Attachment 3_GG Spec R-234-0168 REV H.pdf

REVISION No: H CHANGE No:

OVERHAUL SPECIFICATION

FOR

PRATT & WHITNEY MODEL FT4A

GAS GENERATOR AND GAS GENERATOR MODULES

USED ON 378’ WHEC/400’ WAGB

U.S. COAST GUARD VESSELS

R-234-0168

ORGINATED BY: D. BANNON DATE: 06/94 UPDATED: 05/00

REVISION BY: D. L. HEISEY (Rev H) DATE: 02/2011

ORIGINATOR’S COMMAND: Engineering Logistics Center (ELC)

DEPARTMENT / DIVISION: Main Propulsion Machinery Branch (ELC-026)

SOWRB APPROVAL: DATE

USCG - SFLC

REVISION H 02/2011

OVERHAUL SPECIFICATION FOR PRATT AND WHITNEY

FT4A GAS GENERATOR UNIT

1.0 Scope:

1.1. This document sets forth the requirements for the receipt, disassembly, inspection, condition/test reports, overhaul/repair, re-assembly, testing, preservation, packing, packaging and marking of Coast Guard configured Gas Generators and Gas Generator Modules.

1.2. Government Furnished Property (GFP) Pratt-Whitney Gas Generators and Modules:

a. FT4A-2 Gas Generator 2835-01-273-7715

b. FT4A-12 Gas Generator 2835-01-227-1709

c. Low Compressor, Module “A” 2835-01-F92-0225

d. High Compressor, Module “B” 2835-01-F92-0226

e. High Turbine, Module “C” 2835-01-F92-0227

f. Low Turbine, Module “D” 2835-01-F92-0228

g. N-2 Gear Box, Module “E” 2835-01-215-0465

h. Exhaust Case, Module “F” 2835-01-F92-0229

i. Shipping Container 8145-01-F76-1532

1.3. Government Furnished Material (GFM): The Coast Guard reserves the right to provide, at its option, assemblies; sub-assemblies; equipment or parts as GFM for use at any time during the contract period.

2.0 Applicable Documents:

2.1.General: The documents listed in this section are specified in sections 3, 4, or 5 of this specification. This section does not include documents cited in other sections of this specification or recommended for additional information or as examples. While every effort has been made to insure the completeness of this list, document users are cautioned that they must meet all specified requirements of the documents cited in sections 3, 4, or 5 of this specification, whether or not they are listed here.

2.2.Government Documents: The following specifications and standards form a part of this specification to the extent specified herein. Unless otherwise specified, the documents listed here by number and date shall be those in the Department of Defense Single Stock Point of Specifications and Standards (DODSSP) and supplements thereto.

a. United States Coast Guard USCG-SFLC Specification D-000-0100 Rev G Dated

06/2006, Bar Coding for USCG Surface Forces Logistics Center Material.

b. MIL-PRF-131 Revision K dated 08/2005, Barrier Materials, Water-vapor-proof, Greaseproof, Flexible, Heat Sealable.

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

REVISION H 02/2011

d. MIL-I-8835 Revision A dated 11/20/1984 Indicator, Humidity, Card Chemically Impregnated. Part Number, MS20003-2, 3-spot, 30 to 50 percent relative humidity, 2 inch by 3 inch, reversible.

2.2.1. Document Availability: For the methods and conditions for obtaining copies of these reference documents, see section 6.0.

2.3 . Commercial Documents: The following documents form a part of this specification to the extent specified herein. Unless otherwise specified, the issues of these documents are those cited in the solicitation or contract.

2.3.1 Pratt & Whitney/Turbo Power and Marine Systems Inc:

a. FT4 Industrial Gas Generator Overhaul Manual, P/N 544026 as applicable for FT4A Marine Gas Generators dated 15 October 1991.

b. Standard Practices Manual, P/N 52A138, (most current revision).

c. Pratt & Whitney Power Systems Marine Gas Turbine Engine Illustrated Parts Catalog, P/N 547055A dated 01 July 1993, revised 15 September 2001.

d. FT4A-2 Gas Generator Test Plan T234-0248.

e. FT4A-12 Gas Generator Test Plan T234-0247.

f. Pratt Whitney & Joint Venture Service Bulletins and Special Shop Instructions (SSI):

REVISION H 02/2011

1. 200 25. 71B01 Sup 3 49. 74B34

2. 222 26. 71B06 Rev A Sup 3 50. 74B37

3. 230 Sup 2 27. 71B09 Rev A Sup 1 51. 75B11

4. 259 28. 71B23 Rev B 52. 77M10B (-12 only)

5. 275 29. 71B26 Sup 3 53. 78M06B (-12 Only)

