Drawing 87WPB 562-001 Rev. A, dated 3/10/2009 – 87FT Coastal Patrol Boat

Rudder Details Coast Guard Drawing 87WPB 561-001 Rev. K, dated 5/12/2017 – 87FT Coastal Patrol Boat

Steering System Details

COAST GUARD PUBLICATIONS

Surface Forces Logistics Center Standard Specification 0740 (SFLC Std Spec 0740), 2014, Welding and Allied Processes

OTHER REFERENCES

ANSI/ASQ Q9001, Dated 10/01/2015 – Quality Management Systems – Requirements – T860E ASME B17.1, Dated 1/1/1967, (Reaffirmed 2013) – Keys and Keyseats ASTM A276/A276M-17, Dated 3/15/2017 – Standard Work item for Stainless Steel Bars and

Shapes ASTM D6880/D6880M-11, Dated 2011 – Standard Work item for Wood Boxes

DODD 4140.01-M-1, Dated 7 Sep 2007 – Compliance for Defense Packaging: Phytosanitary Requirements for Wood Packaging Material (WPM)

ISO/IEC 16388:2007 (2014) Information Technology - Automatic identification and data capture techniques - Code 39 bar code symbology specification

ISO/IEC 17025:2017, Dated 11/2017 – General requirements for the Competence of Testing and Calibration Laboratories

MIL-A-22262, Dated 4/05/1993 – Abrasive Blasting Media Ship Hull Blast Cleaning MIL-STD-2073-1E, Dated 1/07/2011 – Department of Defense Standard Practice: Military

Packaging MIL-STD-129R, Dated 2/18/2014 – Department of Defense Standard Practice: Military Marking for Shipment and Storage SAE International, SAE J 448-2011 – Standard, Surface Texture SSPC/NACE International (NACE), Joint Surface Preparation Standard SSPC-SP 10/NACE No

2, 2007, Near-White Blast Cleaning

2.1 Document availability. The documents listed in this section are referenced in sections 3, 4 and 5 of this work item. Several references are listed on Coast Guard drawings 87WPB 562-001 Rev. A and 87WPB 561-001 Rev. K. To obtain the referenced documents see section 6.1.

2.2 Work item order of precedence. The Applicable Documents described are required to be adhered to in fulfilling the contract. In the event of a conflict between the text of this work item and the references cited herein, this work item shall take precedence. Nothing in this document, however, supersedes applicable laws and regulations unless a specific exemption has been obtained.

3. REQUIREMENTS

3.1 General. The Contractor shall provide storage for the GFP when not in use, and safe handling when in use.

3.1.1 Storage. The storage area shall at a minimum be closed on all sides, dry, and locked when unattended.

3.2 Inspection. The Contractor shall carefully remove the rudder from the GFP crate, clean and remove all paint and primer to facilitate a thorough inspection to determine all the necessary repairs to return the rudder to a serviceable “A” condition as defined below. A Condition Found Report (CFR) shall be submitted to the Coast Guard Contracting Officer (KO) within twenty (20) days of receipt of GFP. The CFR shall include all inspection findings and test results as specified below, including a breakdown of estimated cost of labor and materials for any repair work or testing outside of the standard rudder overhaul. This includes the repair or replacement of the shipping crate. The CFR shall also include a breakdown of estimated cost of labor and materials for any repair work that is beyond the scope of work in this work item. No further work shall proceed until authorized by the KO in writing.

NOTE

Serviceable “A” condition is defined as a reconditioned rudder meeting all required design work items and design dimensions in accordance with Coast Guard drawing: 87WPB 562-001 Rev. A and being capable of functioning and performing in the same manner as an identical new rudder although it may not have the appearance of a new rudder.

3.2.1 CFR information. The CFR shall contain the following information as a minimum:

• Contractor name, address and telephone number

• Contract number and delivery order number as applicable

• Name of personnel conducting inspections

• Rudder serial number(s)

• Inspection sheets showing dimensional data and test results for rudder blades only (The entire stock will be cut down and welded back up per section 3.5.1 so initial measurements are not necessary)

• Estimated cost to complete rudder repairs including cost to repair or replace shipping container

3.2.2 Paint removal. The Contractor shall abrasive grit blast all coated rudder surfaces to SSPC-SP 10/NACE No. 2 using grit conforming to MIL-A-22262 with a 1.5-3.5 mil profile.

