CUI A5 SOW Repair HPAC 3 (REV5) 1212_Redacted.pdf

1.0 BACKGROUND:

The Puget Sound Naval Shipyard and Intermediate Maintenance Facility (PSNS&IMF) in support of CVN 68 class aircraft carrier requires Original Equipment Manufacturer (OEM) authorized repair activity to provide urgent services to restore High Pressure Air Compressor (HPAC) No. 3.

1.1 SCOPE:

1.1.1 Remove, replace, and repair No. 3 HPAC.

1.2 LOCATION OF WORK:

1.2.1 Work will be performed Onboard deployed Naval vessel. Pickup location is currently set to be in Singapore. Confirmation of pickup location will be communicated at time of contract award by the COR.

1.2.2 Contractor employees require access to the following compartments to conduct repairs to No. 3 HPAC.

1.2.2.1 HPAC No. 3:

2.0 REFERENCES:

2.1 NAVSEA 389-0288; Radiological Controls

2.2 NAVSEA S9AA0-AB-GOS-010, Rev 10; General Specifications for Overhaul of Surface Ships

2.3 Cleanliness Verification Sign-Off Sheet (Attachment A)

2.4 S6220-EP-MMO-010, Rev 7; AIR COMPRESSOR SEAWATER-COOLED HIGH-PRESSURE

WP5000

2.5 Material History Record (Attachment B)

3.0 REQUIREMENTS:

3.1 Period of Performance: December 30, 2024, through January 14, 2025, or until completion of work.

3.2 WORK CONTROLS:

3.2.1.1 Coordinate with Ship’s Force (SF) to verify boundaries and ensuring entire site is isolated and ready for work.

3.2.1.2 Ensure all work on ship’s systems and components properly authorized and controlled to ensure personnel and ship safety standards are met. Ships Force (SF) will act as the Repair Activity designated representative (s) for the tag out of isolation.

3.3 RESTRICTED DATA

3.3.1 Contractor employees require access to and control of RESTRICTED DATA (RD), regarding Naval Nuclear Propulsion Information (NNPI and U-NNPI), to accomplish the requirements of this contract.

3.4 CONTRACTOR FURNISHED MATERIAL: Provide all parts/components not supplied by the Government in section 4, tools, test equipment, consumables (with exception of hazardous materials), personnel, labor, technical expertise, and Personnel Protection Equipment (PPE) to accomplish requirements.

3.4.1 The OEM will provide shipping and handling services for materials from OEM service provider to and from material staging location: Singapore. The material staging location is subject to change based on evolving deployment status of the Aircraft Carrier and final location and address will be communicated at the time of contract award by the

COR.

3.5 SECURITY REQUIREMENTS:

3.5.1 Contractor personnel will need valid USA passport and synchronized predeployment and operational tracking. Letter of authorization. (SPOT LOA)

3.6 RADIOLOGICAL REQUIREMENTS:

3.6.1 Contractor may be required to accomplish work onboard ship in areas that require personal monitoring of radiation (i.e. wearing a TLD). Contractor employees shall be trained in accordance with 2.1 and be able to check out a TLD. Contracted workers will not handle radioactive materials or perform work on radiological controlled systems.

Contractor shall obtain TLD’s from Ship’s Force (SF) as required.

3.7 Planning, supervising, or performing nuclear work is NOT authorized without the express approval of .

3.8 GOVERNMENT REPRESENTATIVES:

3.8.1 Contracting Officer Representative (COR): Located within the contract

3.9 TECHNICAL WORK REQUIREMENTS:

3.9.1 Accomplish the level II cleanliness requirements of Ref 2.2 section 551W and verify on Ref 2.3.

3.9.1.1 Submit a signed copy of Ref 2.2 to Code 260 via the Contracting Officer’s Representative (COR) upon completion of work on compressor and components.

3.9.2 Document any new deficiencies in a Condition Found Report (CFR) for each compressor that are beyond the scope of this SOW to the COR within three business days. The report should contain the following information: (CDRL A001, DI-MGMT- 81648)

3.9.2.1 A description of the deficient condition found with supporting data.

Include annotated sketches and graphs.

3.9.2.2 Recommendations and a list of material, to include proposed pricing and man-hours needed to repair the deficient condition found. Provide piece/part number, quantity and line item from description provided in equipment technical manual. If the piece/part number is not included in the technical manual provide applicable reference document or if included in proprietary document state so.