6. 293 30. 71B30 54. 79B02

7. 313 31. 72B08 Rev B 55. 80B09 Sup 1

8. 336 32. 72B11 Sup 2 56. 80B14

9. 346 Rev B 33. 72B16 Sup 4 57. 80B15

10. 428 Sup 2 34. 72B17 Rev A Sup 1 58. 83B11 Rev A

11. 445 35. 72B19 Rev B 59. 84B02

12. 447 36. 72B24 Rev A Sup 1 60. 84M04B

13. 452 37. 72B27 Sup 1 61. 85B03

14. 466 Rev B 38. 72B28 62. 85B06

15. 475 Rev A Sup 1 39. 72B32 63. 85B09

16. 486 40. 73B15 Rev B (-12 only) 64. 93B08

17. 498 Rev C 41. 73B34 Rev A Sup 3 65. 97B03

18. 502 Rev B 42. 74B07 Rev A Sup 1 66. 98B17

19. 552 43. 74B11 Rev A Sup 1 67. 01B05

20. 555 Rev A 44. 74B14 Rev B Sup 1 68. 01B20

21. 557 45. 74B21 69. 02B03

22. 583 Rev A 46. 74B24 Rev A 70. SSI 73L04

23. 585 Sup 2 47. 74B26 Rev B Sup 2 71. SSI 74L05

24. 588 Rev A 48. 74B33 Rev A 72. SSI 2004 L08A

73. SSI 2005L01

2.3.2 American National Standards Institute (ANSI), National Conference of Standards

Laboratories (NCSL), American Society for Testing & Materials (ASTM), and American Society for Quality (ASQ).

a. NCSL Z540-3-2006, Dated 2006, Requirements for the Calibration of Measuring and

Test Equipment.

b. ASQ Q9001-2008, Dated 2008, Quality Management Systems – Requirements.

c. ASTM D3951-98, Dated 2004, Standard Practice for Commercial Packaging.

2.3.3. Document Availability: For the methods and conditions for obtaining copies of these reference documents, see section 6.0.

2.4 Specification Order of Precedence: In the event of a conflict between the text of this specification and the references cited herein, the text of this specification takes precedence.

Nothing in this specification, however, supersedes applicable laws and regulations unless a specific exemption has been obtained.

3.0 Requirements:

3.1.General: Inspections, repair/overhaul and testing for each Gas Generator or Module shall be accomplished in accordance with Wood Group Pratt Whitney procedures, the Original Equipment Manufacturer (OEM), for FT4 Marine/Industrial Gas Generator Overhaul Manual Part Number 544026 and all OEM standard practices.

REVISION H 02/2011

3.1.1. Service Bulletins and Special Shop Instructions listed in section 2.3.1.f of this specification that have not been accomplished shall be listed in the condition reports as per 3.2.2 and 3.2.3. Upon the Contracting Officer’s approval, the service bulletins and Special Shop Instructions shall be completed during repair/overhaul.

3.1.2 Upon completion of repairs and testing, each Gas Generator or Module shall be in a ready to operate configuration, preserved and packaged in accordance with section 5.0 of this specification.

3.1.3 Authority to Proceed: The contractor shall not begin any repair or component replacement until authorized in writing by the Contracting Officer. This authorization will provide specific guidance on what type and level of work to be accomplished to include:

a. Repair, reassembly and testing the Gas Generator or Module as a ready to operate overhauled unit.

b. Disposal of any Gas Generator or Module deemed non-repairable as determined by the

Contracting Officer’s Technical Representative.

c. Inspections to the Major Shop Inspection (MSI) level, repair, reassembly and testing of the Gas Generator or Module as a ready to operate unit.

3.1.4 The Gas Generator will be shipped to the contractor’s overhaul facility in a Gas Generator shipping container PN: P-14641J-57. Each Module will be shipped in a reusable wooden box or metal container.

3.1.5 The contractor shall provide inside storage for each Gas Generator or Module immediately following receipt.

3.1.6. The contractor shall assess and provide a separate line item cost for the repair to or replacement of any damaged shipping container.

3.1.7. Certificate of Conformance: Prior to Coast Guard acceptance of the completed Gas Generator or Module, a Corporate Officer of the contractor, authorized to legally bind the corporation, shall provide a Certificate of Conformance indicating that they have repaired/overhauled, re-assembled and tested (if applicable) the Gas Generator or Module in accordance with Wood Group Pratt & Whitney specifications, standards and recommended procedures. Two copies of the certification shall be provided for each unit:

one copy packed with the Gas Generator logbook or Module and one copy forwarded to the Contracting Officer.

3.1.8. The contractor shall be responsible for notifying the Contracting Officer a minimum of ten (10) calendar days prior to the contractor being ready for any inspections and/or tests.

3.2. Reports: The contractor shall submit the following reports, in writing, to the Contracting Officer for each delivery order issued. Each report shall be organized and identified by Gas Generator or Module serial number, delivery order number and contract number. Sub-assemblies and part numbers shall also be listed where applicable.

