HIFR Specification R-542-0604 REV A.doc

REVISION No. A

DATE: 5/18/2011

USCG

Helicopter in-flight refueling hose (HIFR)

Refurbishment R-542-0604

ORGINATED BY: ARNOLD ABBAS CTR.

ORIGINATOR’S COMMAND: SURFACE FORCES LOGISTIC CENTER.

DEPARTMENT / DIVISION: MEC-PL SUPPLY BRANCH.

INTERNAL REVIEWER Stephen Twomey DATE 01 August 2021

1. SCOPE

1.1. This specification describes the requirement for receipt, inspection, condition/test reports, refurbishment, testing, preservation, packing and packaging of the helicopter in-flight refueling (HIFR) hose assembly.

1.2. Government Furnished Property (GFP) - The HIFR hose assembly is managed by the Coast Guard, Surface Forces Logistic Center at Curtis Bay Md.

a. National stock number: 4720-01-488-9498.

Item Name: Hose assembly, nonmetallic.

Part Number: AE708312-1

Manufacture: Eaton Aeroquip LLC, 300 S. East Avenue, Jackson, MI 49203.

Application: 210WMEC, 270 WMEC, 418 WMSL, and 420 WAGB vessels.

1.3. Government Furnished Material (GFM).

1.3.1. Unisex coupling half with ball valve, Aeroquip part number AE82246R, NSN 4730-01-178-2991

1.3.2. Unisex coupling half, Aeroquip part number AE88763R, NSN 4730-01-548-3351

1.3.3. Quick Coupling Half (Emergency Breakaway), Aeroquip part number AE88764R, NSN 4730-01-628-5173

2. APPLICABLE DOCUMENTS

2.1. Document Availability – To obtain the referenced documents see section 6.1

2.2. Government Documents – The following specification and standards form a part of this specification to the extent specified herein. Unless otherwise specified, the documents listed here by number and date shall be those in the current Department of Defense Index of Specifications and Standards (DODISS) and supplements therein.

2.2.1. U.S. Coast Guard drawing :

a. FL 9150-002, revision B, Helicopter in-flight and on-deck refueling equipment. Shown as item 1 of the material list.

2.3. Other Government Documents – The following documents form a part of this specification to the extent specified herein. The documents listed shall be by title and effective date, unless otherwise documented.

a. USCG Surface Forces Logistic Center. D-000-0100, Rev G, change 1, dated 3/6/2006, Bar Coding for USCG SFLC Material.

b. USCG, Government furnished property discrepancy report.

c. Federal Standard 595C, Dated 7/31/2008, Colors used in government procurement.

d. Naval Sea Systems Command, MIL-PRF-24635E, Coating system weather resistant.

2.4. Commercial Documents:

a. American National Standards Institute, ANSI/NCSL Z540-3 dated 2006, Requirement for the calibration of measuring and test equipment.

b. American Society for Testing & Materials, ASTM D3951 dated1998, Standard practice for commercial packaging.

c. National Fire Protection Agency, NFPA 407 dated 2007, Standard for aircraft fuel servicing.

d. American Petroleum Institute, API- 1529 dated 2005, Aviation fueling hose and hose assemblies.

2.5. Specification Order of Precedence – On the event of a conflict between the text of this specification and the references cited herein, this specification shall take precedence.

3. REQUIREMENTS.

3.1. General - The requirements described herein are the minimum necessary used to supplement the original equipment manufacturers refurbishment standards and requirements. These requirements are not intended to replace any procedures, controls, examinations, or tests normally employed by the contractor to insure quality of the product.

3.2. Government Furnished Material– The unisex coupling half, reference 1.3.1, shall be maintained in good condition and stowed properly when not in use. Should the condition of the coupling ever become questionable for use at any time during the contract; the contractor shall notify the contract administrator.