3.9.3 Perform repairs to No 3 HPAC to restore unit to OEM specifications as defined by Ref 2.4, Figure 2-1 as guidance.

3.9.3.1 Retain all damaged components, preserve found condition of items to maximum extent possible, and turn items over to the Government for failure analysis.

(V) (G) CHECK POINT “OPERATIONAL TEST” of No.3 HPAC:

3.9.4 Operational test will be a four-hour run at normal conditions.

3.9.4.1 Complete and submit log sheet (Figure 2-7 of Ref 2.3 or vendor equivalent) (CDRL A002, DI-MISC-81617) to Code 260 via the Contracting Officer’s Representative.

3.9.5 Accomplish the material history requirements of Ref 2.4 and verify on Ref 2.5.

Submit one legible copy, in electronic media, of the Material History records to Code 260 via the COR within three (3) business days of completion of HPAC repairs.

3.9.6 Submit one legible copy, in electronic media, of the completion report, including OEM service provider assessment of failure root cause, to Code 260 via the COR within three (3) business days of completion of HPAC repairs containing the following information (CDRL A004, DI-MGMT-82050).

4.0 GOVERNMENT WILL PROVIDE:

4.1 Government Furnished Material as listed below:

4.1.1 Bareshaft Compressor (PN 065089)

4.1.2 Safety Relief Valve 4th Stage (PN 065643)

4.1.3 Seawater Pipe Flange Gasket (PN 053165)

4.2 Services provided as listed below:

4.2.1 Provide rigging/crane support.

4.2.2 Provide drain/disposal/replenishment of 2190 oil.

4.2.3 Provide drain/disposal/replenishment of Jacket Water 50/50 Coolant Mix.

4.2.4 Provide temporary support services such as staging/air/piping/electricity.

4.2.5 Provide crating services for shipment of damaged HPAC components.

5.0 QUALITY:

5.1 Quality Assurance Surveillance Plan (QASP): The Quality Assurance Surveillance Plan (QASP) is a tool the Government utilizes to verify the contractor is performing all services and delivery/installation of replacement parts required by the above requirements in a timely, accurate and complete fashion.

6.0 DELIVERABLE ITEMS:

Number Name Frequency Quantity

A001 Condition Found Report (CFR) As needed 1 Each

A002 Operational Test One Time 1 per compressor

A003 Completion Report Within 3 business days 1 per compressor

Level II Cleanliness Certification Ref 2.4 Within 3 business days 1 per compressor

Material History Log Ref 2.4 Within 3 business days 1 per compressor

Attachment A:

TITLE: Verification of Levels of Cleanliness Sheet

DISTRIBUTION STATEMENT D:

Distribution authorized to DOD components and DOD contractors only; Critical Technology; May 2017. Other requests for this document shall be referred to Puget Sound Naval Shipyard (Code 260).

Destroy by any method that will prevent disclosure of the contents or reconstruction of the document.

Ship System: Compressed Air Systems, SWLIN 551 Equipment: High Pressure Air Compressor, SWLIN 551 References: 1) NAVAL SHIPYARD QUALITY PROGRAM MANUAL (NAVSEA TL855-

AA-STD-010 Rev 4)

2) INSPECTIONS AND VERIFICATIONS IN NONNUCLEAR SHIPS

SYSTEMS (PSNS&IMFINST 4730.62 31 Aug 2018)

3) ENGINEERING AND PLANNING PROCEDURES MANUAL (EPPM)

ENGRDEPT P5200(2) (Rev LATEST)

4) GENERAL SPECIFICATIONS FOR OVERHAUL OF SURFACE SHIPS

(S9AA0-AB-GOS -010 Rev 10), PARAGRAPH 505J.

5) UNIVERSAL PROCESS INSTRUCTION (UIPI) 0505-908 (Rev LATEST)

LEVEL II AND III CLEANLINESS FOR PIPING SYSTEMS/EQUIPMENT

Definitions:

System Entry: Contractor technicians have entered/opened up the respective fluid portion of the specific system.

Level II Cleanliness: Surface shall be visually free of grease, oil, flux, scale, dirt, loose particles, and any other contamination foreign to the base metal. Tap water residues on all metals and light superficial rust on carbon steel surfaces, caused by short time exposure to the atmosphere, are permitted. Light dust on cleaned surfaces is not objectionable, if the quantity and size of the particles does not adversely affect the system operation.