REVISION H 02/2011

3.2.1. Initial Receiving Report: Required seven (7) calendar days after receipt of any GFP or GFM. This report shall outline the general condition of the property or material and include:

a. A validation of part number, serial number, any damage noted, and a listing of any item(s) found missing, including accessories listed in section 3.5.1 of this specification. Additionally, the contractor shall account for all external brackets, supports, spacers, fasteners, pre-formed oil/air piping/tubing, and other hang-ons using a Coast Guard approved configuration checklist. All missing items, including quantity, shall be noted.

b. Information regarding the condition of the shipping container with recommended repairs.

c. Photo documentation in accordance with section 3.3 of this specification.

d. Data File in accordance with section 3.4 of this specification.

3.2.2. Disassembly Condition, Dirty Inspection Report: Required 28 calendar days after the receipt of the GFP. This report shall also include the following information:

a. Gas Generator or Module configuration

b. Service Bulletins or Special Shop Instructions required

c. Inspection results

d. Repairs required

e. Parts required

f. Shipping container repairs

g. Any additional inspections or disassembly required beyond sub-assembly level down to and including a complete MSI

h. Requirements to un-stack the rotors or de-blade the disks

i. Detailed listing of work levels, hours and cost

j. Detailed listing of scrap parts

k. Requirements of 3.3 Photo Documentation and 3.4 Data File.

l. The Coast Guard will review this report upon receipt to validate proposed repairs/replacement parts, reasonableness of costs, and need for additional inspections beyond the sub-assembly level. The Contracting Officer will provide the contractor with written authorization to proceed with those repair items on the Disassembly Condition, Dirty Inspection Report that are approved.

3.2.3. Disassembly Condition, Clean Inspection Report: Required 45 calendar days after approval of the Disassembly Condition, Dirty Inspection Report. This report shall include all Contracting Officer approved repair items from the Disassembly Condition, Dirty Inspection Report and indicate any additional work that is required as a result of approved inspections beyond the sub-assembly level. The report shall also reflect a final cost for all work items needed to complete the repair/overhaul of the Gas Generator or Module, and include the following information:

a. Gas Generator or Module configuration

REVISION H 02/2011

b. Service Bulletins required and Service Bulletins recommended

c. Results of inspection after disassembly of the Gas Generator or Module and accessories detailing measurement of critical dimensions and applicable overhaul tolerances

d. Repairs required

e. Parts required

f. A complete cost breakdown for all parts and labor listed in the contract including contingency items that will be required for the repair/overhaul of the Gas Generator or Module including the shipping container

g. Results of additional inspections or disassembly beyond the sub-assembly level down to and including a complete MSI

h. Detailed listing of parts to be scrapped

i. Requirements of 3.3 Photo Documentation and 3.4 Data File

j. The Coast Guard will review this report upon receipt to validate proposed additional repairs/replacement parts and reasonableness of associated costs. The Contracting Officer will provide the Contractor with written authorization to proceed with those additional repairs on the Disassembly Condition, Clean Inspection Report that are approved.

3.2.4. Re-assembly Report: Required fourteen (14) calendar days after completion of the final acceptance test. This report shall include all required inspections, fits and clearances as per the overhaul manual for final assembly.

3.2.5. Test Report: Required fourteen (14) calendar days after completion of the final acceptance test. This report shall include all readings, parameters, performance graphs/plots, vibration data and tolerances from the test data sheets.

3.2.6. OEM Summary Report: The OEM Representative shall submit a written narrative

Summary Report to the Contracting Officer fourteen (14) calendar days after completion of the final acceptance test. The OEM Summary Report shall cover all items listed in section 3.13.3. During each OEM visit to the contractor’s facility, the OEM Representative shall brief the Contracting Officer’s Technical Representative (COTR), either verbally or via e-mail, concerning the progress of repairs/overhaul on each delivery order and the status of any pending issues.

3.2.7. GFP and GFM Report: Required whenever GFP/GFM is considered unusable or unacceptable for any reason, within seven (7) calendar days after receipt of the discrepant GFP/GFM. This report shall provide a detailed explanation as to why the GFP/GFM must be rejected along with recommendations for USCG retention or disposal.

3.2.8. Warranty Report: Required within seven (7) calendar days after the completion of any warranty issue. This report shall contain the following information:

a. Contract Number

b. Delivery Order Number

c. Serial Number of the unit

d. Operating hours on unit

e. Conditions found

f. Results of all inspections

g. All required measurements/readings

h. Repairs required

REVISION H 02/2011

i. Repairs performed

j. Parts required

k. Parts expended

l. Name of technical representative

m. Time of arrival and departure

3.3. Photo Documentation: The Contractor shall provide Photo Documentation to the

Contracting Officer as part of the Initial Receiving Report, the Disassembly Condition, Dirty Report, the Disassembly Condition, Clean Report, during acceptance testing, and prior to shipment as follows:

a. During initial opening of the Gas Generator or Module after receipt, including serial numbers and data tags.