3.3. Receiving inspection and report- Upon receipt of the HIFR hose assembly, the shipping container and hose assembly shall be visually inspected for damage and receipt of the correct and complete hose assembly identified in reference 2.2.1a. The shipping container shall be in good reusable condition and meet the requirements of section 5. Any discrepancies noted shall be documented and reported immediately to the contract administrator on a government furnished property discrepancy report. A Receiving Inspection Report is due to the government with five (5) working days of receipt of a HIFR hose assembly for repair.

3.4. Inspection, Disassembly and Repair Estimate- Prior to complete disassembly, the integrity of each component of the HIFR hose assembly shall be visually inspected and physically operated to assure proper operation as originally intended. A Condition Found Report with Repair Proposal shall be due to the government within fifteen (15) working days of receipt of a HIFR hose assembly for repair.

3.5. Hydrostatic test (initial)

a. After removal of the hose from the support bracket, the hose assembly shall be subjected to a hydrostatic test using clean fresh water at 1.5 times the hose working pressure for one minute. In the case where a hose assembly was not received with a unisex coupling half the GFM coupling shall be utilized. The test shall be documented and a condition found report submitted which documents all findings. Any leaks discovered during the test are deemed unacceptable.

b. Any hose assembly that is received with noticeable damage to the fittings and/or hose material which would make testing questionable, shall be waived from this initial test.

c. For hose assemblies where only the hose material is damaged, the fitting shall be retained for possible re-use. The fittings shall be subjected to a final pressure test after the hose assembly refurbishment, see section 3.8.4.

3.6. Disassembly- The hose assembly shall be completely disassembled and the existing materials identified in section 3.7 shall be discarded. Clean and visually inspect each of the remaining components of the assembly for any damage that would deem the component unsuitable for refurbishment of the HIFR hose assembly. The contractor shall submit a detailed condition found report (CFR) with fourteen (14) working days of receipt to the contract administrator which identifies all findings and determinations as a result of the inspections and initial hydrostatic test. The CFR shall also include the estimated cost of all labor and material which covers complete refurbishment of the hose assembly including test, paint, preservation, packaging, bar code, hose and container marking, container repair and/or replacement (where required). A material list of components that are deemed necessary to be renewed shall accompany the CFR. The material list shall include the component name, quantity, and unit cost of the individual components. After submittal of the CFR, no further work shall be performed until the report is reviewed and a determination as made by the Contracting Officer.

3.7. Refurbishment- Upon authorization from the Contracting Officer to proceed, the following components shall be renewed regardless of condition. All other components shall be cleaned and reconditioned for re-assembly of the HIFR hose assembly.

a. Hose material, to include bands/clamps and protective sleeves.

b. Hoist shackle and bolt (1 each).

c. Miscellaneous fasteners i.e. nuts, bolts, washers.

d. Breakaway cable.

e. All seals.

f. If the Half Clamps have damaged threads or broken fasteners they can be repaired by drilling out the fastener and tapping the holes or if oversized, installing Heli-coil in the hole to the correct fastener size.

3.7.1 The cast metal hose bracket, breakaway cable split clamp, actuator arm and handle shall be cleaned in such a manner that will remove any corrosion without damage. Each component shall be visually inspected for damage to include cracks and worn areas in and around the gussets of the hose bracket. Regardless of the condition of the anodized coating, the surfaces shall be prepared and painted in accordance with the paint manufactures recommendation. Apply 2.5 Mil minimum DFT (Dry Film Thickness) of silicone alkyd enamel paint qualified to MIL-PRF-24635E, type 2 or 3, class 1, grade A. The paint shall be color gloss purple to FED-STD-595 code 17142.

3.8. HIFR hose re-assembly:

3.8.1. Each re-assembly process step shall be documented and verified by the contractor’s quality control officer through the use of a traveler that should accompany each hose assembly though out the refurbishment process.

3.8.2. The replacement hose material shall be certified and equal to or exceed the hose material that is being renewed. The hose material and fittings shall meet the requirements API standard 1529 and be of an electrically bonded type.

3.8.2.1 The hose material shall have a cure date that does not exceed 3 years (12 quarters) from the date of manufacture. A copy of the hose material certification shall be provided and packaged with each HIFR hose assembly.