Background:

Reference (1) Chapter 7 tasks the shipyard to “develop and maintain procedures to ensure work performed associated with repair or conversion of Naval ship systems and/or components meet specified requirements in order to preclude downstream failures.” Reference (1) Section 7.2 establishes Inspection and Verification (I&V) Attributes that the shipyard is responsible for in ensuring that the NAVSEA I&V attributes are invoked in locally developed Technical Work Instructions. Further local guidance is provided in Reference (2) for PSNS & IMF and associated entities. Reference (3), Appendix C-54, establishes <V> attribute 551-001 for system cleanliness on compressed air systems.

Reference (1 & 2) establish that verification attributes <V> may be performed by either PSNS & IMF production (shop supervisor or mechanic), Quality Assurance Officials (QAO), or other personnel that have been appropriately trained to perform this function.

As required by Reference (2), the person designated to sign for an action verifies, based on personnel observation or Objective Quality Evidence, and certifies by his/her signature that the action has been performed in accordance with the specified requirements. Any work performed by the Task Group Instruction (TGI) involving an I/V which is subsequently voided by additional work or requires performing an I/V attribute that already has been signed off will require that affected I/V attribute to be reinvoked.

NOTES:

1) This document here by serves as a briefing to allow contractors to complete <V> attributes as follows in this document.

2) Attributes have been modified to be worded for Contractor mechanics or Contractor supervisor to be able to complete.

3) Additional guidance for Level II Cleanliness is provided in Reference (5). Contractor can reach out to Contracting Official Representative (COR) or Project Engineer (PE) for further guidance and clarification on technical requirements for Level II Cleanliness.

Procedure & Signatures:

1) Prior to certification of work, contractor shall complete the following signatures for <V> Attribute 551-001 as implemented by References (1 – 5).

1.1) Instructions for completing signatures (NOTE: Print in “Name” block):

1.1.1) If entry into the air system, as previously defined, was not performed, then contractor technician shall mark “No” and complete “Level II Cleanliness Maintained” marked as “N/A”.

Contractor shall then complete “Name”, “Signature”, and “Date”.

1.1.2) If entry into the air system, as previously defined, was performed, then the contractor technician shall mark “Yes” and complete “Level II Cleanliness Maintained” marked as “Yes” (upon verifying that system meets Level II requirements, as previously defined, upon closure of the syste,).

Contractor shall then complete “Name”, “Signature”, and “Date”.

2.) After completion of signatures, submit either original or copy of signed sheet (in forms of electronic media as specified in the PWS) to the COR.

See following sheets for signatures to complete.

High Pressure Air Compressor No. 3:

System Entry – Yes: No:

<V> Attribute 551-001: Accomplish signoff for cleanliness per PSNS&IMFINST 4730.62. Acceptance criteria: After completion of work FME & Level II Cleanliness was maintained on High Pressure Air Compressor No. 3 was maintained per UIPI 0505-908.

Comment:

Level II Cleanliness Maintained – Yes: N/A: ____

Name:

Signature:

Date:

Attachment B

MATERIAL HISTORY DATA SHEET

MH Document #

Ship’s Name:

Hull:

Plant:

Ship's System:

Common Name of Equipment:

Accomplished by:

Location and Compartment:

FOR SHIPYARD USE ONLY: Applicable ICN and KeyOp(s):

Electrical Electronic Hull Machinery

MATERIAL HISTORY DATA SHEET SUMMARY:

Modifications/Alterations (Areas to Consider)

ShipAlt, Field Change, or A&I Number and Revision:

Brief Description of Work Accomplished

Preventative Maintenance (Areas to Consider)

Maintenance Requirement:

Brief Description of Maintenance :

Problems Identified and Resulting Corrective Maintenance :

Corrective Maintenance (Areas to Consider) Replacement Part Information Detailed Description of Problem and Symptoms Details of Actions Taken Including Testing Performed

Supporting Documentation (Areas to Consider)

Description of Enclosures:

Highlight Applicable Information

MATERIAL HISTORY DESCRIPTION OF EVENT:

Date Remarks

ORIGINATOR/POINT OF CONTACT:

NAME (Print) Code Phone Number Date

REVIEWER:

NAME (Print) Code Phone Number Date

Sheet 1 of

MATERIAL HISTORY CONTINUATION DATA SHEET

MH Document #

Ship’s Name:

Hull:

Plant: Ship's System:

Common Name of Equipment: Location and Compartment:

MATERIAL HISTORY DESCRIPTION OF EVENT (Continued):

Date Remarks

Sheet of