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

c. When other significant or unusual findings such as failed part(s) or damage are discovered.

d. When the Gas Generator is tested to document configuration.

e. When the Gas Generator or Module is prepared for shipment to document “as shipped” configuration including images of the packing, packaging and marking.

3.3.1. Photo documentation shall consist of photos taken with a digital camera with the images provided on the CD.

3.4.Data File: In addition to a printed version of all reports, the contractor shall provide a compatible data file in Microsoft Excel format.

3.4.1. Database program - the data elements, field selections, organization and storage of medium will be at the mutual agreement of the Coast Guard and the Contractor.

3.4.2. The contractor shall provide a sample version of the data file to the Contracting Officer for approval within sixty (60) calendar days after contract award.

3.5.Initial Receipt of Unit: The Contractor shall notify the Contracting Officer upon receipt of the Gas Generator or Module. The Coast Guard reserves the right to have a representative present when each unit is removed from its respective shipping container. The contractor shall complete the requirements of an initial receiving report as per section 3.2.1 of this specification.

3.5.1. The Gas Generator shall have the following assemblies and accessories attached:

a. Nose Cone

b. Inlet case

c. Anti-Icing Valve

d. Ignition Exciters (two each)

e. Ignition Exciter leads (two each)

f. Oil Tank (FT4A-2 only)

g. N2 Gear Box

h. Fuel Pump Assembly

REVISION H 02/2011

i. Oil pump Assembly

j. Igniter Plugs (two each)

k. P&D Valve Assembly

l. Fuel Control Plumbing (FT4A-2 only)

m. LQ25 Fuel Modulating Valve (FT4A-2 only)

n. Altair Valves (two each)

o. 3-way solenoid valve & associated tubing (FT4A-2 only)

p. Magnetic Pick-up Assembly

q. Tt7 Thermocouples

r. Log Book

3.5.2. Missing Parts: If the Contractor determines any of the items in section 3.5.1 or the Coast

Guard Configuration Checklist are missing during the initial inspection, the Contracting Officer may require the contractor to supply the missing item(s) or the Coast Guard may provide the item(s) as (GFM).

3.5.3. Missing item(s) identified on the CG Configuration Checklist shall be included in the condition reports.

3.6.Disassembly/Inspection for Dirty Condition Inspection Report: The Gas Generator or Module shall be disassembled and inspected to the sub-assembly level in order to develop a first condition dirty inspection report as per section 3.2.2.

3.6.1. If additional disassembly and inspection is required past the Major Shop Inspection

(MSI) level to determine the condition of a Gas Generator or Module, the contractor shall obtain authorization from the Contracting Officer before proceeding further. See section 3.1.3.

3.7. Disassembly/Inspection for Clean Condition Report: The contractor shall disassemble the complete Gas Generator or Module unit and inspect all components as per the OEM manuals, including all Non-Destructive Testing (NDT), to develop a final condition report as per section 3.2.3.

3.8. Repairs: All repairs shall be performed in accordance with the OEM overhaul manual or the standard practices manual when referenced. All other repairs shall be noted in the condition reports.

3.9. Parts: The contractor shall use only new or refurbished parts approved by the OEM, Wood

Group Pratt & Whitney Power Systems, applicable to marine applications. The contractor shall provide documentation that certifies all parts used on each Gas Generator or Module meets OEM requirements.

3.9.1. Expendable/Consumable Parts: The contractor shall provide and install all new fasteners, gaskets, seals and sealant as specified in the FT4 Marine/Industrial Manual, the Overhaul Standard Practices Manual and this specification during reassembly.

a. The contractor shall provide a list, in writing to the Contracting Officer, of all expendable/consumable parts used during the repair/overhaul of each Gas Generator or Module with the Disassembly Condition, Clean Inspection Report.

REVISION H 02/2011

3.9.2. Precedence of Parts Usage: After receipt and review of the Disassembly Condition, Dirty Inspection Report, the Coast Guard reserves the right to satisfy parts requirements, unless otherwise specified as “new only”, in the following priority:

a. Refurbish, recondition, or repair damaged or worn part(s) and reuse. Exchange of parts is not authorized without written approval of the Contracting Officer.

b. Use Coast Guard furnished parts. The use of GFM shall not relieve the Contractor from any responsibilities as required in the Contractor’s warranty.

c. Use contractor furnished parts.

3.9.3. Scrap and Discarded Parts: Parts and/or assemblies deemed scrap by the Contractor shall be secured in a designated storage area and individually tagged. Each tag shall include the part number, Gas Generator or Module serial number, applicable contract/delivery order number, reason for rejection, inspector and date. Expendable/ consumable parts for each delivery order shall be kept together in a suitable container.

a. A Coast Guard inspector will inspect and verify all items designated as scrap.

b. The Contractor shall return all scrap parts/assemblies to the Coast Guard unless local disposal is authorized by the Contracting Officer.