3.2.2.1 All pipe plugs shall be installed prior to grit blasting.

3.2.3 Visual inspection. Visually inspect the rudder for the following:

• Straightness of stock and blade

• Corrosion and other mechanical defects

3.2.4 Ultrasonic test. Perform ultrasonic testing to the rudder to measure blade plate thickness if there are signs of corrosion or wear. Take as many UT shots as necessary on each side, log readings and location on CFR.

3.2.5 Air pressure test. The Contractor shall conduct an air pressure test on the blade section after all the paint and primer are removed. Using a calibrated 0-5 PSI pressure gage, apply air pressure to the air cavity and hold at 2 PSI for 10 minutes. Any loss of air pressure will constitute test failure. If any pressure loss is noted, check porosity areas, plug threads, and all welds using a soapy water solution to expose leaky areas. The active formation of air bubbles on the blade surface indicates the presence of cavitation erosion damage. This condition needs to be repaired prior to acceptance. Subsequent air tests will need to be performed in order to ensure the void does not leak. All traces of soapy water solution shall be removed.

3.2.6 Indicated leakage through skin or welds. If air leaks are found through the skin or welds the Contractor shall include the extent of the leakage to the Contracting Officer in the CFR with recommended repairs and cost. The Coast Guard shall determine if excessive leaking should be repaired or scrapped based on the Contractor recommendation, extent of leaks and cost to repair per section 3.5.

• The air pressure test shall be repeated on rudders that undergo weld leakage repair work

• The cost of additional air test(s) if required shall be covered under the repair

• Weld repair increments for the blade section are listed in section 6.2

3.3 Rudder disposition. The Coast Guard will review the CFR and determine if rudder(s) will be repaired or scrapped due to the extent of necessary repairs and determine disposition. Disposition options are as follows:

• Contractor to scrap on site and provide credit to the Coast Guard based on current U.S.

stainless steel scrap prices

• Rudders to be re-packaged in the original shipping container, properly marked per section 5.5 and returned to SFLC Baltimore, MD at the address listed in section 5.7.

3.4 Welding certifications. The Contractor shall have welders qualified in accordance with Qualifications Standard for Welding and Brazing, also per SFLC STD Spec 0740. Certification documentation shall be maintained and available to the KO, Contracting Officer’s Representative (COR) or Coast Guard Quality Assurance personnel (QA) for review at any time during the contract period.

3.4.1 Penetrant testing. Liquid dye penetrant testing per SFLC Std Spec 0740 shall be completed in all areas in way of the keyways, tapers, bearing and seal areas, and welds from all welding and weld repairs.

All test results shall be recorded on the Final Inspection Report.

3.4.2 Surface finish. All surface finishes shall be in accordance with Coast Guard Drawing 87 WPB 562- 001, Rev A.

3.5 Rudder repairs. The Contractor shall:

3.5.1 Rudder stock. Starting where the stock meets the rudder blade above the knuckle, machine to undercut the entire stock diameter 0.1875”. Clad weld buildup with 316L stainless steel material to facilitate finish machining IAW drawing 87WPB 562-001 Rev. A. The surface finish indicated on the drawing shall be in accordance with SAE J 448-2011 Standard. Polish all machined surfaces above the knuckle to a 63 RMS or smoother.

3.5.2 Rudder blade. Leakage through skins or welds as identified in the initial inspection and approved for repair by the KO shall be repaired by welding per SFLC STD Spec 0740.

3.5.2.1 The Contractor shall conduct an air pressure test (section 3.2.5) after repairs paying particular attention to welded areas. Any leakage found during the air pressure test shall be corrected by welding with an additional air pressure test conducted after weld repairs are complete. This process shall be repeated until all leakage has been corrected and rudder passes air pressure testing.

