Attachment 7 - 2040016850059_RddrAssy_R.pdf

SRT_0316

WORK ITEM 1: 2040-01-685-0059, Rudder Assembly, Overhaul

1. SCOPE

1.1 Intent. This work item describes the requirements for the Contractor to overhaul to a serviceable “A” condition of rudder assembly(s) in accordance with the referenced drawing(s) and data provided within.

NOTE

Serviceable “A” condition is defined as a reconditioned rudder meeting all required design specifications and design dimensions in accordance with Coast Guard drawing: 618-

WMEC-562-003 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.

1.2 Government-Furnished Property.

MTI ITEM DESCRIPTION NSN

P/N

QTY (EA.)

Y ***Rudder Assembly NSN: 2040-01-685-0059

618-WMEC-562-003

Y ***Rudder Blade, A&B

Class

NSN: 2040-01-336-6545 1

Y ***Rudder Stock, A-

CLASS

NSN: 2040-01-332-2720 1

N

*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

COAST GUARD DRAWINGS

618-WMEC-562-003, Rudder Assembly

627-WMEC-562-003, Rev A, Rudder Blade Construction

618-WMEC0562-001, Rev H, Arrangement & Details Rudder Stocks, Bearings & Stuffing Box

COAST GUARD PUBLICATIONS

Surface Forces Logistics Center Specification D-000-0100, Rev. G, Change 1, Bar Coding for

SFLC Stocked Material

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

Surface Forces Logistics Center Standard Specification 6310 (SFLC Std Spec 6310), 2014, Requirements for Preservation of Ship Structures

Surface Forces Logistics Center Standard Specification 0000 (SFLC Std Spec 0000), 2014, General Requirements

OTHER REFERENCES

ASTM-E797/E797M Standard Practice for Measuring Thickness by Manual Ultrasonic Pulse –

Echo Contact Method

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

MIL-PRF-16173E w/ Int. Amendment 1, Sep 2006, Corrosion Preventive Compound, Solvent

Cutback, Cold- Application

SPCC-SP 10 Near White Blast Cleaning

3. REQUIREMENTS

3.1 General.

The complete Rudder Assembly consists of the following items:

Rudder Blade, 1 each

Rudder Nut, 1 each

Rudder Nut Keeper, 1 each

Rudder Nut Wrench, 1 each

Rudder Blade Key, 1 each

Rudder Stock, Finished, 1 each

Rudder Stock Sleeve, 1 each

Tiller Keys, 2 each

Hoist Ring for Rudder Stock, 1 each

Threaded Bushing for Hoist Ring, 1 each

3.2 Inspections. The Contractor shall receive the rudder assembly and preform a Receiving

Inspection to ensure the correct items have been received and complete. The contractor shall provide the Contracting Officer (KO) a Receiving Inspection Report within two working days of receiving the rudderstock assembly. The contractor shall remove the rudder assembly from the

GFP crates and conduct a thorough inspection to determine all conditions included in section 3.1.

A Condition Found Report (CFR) shall be submitted to the Coast Guard KO within ten (10) days of receipt of GFP. The CFR shall include all inspection findings, test results as specified below, including any recommended work required to return the rudder assembly to serviceable “A” condition. The CFR shall also include a breakdown of estimated cost of labor and materials for any overhaul work that is beyond the scope of work in this specification. No further work shall proceed until authorized by the KO. The contractor shall provide a Final Inspection Report within two hundred calendar days from authorization to proceed with repairs from the KO.

3.2.1 Dimensional inspection. Dimensionally inspect the rudder assembly for the following:

• All dimensions found in USCG Drawing, 618-WMEC-562-003, Rudder Assembly

• Excessive wear on the taper surfaces.

• Straightness of blade.

• Keyways excessive wear.

• Any worn or damaged threads.

• Corrosion and other mechanical defects

3.2.2 Paint removal. Abrasive grit blast all coated rudder surfaces to SSPC-SP 10/NACE No. 2 using grit conforming to MIL-A-22262 with a 3.0-4.0 mil profile. All pipe plugs shall be installed prior to grit blasting in accordance with Surface Forces Logistics Center Standard

Specification 6310 (SFLC Std Spec 6310), 2014, Requirements for Preservation of Ship

Structures.

3.2.3 Ultrasonic test. Perform ultrasonic testing to the rudder to measure blade plate thickness.

Ultrasonic testing shall be in accordance with ASTM-E797/797M. Take 20-30 UT shots on each side and log readings and location on CFR. Degradation in excess of 25% will render the rudder non-repairable.

3.3 Air pressure test. The Contractor shall conduct an air pressure test on the blade section after all the paint and primer are removed as per 3.2.2. Using a calibrated pressure gauge, test shall be performed at 5 PSI for a period of 10 minutes. 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. A second air test will need to be performed in order to ensure the void does not leak. All traces of soapy water solution shall be removed.

3.3.1 Indicated leakage through welds. Rudders shall be serviceable if leakage is only found coming through welds but not through the skin surface. If air leaks are found through welds only, then the Contractor shall include the extent of weld leakage to the Contracting Officer in the CFR with recommended repairs and cost. The Coast Guard shall determine if double skinned rudders having leaking welds should be repaired in accordance with Surface Forces Logistics Center

Standard Specification 0740 (SFLC Std Spec 0740), 2014, Welding and Allied Processes or scrapped based on the extent of leaks and total cost to repair.

The air pressure test shall be repeated on rudders that undergo weld leakage repair work (see 3.5). The cost of additional air test if required shall be covered under the repair.

3.4 Beyond economical repair. Any rudder the Contracting Officer deems “Beyond Economical

Repair” shall be returned to the Coast Guard at the address listed in 5.6.1 and shall be marked in

“H” condition as described in 5.5.

3.5 Preservation. The interior and exterior surfaces of the rudder blade shall be preserved as follows:

3.5.1 Flow coating (Interior). The rudder internal cavities shall be cleaned as appropriate to facilitate preservation. Once cleaned, fill and drain (flow coat) with corrosion preventative compound that confirms to MIL-PRF-16173 Grade 3. Replace pipe plugs with new stainless steel plugs.

3.5.2 Rudder coating system (Blade). Painting of the blade shall be accomplished after all other repair work is complete. Reference: Surface Forces Logistics Center Standard Specification

6310 (SFLC Std Spec 6310), 2012, Requirements for Preservation of Ship, Appendix A.

3.6 Paint data sheet. Paint data sheets per Surface Forces Logistics Center Standard Specification

6310 (SFLC Std Spec 6310), Appendix E shall be prepared to certify the paint type and mil thickness used on the rudder blade. The paint data sheets shall verify all manufacturers’ instructions were followed throughout the entire coating process. The paint data sheet shall be packed with each reconditioned rudder.

3.7 Blade bore taper. Each rudder blade taper bore shall be thoroughly coated with Grade 3 preservative IAW MIL-PRF-16173E INT AMD 1, ref., 2.2.2.b. Cover taper bore ends using wooden blanks with a minimum thickness of 1-1/2” installed over thin rubber sheeting. Use 5/8” minimum diameter all-thread, with nylock style nuts, fender washers and and commercial grade sealant between the nuts, washers and wooden blanks to secure the wooden blanks in place.

4. QUALITY ASSURANCE

4.1 Inspections & tests (completed units). 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.

4.1.1 Validation. Contractor shall have the latest versions of the drawings, specifications, tolerances, approved test procedures and test equipment calibration certificates available traceable to NIST for inspection, as necessary.

4.1.2 Quality assurance inspections. The contractor shall be responsible for notifying the

Contracting Officer within ten (10) business days of Quality Assurance inspections. The contractor is responsible for providing all facilities, materials and personnel for conducting inspections. These actions are required and will be monitored by a Coast Guard SFLC Quality

Assurance Representative.

• Overall dimensional tolerances are in accordance with the drawing.

• Surface texture (stock section).

• Weld inspection.

• Air pressure test.

• Paint thickness check.

• Paint data sheets.

• Float coat application.

• Blade straightness in reference to the centerline on the drawing.

• Slade packing kit secured and marked in crate.

• Packing, packaging, marking and bar-coding of rudder prior to shipping.

5. PACKING, MARKING, AND SHIPPING

5.1 Packing. Each rudder shall be individually packaged in its own reusable wood box, or a new reusable shipping container.

NOTE

All GFP must be stored indoors in a locked, environmentally controlled location at the contractors facility. Any new crates fabricated per this statement of work shall be safe guarded and stored in the same place as other GFP.

5.2 New reusable shipping container. When a change request is authorized by the KO, the

Contractor shall construct a new reusable shipping container as follows:

5.2.1 The wooden box shall be constructed using 2” x 8” framing and ¾” plywood top and bottom. Particle board, flake board, OSB etc. will not be acceptable. The box shall be skid mounted and constructed with a removable lid secured with corrosion resistant wood screws to allow easy access and removal of the rudder without damage to the box.

5.2.2 Wood packing material (WPM) Requirements. The new shipping container shall meet the

Phytosanitary Requirements for WPM in accordance with DOD 4140.01-M-1, Compliance for

Defense Packaging Ref. 2 paragraph C2.1.1. 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).

5.2.3 WPM markings. All new shipping containers shall have the appropriate markings in accordance with DOD 4140.01-M-1, Compliance for Defense Packaging Ref. 2 paragraph C2.5

5.2.4 Newly manufactured shipping containers shall be secured and stored per 5.1 note.

5.3 Marking. Shipping container shall be stenciled with the information 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 1inch height black characters on a highly contrasting painted background, using permanent waterproof ink or enamel paint.

Required marking for (ready for issue) “A” Condition rudder blades

National Stock Number: 2040-01-486-0550

Item Name: RUDDER STOCK ASSEMBLY

Drawing Number: 901-WMEC-562-005 REV J

Shipping Weight: Contractor Provide

Coast Guard Contract Number See Contract

Delivery Order Number: See Contract

Statement: COAST GUARD SFLC MATERIAL

CONDITION "A", 1 EACH

Required marking for (scrap) “H” Condition rudders:

National Stock Number: 2040-01-336-6545

Item Name: RUDDER, MARINE

Drawing Number: 627WMEC-562-003 REV-

Shipping Weight: Contractor Provide

Coast Guard Contract Number See Contract

Delivery Order Number: See Contract

Statement: COAST GUARD SFLC MATERIAL

CONDITION "H", 1 EACH

5.4 Bar coding. A bar coded label, in accordance with SFLC specification D-000-0100 shall also be applied. The Bar Code Label can be applied separately or as part of the marking required in

5.3 of this specification.

The actual labels shall be Type "V", Grade "C" Style "2", Composition "a" with or without plastic laminate.

Each label shall contain encoded data for the Stock Number.

5.5 Shipping. The Contractor shall ship, and deliver the repaired rudder to the government address specified in paragraph. 5.5.1 Notice the Contracting Officer representative (COR) and

KO about the shipment 7 days in advance. Provide timely shipping information to 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.

5.5.1 Unless otherwise specified, the Contractor shall ship, and deliver the rudder(s) to the following government address:

U.S. Coast Guard

Surface Forces Logistics Center

2401 Hawkins Point Rd, Bldg. 88

Baltimore, MD 21226

NOTE

Normal deliver hours at the warehouse are Monday through Friday 0730-

1300. If delivery is needed to be made outside that delivery window the

Contractor shall notify the Contracting Officer.

6. NOTES

This section is not applicable to this work item.