3.10. Reassembly: The Gas Generator or Module shall be reassembled in accordance with this specification and all cited documents in section 2.3. In addition to the coatings called for in the reference documents, all exterior surfaces of the Gas Generator or Module, with exception of titanium components, shall be coated with PWA 110-31 (.001 - .003 inches thick).

3.11. Overhaul: The Gas Generator or Module shall be overhauled and tested within 70 calendar days after approval of the Disassembly Condition, Clean Inspection Report in accordance with this specification and all cited documents in section 2.3.

3.11.1. Any Gas Generator or Module deemed un-repairable shall be reassembled in accordance with the OEM manual, less gaskets and seals. All surfaces shall be coated with a light coat of preservation oil.

3.11.2. LQ25 Liquid Fuel Valve: The contractor shall make arrangements with Woodward

Governor Co. to receive, inspect, overhaul, test and return this valve within the allotted Gas Generator overhaul period.

3.11.3. Woodward Magnetic Pick-up Assembly: The Contractor shall clean, inspect and overhaul, including replacing the bearings, test and return this assembly within the allotted Gas Generator overhaul period.

3.12. Performance Testing: The Gas Generator shall be tested in a ready to operate condition to

Coast Guard configuration requirements with all accessories. The test shall be conducted in accordance with the test specification referenced in section 2.3.1.d. for the FT4A-2 Gas Generator and 2.3.1.e. for the FT4A-12 Gas Generator. This is a performance and final acceptance test run. Any work that requires repair, adjustment, modification, disassembly or replacement of internal parts of the Gas Generator after conclusion of the test constitutes a re-test before Coast Guard acceptance. The test shall be conducted in the presence of a Coast Guard Representative and the OEM Representative.

REVISION H 02/2011

3.12.1. The contractor shall notify the Contracting Officer a minimum of ten (10) calendar days prior to any testing of a Gas Generator. Prior to the final acceptance test, the contractor may conduct a pre-acceptance operational test run to ensure the unit is ready for acceptance. This pre-acceptance operational test may be accomplished with or without the presence of a Coast Guard Representative. A copy of the pre-acceptance test run shall be part of the test report.

3.13. OEM Representative:

3.13.1. At a minimum, the OEM representative shall meet the following qualification criteria:

a. Hold current employment with the Original Equipment Manufacturer (OEM) “Wood

Group Pratt & Whitney/Pratt & Whitney Power Systems”

b. Work in the engineering field for the OEM

c. Serve or have served as an overhaul shop specialist for the oversight of repairs for the OEM or be a designated senior field service representative for the OEM for this product line or be a designated Senior Service Engineer for the OEM for this product line.

3.13.2. The contractor shall submit the résumé of the individual that will be performing the duties of OEM Representative to the Contracting Officer for approval. During the contract period, any proposed OEM representative change shall be requested in writing, accompanied by the individual’s résumé, to the Contracting Officer for approval.

3.13.3. The OEM Representative shall be present at the contractor’s facility during the following critical points in the repair/overhaul process:

a. During initial inspection of the Gas Generator or Module at the overhaul facility to:

(1) Assist in determining the initial condition of the Gas Generator or Module.

(2) Review the Gas Generator logbook and service bulletins.

b. After the gas generator or module is disassembled to:

(1) Assist in determining if further disassembly is required.

(2) Review the disassembly sheets and compare dimensional data to applicable manuals.

(3) Provide recommendations regarding areas of the overhaul that warrant extra consideration.

(4) Provide recommendations related to compressor de-stacking. The OEM representative shall re-visit the shop to inspect the de-stacked components and review the conditions found.

(5) Review the contractor’s initial condition report and provide recommendations regarding Service Bulletin implementation.

REVISION H 02/2011

c. Following disassembly, cleaning, recording of all dimensional data, NDT inspection, stripping, bearing and seal inspection, review condition report and Gas Generator or Module components:

(1) Discuss with the contractor the recommended repair procedures and to ensure compliance with OEM authorized/recommended repair procedures.

(2) Review the contractors “as found” dimensional readings of Gas Generator or

Module components as outlined in the overhaul manuals.

(3) Review for concurrence the parts listed as unserviceable (scrap).

(4) Assist the Coast Guard during negotiations with respect to the repairs outlined in the condition reports and to recommend to the Coast Guard an estimate of the number of shop hours and labor categories required for each item. The OEM representative shall be provided a copy of the condition report a minimum of two working days prior to the shop visit.

d. Physically review all “in-house” and subcontractor repaired items prior to being assembled into the Gas Generator or Module. This includes items that require weld repair, machining, plating, coating, blending, stress relieving or any other shop or machining process outlined in the overhaul manual, standard practices manual or service bulletins.

e. Review build sheets of Gas Generator or Module sub-components.

f. Final assembly of the Gas Generator or Module. This includes the subassembly chapter of the overhaul manual.

g. Compressor assembly balancing.

(1) Witnessing the balance of individual disks is not required, however, the balance sheet data shall be available for review upon request.

(2) The presence of the OEM representative during assembly of external components as outlined in the Final Assembly Chapter of the Overhaul manual is not required.

h. Testing:

(1) To witness the Gas Generator acceptance test in the test cell and review performance data. To sign the test sheet and validate recorded readings.

(2) To inspect the Gas Generator after the test (bore-o-scope) and annotate findings on the test sheet.

3.14. Gas Generator Logbook:

3.14.1. The contractor shall document all repair/overhaul work performed on each Gas

Generator in the applicable logbook that accompanies the unit. If the logbook is missing, the contractor shall start a new logbook that includes the required entries. All service bulletins and special shop instructions incorporated during the repair/overhaul process shall also be included in the logbook.

3.14.2. The original Gas Generator Logbook and a Photostat copy of the Test Report (section

3.2.5) shall be placed in a waterproof bag attached to the exterior surface of the Gas Generator. A Photostat copy of the Gas Generator Logbook and Test Report (section 3.2.5) shall be placed in a moisture proof envelope and secured in the metal tube located on the lower exterior side of the metal shipping container. A second Photostat copy of the Gas Generator Logbook and Test Report shall also be provided to the Contracting Officer’s Technical Representative.

3.15. Shipping Containers: Each shipping container shall be restored to a serviceable condition such that it will provide safe long-term storage for the Gas Generator or Module.

Recommended repairs required for each shipping container shall be documented in the initial receiving report.

3.15.1. Gas Generator Container: At a minimum, repairs shall include, but are not limited to, repairs required to correct any deficiencies to the O-ring channel, welded seams, fork lift guides, alignment pins, seals around the inspection port glass, schraeder valve, relief valve and cap.

3.15.2. Relief valves shall be inspected and tested to ensure they relieve at the design pressure with a tolerance of plus or minus 1 psig.

3.15.3. The container shall be painted if required prior to delivery. The process shall include surface preparation, priming and color coating of all metal surfaces as necessary to preserve against container deterioration and give a uniform dark blue color upon completion. All repairs/re-preservation shall be documented in the condition report.

3.15.4. Module Container: Each Module container shall be inspected upon receipt. If repair/re-preservation is required, it shall be included in the initial receiving report. The container shall be returned to a condition that will allow for safe long-term storage of the module.

3.16. Warranty: The contractor shall provide technical onsite expertise to resolve all warranty issues. Warrantable repairs, trouble shooting and failure analysis shall be accomplished in the vessel. In the event the Gas Generator must be removed from the vessel to accomplish warranted repairs, the contractor’s field service representative shall ensure removal is accomplished in accordance with OEM procedures. For other warranty terms see section H of this contract.

3.16.1. Locations: Warranty services will primarily be required in vessel homeports including

Alameda, CA, San Diego, CA, Seattle, WA, Honolulu, HI, Kodiak, AK and Charleston, SC. However, services may also be required at remote locations throughout the world if the cutter is underway on patrol or participating in special operations.

3.16.2. Response: The contractor shall supply a Field Service Representative to the designated location within 36 hours after notification of a warranty issue by the Contracting Officer.

3.16.3. Warranty Parts replacement: Parts replacement: The contractor shall provide the required part(s) to correct a warranty issue. If the contractor is unable to acquire the needed part(s) in a timely manner, the affected Coast Guard vessel may provide these part(s), if available, to assist in corrective actions. Any inspection or modification to GFM will be the contractor’s responsibility unless previously negotiated with the Contracting Officer. The contractor shall expedite replacement of all USCG GFM and

REVISION H 02/2011

provide documentation to the Contracting Officer within 7 calendar days that expended part(s) used in the repair were ordered for delivery to the vessel’s homeport address.

3.16.4. Warranty Report: The contractor shall submit a Warranty Report, in writing, to the

Contracting Officer 7-calendar days after the completion of the warranty issue in accordance with section 3.2.8 of this specification

3.17. Contractor’s Field Service Representative: The contractor shall provide a Field Service

Representative for onsite removal, installation, and oversight when a Gas Generator, which was repaired under this contract, is installed into a vessel. This service will be required while this contract is in force and/or the Gas Generator being installed is under warranty.

3.17.1. The Contractor’s Field Service Representative shall ensure that the removal/installation fully complies with OEM standard practices and that the removal/installation does not in any way void or affect the contractor’s warranty.

3.17.2. The cost of the Contractor’s Field Service Representative shall be computed using a daily flat rate charge. The flat rate charge shall be a separate contract line item. In addition to the flat rate charge, the contractor will be reimbursed by the Coast Guard for costs incurred for transportation (coach rate for airlines and mid-size for rental cars), lodging and meals as delineated in the Joint Federal Travel Regulation (JFTR) and FAR Part 33.