3.5.3 Workmanship. Rudders shall have a professional appearance and be free of dirt, grease, burrs or sharp edges.

3.6 Rudder key stock. The Contractor shall provide a rudder key stock as part of each repaired rudder.

3.6.1 Dimensions. The rudder key stock dimensions shall be in accordance with Coast Guard drawing 87WPB 561-001 Rev. K, piece 19.

3.6.2 Manufacturing. The rudder key stock shall be manufactured from 316 key stock meeting ASTM A276/A276M-17.

3.6.3 Keyway fit. The key to keyway fit shall be Class 1 per ASME B17.1.

3.6.4 Packaging. The Rudder Key shall be secured in the shipping container to prevent movement and be clearly marked “RUDDER KEY” with black waterproof markings.

3.7 Rudder nuts. The Contractor shall provide (1) each of the following nuts and washer for each repaired rudder per drawing 87WPB 561-001 Rev. K.

• Nut, Steel 2 ½” x 4 TPI, piece 05

• Washer, ½” Thick x 89mm I.D. x 127mm O.D., piece 06

• Nut, Locking, Steel M90 x 2, piece 07

3.7.1 Welding. Nut, Steel 2 ½” x 4 TPI, piece 05 and Washer, ½” Thick x 89mm I.D. x 127mm O.D., piece 06 shall be welded together IAW drawing 87WPB 561-001 Rev. K, sheet 3, detail 21 D.

3.7.2 Fitting. The rudder nuts shall screw on the rudder stock threads with a Class 2A/2B fit in accordance with ANSI/ASME B1.1-2003.

3.7.3 Packaging. The rudder nuts shall be secured and cushioned individually to prevent movement or damage to the threads during shipping and handling.

3.7.4 Marking. The rudder nuts shall be clearly marked “RUDDER NUT” with black waterproof markings.

3.8 Serial numbers. All repaired rudders with no serial numbers shall be marked on the stock end face with a stamped-in serial number at least 1/8” high. The Contracting Officer (KO) will provide rudder stock serial numbers as required.

3.9 Final inspection and test report. A detailed Final Inspection and Test Report shall be submitted to the KO for approval prior to scheduling QA personnel. The report shall depict the final condition of the rudder after all work has been completed. A copy of the inspection and test report shall be turned over to the QA representative upon arrival for final inspection and testing. The inspection and test report shall contain the following information as a minimum:

• Contractor name, address and telephone number

• Contract number and delivery order number as applicable

• Rudder serial number(s)

• Written dimensional survey showing the rudder measurements and test results are within tolerance for each dimension shown on the drawing or per this work item.

• Name of the person conducting the testing

• Test equipment used, nomenclature, serial number, and calibration date

• Pressure test certification

• NDT test results

3.9.1 Rudder measurement form. The Contractor shall use the rudder measurement form in section 6.3 as part of the Final Inspection and Test Report.

3.10 Warranty. Standard manufacturer’s warranty applies to items manufactured or repaired under this work item.

3.11 Notifications and inspections. The Contractor shall be responsible for notifying the KO at least ten

(10) calendar days prior the Contractor being ready for any Quality Assurance inspections or testing as required herein. The rudders require a one hundred percent Coast Guard Quality Assurance inspection.

4. QUALITY ASSURANCE

4.1 General. The Contractor shall maintain an inspection system, which shall insure each item offered to the Coast Guard for acceptance or approval conforms to the contract requirements. The inspection system shall be in accordance with ANSI/ASQC Q9001, 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 ISO/IEC 17025. 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 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 or have performed any of the inspections that are deemed necessary to assure that supplies and services conform to the prescribed requirements.

4.5 Responsibility for compliance. All items shall meet the provisions of sections 3 & 5. The inspections set forth in this work item shall become part of the Contractor’s overall inspection system or quality program. The absence of any inspection requirements in the work item 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 Tests and inspections. The inspections/tests required here and in section 3.0 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.