3.8.3. The HIFR hose assembly shall be reassembled with new and/or retained components to the configuration as shown in reference 2.2.1a. Reassembly of the hose assembly shall be performed in such a manner that will not interfere with required test.

3.8.4. Each HIFR hose assembly shall be subjected to the following test in accordance with section 7.2.1, 7.2.2 and 7.3 of API standard 1529 to include:

a.

Visual inspection.

b.

Proof pressure test.

c.

Electrical conductive test.

d.

Identification.

3.8.4.1 During this test, either the exiting unisex half coupling (originally installed) or a new coupling shall be used. The GFM unisex half coupling shall not be used for this test. The test shall be performed and documented in the presence of a Coast Guard, Quality Assurance Representative (QAR).

3.8.4.2 The hose assembly shall be thoroughly drained and blown out with compressed air. The hose assembly shall remain to air dry for a minimum of 24 hours and be visually inspected for contaminates just prior to packaging.

3.8.5. Upon completion of the HIFR hose re-assembly, the assembly shall be visually inspected for workmanship, see section 3.9, and all components shall be physically tested for proper operation.

3.8.6. The break away release cable swage sleeves shall be inspected and witnessed by a Coast Guard QAR by use of a gauge manufactured by the original manufacture of the swage tool to assure proper compression.

3.8.7. Identification markings- each hose coupling shall be marked in accordance with section 7.3.3 of API 1529.

3.8.8. Hose assembly certification- Each hose assembly that is successfully tested shall be individually certified and documented in accordance with section 8.2 of API 1529.

3.8.9. Hose tag- The hose shall be tagged to include information as to the lot number, cure date, serial number and date of hydrostatic test and include the contract number and an identifier that will only be unique to an individual HIFR assembly. The tag shall be made of a material which is impervious to a marine environment.

3.9. Workmanship.

a. The HIFR assembly hose and fittings shall be free of all sharp edges.

b. Ends of the hose and emergency release wire shall not be exposed.

c. The hose shall be free of all lubricants/water or contaminates.

d. All hose to fitting connections shall have a neat and uniform appearance.

e. The release cable shall be capable of smooth and free operation with no binding during operation.

f. The swivels and shutoff valve shall rotate smoothly without binding.

g. The breakaway shall be activated to assure proper actuation and release.

h. All painted surfaces shall be free of runs, drips, and over spray on other surfaces.

i. The hose assembly tag shall be clear and legible to read.

3.10. Measure and Test equipment– All measuring and test equipment shall be certified to be in current calibration within the past year and traceable to the National Institute of Standards and Technology (NIST) standards. See section 4.3.

4. 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 ANSI/NCSL Z540-3 or a comparable program. 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 rights 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 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. Inspection 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. The inspection system shall be documented and available for review by the Coast Guard.

4.6.1. Specifications currently in use.

a. ANSI/ASQC Q9001-1994 – Quality Systems – Model for Quality Assurance in Design, Development, Production, Installation, and Servicing.

b. ANSI/ASQC Q9002-1994 – Quality Systems – Model for Quality Assurance in Production, Installation, and Servicing.

c. ANSI/ASQC Q9003-1994 – Quality Systems – Model for Quality Assurance in Final Inspection and Test.

4.7. Notifications & Inspections – The contractor shall be responsible for providing a Final Inspection Report to the Contracting administrator within fourteen (14) working days of authorization to proceed with repairs. The contractor is also responsible for notifying the Contracting administrator at least seven (7) working days prior to said contractor being ready for any government inspections.

4.8. Tests & Inspections – The following are a list of test and inspections that shall either be performed or verified in the presence of a Coast Guard QAR. The inspections and tests required below and in the appropriate subsection in section 3 and 5 are not intended to supplant any controls, examination, inspections or tests normally employed by the contractor to assure the quality of the item.

4.8.1. Verification of records/ component:

a. Receiving and inspection report, see section 3.3.

b. Initial hydrostatic test certification, see section 3.5.

c. Condition found report, see section 3.6.

d. Hose assembly traveler report, see section 3.8.1.

e. Hose material certification, see section 3.8.2.

4.8.2. Witness of test:

a. Final hydrostatic test, see section 3.8.4.

b. Conductivity test, see section 3.8.4.

c. Compression sleeve gauging, see section 3.8.6.

d. Workmanship, see section 3.9.

e. Hose and container marking, and final packaging, see section 3.8.9 and 5.

4.9. Failure Responsibility – If the hose assembly fails to pass any inspection/test the contractor shall report the failure and the recommended fix to the contract administrator. If approved, the corrective action on the materials or processes shall be taken in accordance with this section.

4.9.1. General Statements

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

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

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

d. 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.

e. All corrective actions shall be documented as part of the contractor’s inspection system and submitted for approval to the Contracting Officer.

f. 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.

4.10. Non-usable Parts – All non reusable parts shall be disposed of locally.

4.11. Test & Inspection Reports- A copy of any test, inspection, or tolerance report shall be turned over to the Quality Assurance Representative upon arrival at the contractor’s plant.

4.12. Packing Inspection – The contractor shall have the packaging and container marking complete and available for verification at the time of the Coast Guard QAR visit to avoid additional visits.

5. PRESERVATION, PACKING, & MARKING

5.1. Preservation– Each hose assembly shall be capped on both ends to prevent intrusion of contaminates.

5.2. Packaging - Each hose assembly shall be individually containerized in a fully enclosed wooden container per ASTM D3951-98. The unit container shall be appropriately sized to the hose assemble when coiled which not allow excessive movement within the container.

5.3. Marking – Each preserved and packaged item shall be marked in the upper left-hand side of the two longest sides (two opposite sides if square) of each container. The lettering shall be at least 1/2” high, in black print lettering on a highly contrasting white enamel paint background.

5.3.1. Marking shall consist of only the data shown below within the brackets.

STOCK NUMBER

(4720-01-488-9498)

ITEM NAME

(Hose assembly, nonmetallic)

PART NUMBER

(AE708312-1)

CONTRACT NUMBER

(SEE CONTRACT)

DELIVERY ORDER

(AS DETERMINED BY CONTRACT)

SHIPPING WEIGHT

(AS DETERMINED BY CONTRACTOR)

CONDITION CODE

(CONDITION A)

QUANTITY & UNIT OF ISSUE

(1 EACH)

(COAST GUARD SFLC MATERIAL)

5.4. Bar Coding – Contractor shall supply bar code as follows:

a. Bar coded labels shall be in accordance with reference 2.3.a.

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

c. Each label shall contain encoded data for the Stock Number, Contract Number, and the Delivery Order Number as applicable.

d. The marking required in 5.3 can be applied separately or as part of the Bar Code Label.

e. The bar code label shall be applied to the shipping container directly under the markings.

6. NOTES

6.1. Government & Commercial Document Sources

6.1.1. Government Documents

a. Specification and Standards (DODISS Documents)

Standardizations Document Order Desk

700 Robbins Avenue

Building #4, Section D

Philadelphia, PA. 19111-5094

215-697-1187

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

Naval Publication and Forms Center

5801 Tabor Ave.

Philadelphia, PA. 19120

215-697-2000

c. USCG Surface Forces Logistics Center 2401 Hawkins Point Road

Baltimore, MD.. 21226-5000

410-762-XXXX (K.A.)

ATTN: Contracting Branch

6.1.2. Commercial Documents

a. American Society for Testing & Materials (ASTM)

1916 Race Street

Philadelphia PA. 19103-1187

215-299-5585

FAX 215-977-9679

b. American National Standards Institute (ANSI)

1430 Broadway

New York, NY 10018

212-642-4900

c. American Society for Quality Control (ASQC)

611 East Wisconsin Avenue

Milwaukee Wisconsin 53202

d. National Fire Protection Agency (NFPA)

1 Batterymarch Park

Quincy, Mass. 02169

e. American Petroleum Institute (API)

1220 L Street N.W.

Washington DC, 20005