3.17.3. If a Gas Generator is being shipped directly from the contractor’s facility to a Coast Guard vessel for immediate installation, the cost of the representative will be included as a separate contract line item in the delivery order for that unit. If the Gas Generator is issued from ELC stock, funding for the Contractor’s Field Service Representative will be provided through issuance of an individual delivery order.

3.17.4 In each event where a contractor Field Service Representative is needed, the Contracting Officer and the contractor shall mutually agree on the dates/times required.

Once established, only the Contracting Officer may authorize changes to these dates/times.

4.0 Quality Assurance:

4.1.Responsibility for Inspection: The contractor is responsible for the performance of all inspection requirements as specified herein. The contractor may use his own or any other facilities for the performance of the inspection and tests, unless disapproved by the Coast Guard. The Coast Guard reserves the right to perform or witness any of the inspections and tests set forth in this specification at any time.

4.2.Responsibility for Compliance: - All items shall meet the requirements of this specification.

The inspections set forth in this specification shall become part of the contractor’s overall inspection system or quality program. The absence of any inspection requirements in the specification shall not relieve the contractor of the responsibility of assuring that all products or supplies submitted to the government for acceptance comply with all requirements of the contract. Sampling for quality conformance does not authorize submission of known defective material (either indicated or actual) nor does it commit the government to acceptance of defective material.

REVISION H 02/2011

4.3.Quality Control Program: - The contractor shall maintain a documented Quality Control (QC) Program conforming to ASQC Q9001-2008. A copy of this program shall be submitted to the Contracting Officer for approval within 15 days after contract award.

4.4.Calibration System: The contractor shall submit and maintain a test equipment calibration program conforming to NCSL Z540.3-2006. The contractor shall have a copy of the calibration program readily available during the term of this contract for review by any Coast Guard personnel upon request.

4.5.Performance Testing: Each contractor overhauled Gas Generator shall be tested in accordance with the procedures outlined in Wood Group Pratt & Whitney Gas Generator Test Specification (section 2.3.1 of this specification), in the presence of a Coast Guard representative. Any deviation from acceptance criteria within the test specification shall constitute failure of the Gas Generator to meet operational requirements, and the Coast Guard representative will reject the unit.

5.0 Preservation, Packing, Packaging and Marking:

5.1.Preservation: Each Gas Generator or Module shall be prepared for storage within 15 calendar days after the completion of final acceptance testing or inspection. Each Gas Generator or Module shall be secured in its respective shipping container in a ready to operate configuration, and be prepared for long-term storage (29 plus days) in accordance with the FT4 Marine/ Industrial Gas Generator Overhaul Manual PN: 544026 and section 2.0 using the following items:

5.1.1. Humidity Indicator, one (01) each, in accordance with MIL-I-8835 Revision A, Part

Number MS20003-2, 3-spot, 30-50 relative humidity for each Gas Generator.

5.1.2. Desiccant, conforming to MIL-D-3464, Type 1

a. Fifty (50) one (01) pound (16 unit) bags secured in the wire basket in the base of the shipping container for each Gas Generator.

b. Ten (10) one (01) pound (16 unit) bags for each “A” through “D” and “F” Module.

c. Two (02) one (01) pound (16 unit) bags for each “E” Module.

5.1.3. Protective Envelope using water-vapor-proof, greaseproof, flexible, heat sealable barrier paper in compliance with MIL-PRF-131 Class 3 for any Module being shipped in a wooden crate.

5.2.Packing and Packaging: On Modules being shipped in wooden crates vice metal containers, all sharp corners, edges and protrusions, capable of puncturing the protective envelope, (as described in section 5.1.c) shall be protected and padded. The appropriate amount of desiccant (see section 5.1.b) shall be placed inside the protective envelope and just prior to sealing it, all excess air shall be evacuated using a suitable vacuum device.

CAUTION: Great care must be exercised when evacuating the air so as not to crush the protective envelope to such a degree that it is torn or damaged.

REVISION H 02/2011

After proper evacuation, the protective envelope shall be sealed closed utilizing a heat-sealing device designed for this purpose.

CAUTION: Care must be exercised during this procedure to insure enough heat is applied to the seam to properly and securely seal the envelope while avoiding excessive heat that will cause the protective envelope to melt.

Notes: (1) When properly evacuated and sealed, the protective envelope should form completely and snuggly around the Module and remain in that posture after 24 hours elapsed time.

(2) Once the above packing and packaging procedure is initiated, it must be completed without delay so as to minimize the exposure of the desiccant to atmospheric moisture.

5.2.1. Gas Generator: In order for the Gas Generator to properly fit inside its shipping container, the 1¼” fuel pipe from the LQ25 Liquid Fuel Valve to the Altair Valve shall be removed in accordance with the following procedure:

a. Prior to placement of the Gas Generator in the shipping container, disconnect and remove the preformed 1¼” fuel oil pipe from the LQ25 Liquid Fuel Valve to the Altair Valve.

b. Cap off both ends of the 1 ¼” fuel pipe with plastic inserts and set aside

c. Cap off the inlet to the engine mounted Altair Valve and outlet from the engine mounted LQ25 Liquid Fuel Valve using plastic inserts

d. Place gas generator in the shipping container and secure

e. Carefully strap the 1 ¼” fuel pipe to the Gas Generator in a manner that will prevent damage or movement during shipment

(1) Provide written fuel pipe reinstallation instructions in accordance with section

5.5.1 of this specification

(2) Complete preservation and packaging procedures in accordance with section

5.4 of this specification

5.3. Packing List: Each unit shall contain a packing list of all items it contains. The packing list shall state the Contract Number and Delivery Order Number.

5.4.Shipping Container: Each Gas Generator shipping container shall have the following items installed prior to final sealing:

5.4.1. Desiccant, fifty (50) one (01) pound (16 unit) bags placed in wire basket and secured.

5.4.2. Original logbook with warranty information.

5.4.3. Humidity Indicator, installed so that it is clearly visible through the view-port.

5.4.4. Gas Generator: After all items have been installed inside the container, the cover shall be sealed with a new rubber gasket and a bead of RTV. The container cover bolts shall be secured by diametrically tightening starting at the center and working outward. The sealant shall be allowed to cure for 24 hours prior to pressurizing the container. After the sealant has cured, pressurize the container with 4-5 psi of dry air. Check all fittings and sealed joints for leaks using a soapsuds solution. Zero leakage is permitted. If leakage is detected, regardless of how small, it shall be corrected. Pressure must hold for a minimum of 24 hours. If no leaks are present, drain the dry air charge and charge the container with 4-5 psi of dry nitrogen. Replace all protective fittings and covers.

5.4.5. Modules: Each Module container shall be sufficient to provide protection to the module for a period of at least two years and shall be constructed in accordance with section 2.3.2.c. of this specification.

5.5 Warning Tag: A red tag marked “Preservation Actions/De-preservation Actions required” shall be attached to each Gas Generator or Module when such actions have been taken. A typewritten notice of all preservation actions taken, safety precautions, and related Material Safety Data Sheets shall be attached with the warning tag.

5.5.1. Additionally, the contractor shall provide specific instructions to restore each Gas

Generator or Module to operating condition, including reinstallation of fuel oil piping from the LQ25 liquid fuel valve to the Altair valve and minor items such as removing cardboard duct covers, taped end fittings, etc. The instructions shall be thoroughly detailed such that no other reference material is required to de-preserve the unit.

5.6 Marking for Shipping Container:

5.6.1. Container: Each shipping container shall be stenciled on two opposite sides in two (2) inch white enamel paint letters with the following information:

Stock Number: “As submitted”

Model Type: “As submitted” Serial Number: “As per enclosed item” Gross Weight: “As determined” Date Shipped: “From the Contractor” Contract Number: “See contract page 1” Delivery Order Number: “As submitted”

Coast Guard ELC Material Condition “A” Quantity and unit of Issue: “1 EA” Reusable Skid: Do Not Destroy

The Contractor shall remove all other invalid or outdated information that may be present on the shipping container.

REVISION H 02/2011

5.7 Bar Coding: A Bar code label shall be attached to each Gas Generator or Module shipping container prior to shipment from the contractor’s facility. All bar coded labels shall be in accordance with ELC specification D-000-0100 Rev F Dated 06/2000. The actual label shall be Type “V” style 2 Composition “B” with plastic laminate. Each label shall contain encoded data for the Stock Number, Contract Number and Delivery Order Number

5.0 Notes:

6.1 GOVERNMENT & COMMERCIAL DOCUMENT SOURCE

6.1.1 GOVERNMENT DOCUMENTS

Department of Defense Single Stock Point (DODSSP Documents) 700 Robbins Avenue Building #4, Section D Philadelphia, PA. 19111-5098

FAX (215) 697-9398

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

DOD & Navy Publications & Forms (Other than DODISS)

Naval Publication and Forms Center 5801 Tabor Ave.

Philadelphia, PA. 19120

(215) 697-2197

U.S.C.G. Surface Forces Logistics Center Long Range Enforcer Product Line Mail Stop 26, Bldg. 3, 2nd Floor, (CPD-2) 2401 Hawkins Point Road Baltimore, MD. 21226-5000

6.1.2 COMMERCIAL DOCUMENTS

Wood Group Pratt & Whitney Industrial Turbines Services, LLC 1460 Blue Hills Avenue Bloomfield, CT 06002

(860) 256-4600

American National Standards Institute (ANSI) 25 West 43rd Street (Between 5th and 6th Avenues) 4th Floor New York, NY 10036 212-642-4900

FAX 212-398-0023

www.ansi.org

American Society for Testing Materials (ASTM)

REVISION H 02/2011

1916 Race Street Philadelphia, PA 19103-1187

(215) 299-5585