4.6.1 The following are required and will be witnessed by Coast Guard SFLC Quality Assurance Representative(s):

• Overall dimensions and dimensional tolerances are in accordance with the drawings

• Surface texture (stock section), per section 3.5.1

• Weld inspection per section 3.5.2

• Air pressure test per section 3.5.2

• Blade straightness in reference to the centerline on the drawing

• Rudder Key per section 3.6

• Rudder nuts (2) tested for thread fit, secured and marked in crate per section 3.7

• Preservation, packing, marking and bar-coding of rudder prior to shipping per section 5

4.6.2 The Rudder inspection requires 100% verification to assure compliance with the applicable drawings and this work item.

4.6.3 For the safety of Coast Guard personnel and shop workers, QA inspections shall be completed indoors away from Normal shop work, operating machinery, loud noise, welding (arching) and grinding operations if permissible.

4.7 Failure responsibility. If a rudder fails to pass any inspection/test, the Contractor shall report the failure and the recommended fix to the Contracting Officer. If approved, the corrective action on the materials or processes shall be taken in accordance with this section.

• The Contracting Officer reserves the right to totally reject any failed item without considering any suggested corrective action

• The inspection/testing shall be discontinued until all corrective action has been taken

• After all corrective actions have been taken the inspection/tests shall be continued or repeated at the option of the Contracting Officer

• Acceptance shall be withheld until re-inspection has been shown that the corrective action was successful and the item satisfactorily passes all inspections and tests

• All corrective actions shall be documented as part of the Contractor's inspection system and submitted for approval to the Contracting Officer

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

4.8 Tests and inspection reports. One copy of any required inspection, test or tolerance check done on each delivery order shall be sent to the KO.

4.8.1 Quality assurance representative. A copy of any test, inspection or tolerance report shall be turned over to the SFLC QA Representative upon arrival at the Contractor’s plant.

4.9 Packing inspection. The KO shall be notified prior to the packaging and marking of the completed units in accordance with section 3.11 of this work item.

5. PRESERVATION, PACKING, MARKING, AND SHIPPING

5.1 General. Each rudder shall be individually preserved, packed, marked and bar-coded in its own reusable wood box, or a new reusable wood box if approved. Preservation, packaging, packing, marking and bar-coding will be inspected by Coast Guard SFLC QA personnel at Contractor’s facility.

5.2 Preservation. Each rudder manufactured under this contract shall be preserved in accordance with MIL-STD-2073-1E, Method 10. The rudder stock shall be supported in the box by use of cradles and blocking that will not allow shifting of the rudder within the box. The entire rudder stock shall be protected with PVC pipe or a heavy plastic mesh.

5.3 Packaging. Each preserved and packed rudder shall be packaged in its own completely enclosed shipping container. The container shall be constructed of 1/2” minimum thickness plywood sheathing with 2” X 3” minimum wood framing for strength. Particleboard, flake board, OSB etc. will not be acceptable. The container shall be skid mounted using 4”x4” wooden posts and constructed with a removable lid secured with corrosion resistant self-tapping wood screws to allow for easy access and removal in accordance with ASTM D6880/D6880M.

5.4 New reusable shipping container. When authorized by the KO, the Contractor shall construct a new reusable wood box manufactured IAW 5.3 and ASTM D6880/D6880M.

5.4.1 Wood Packing Material (WPM) requirements. New reusable wood boxes shall meet the Phytosanitary Requirements for WPM in accordance with paragraph C2.1.1 of DODD 4140.01-M-1, Compliance for Defense Packaging. WPM is defined as wood pallets, skids, load boards, pallet collars, wooden boxes, reels, dunnage, crates, frames and cleats. Packaging material exempt from the requirements are materials that have undergone a manufacturing process such as corrugated fiberboard, plywood, particleboard, veneer and oriented strand board (OSB). All new purchases of WPM shall be constructed from heat treated (treated to 56° C. core temperature for 30 Minutes) lumber and certified by an accredited agency recognized by the American Lumber Standard Committee (ALSC).

5.4.2 WPM markings. All new wood boxes shall have the appropriate markings in accordance with DODD 4140.01-M-1, Compliance for Defense Packaging Ref. 2 paragraph C2.5.

5.4.3 Newly manufactured wood boxes shall be secured and stored per section 3.1.

5.5 Marking. Each wooden box shall be stenciled with the information as laid out below. Markings shall be placed on each side of the two longest sides of the container so it will be visible to a forklift driver during storage and shipment. Stencil shall be applied directly on the container and a minimum of 3/4 inch height black block characters on a highly contrasting painted white background, using permanent waterproof ink or enamel paint. Laminated paper stencils will not be acceptable.

5.5.1 Marking layout (ready for issue) “A” condition Port Rudder.

2040-01-461-1944

ITEM NAME RUDDER

PART NUMBER 87 WPB 561-001 PORT

CONTRACT NUMBER (See Contract)

SHIPPING WEIGHT (LBS) As Determined by Contractor

QUANTITY & UNIT OF

ISSUE

1 - EA

CONDITION CONDITION A

OTHER DATA AS

DIRECTED

5.5.2 Marking layout (scrap) “H” condition Port rudder.

2040-01-461-1944

ITEM NAME RUDDER

PART NUMBER 87 WPB 561-001 PORT

CONTRACT NUMBER (See Contract)

SHIPPING WEIGHT (LBS) As Determined by Contractor

QUANTITY & UNIT OF

ISSUE

1 - EA

CONDITION CONDITION H

OTHER DATA AS

DIRECTED

5.6 Bar coding. U.S. Coast Guard requires bar coding of the NSN, IAW MIL-STD-129R. See paragraph 5.4.1.2.1, page 51 of MIL-STD-129R for identification linear (Code 39) and 2D (PDF417) bar code markings and locations.

5.6.1 The Bar Code Label can be applied separately or as part of the marking required in 5.5.

5.7 Shipping. Unless otherwise directed, the Contractor shall ship and deliver the parts and components to the government address specified in paragraph 5.7.1. Notify the COR and KO about the shipment (07) days in advance. Provide timely shipping information to KO and COR including the name of the shipping company, date of shipment leaving Contractor’s facility, and expecting arrival date and time at the government facility. No shipment shall arrive outside of government normal business hours as determined by the KO.

5.7.1 Address. Unless otherwise specified, the Contractor shall ship, and deliver all parts to the following government addresses:

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

6 NOTES

6.1 Document sources.

6.1.1 Government document sources.

• Department of Defense Single Stock Point (DODSSP)

Building 4, Section D 700 Robbins Avenue Philadelphia, PA 19111-5094 215-697-2667/2179

FAX 215-697-1462

• DOD & Navy Publications & Forms (Other Than DODSSP) Naval Publication and Forms Center 5801 Tabor Ave.

Philadelphia, PA 19120 215-697-2000

• USCG Surface Forces Logistics Center 2401 Hawkins Point Road Baltimore, MD. 21226-5000 Phone: 410-762-6649 ATTN: Contracting Branch, CPD1

6.1.2 Commercial document sources.

• ASTM International

1916 Race Street Philadelphia, PA 19103-1187 Phone: 215-299-5585 Fax: 215-977-9679

• American National Standards Institute (ANSI) 1430 Broadway New York, NY 10018 Phone: 212-642-4900

• International Standard Organization (ISO) 1, ch. De la Voie-Creuse CP 56 - CH-1211 Geneva 20 Switzerland Phone: +41 22 749 01 11 Fax: +41 22 733 34 30

• American Society of Mechanical Engineers (ASME) Two Park Avenue New York, NY 10016-5990 Phone: 800-843-2763

• The Society for Protective Coatings (SSPC) 800 Trumbull Drive Pittsburg, PA 15205 Phone: 1-877-281-7772 Fax: 412-444-3591

Society of Automotive Engineers (SAE) 400 Commonwealth Drive Warrendale, PA 15096 Phone: 724-776-4841 Fax: 724-776-0790

6.2 Weld Repair Increments: The Coast Guard has derived weld repair increments for rudder repair. They are as follows:

6.2.1 General - Rudder blade: 4 square inch of blade skin removed, replaced, welded and tested.

6.2.2 Blade welds, 3 inch – based on welding a 3 inch length to repair leakage and test.

6.3 Rudder Measurement Form: