Final _Various_Pump_Overhaul_R-503-0519.docx

USCG MEDIUM ENDURANCE CUTTERS (WMEC)

SPECIFICATION FOR PUMP OVERHAUL

R-503-0519

Developed By: Stephen Twomey

TABLE OF CONTENTS

Consolidated list of Pumps: Page Work Item 1: 270’ EDG Sea Water Cooling Pump Unit Overhaul, 4320-01-118-5085 11 Work Item 2: 270’MDE/RG Lube Oil Transfer Pump Overhaul, 4320-01-106-7631 15 Work Item 3: 270’ JP-5 Service Pump Overhaul, 4320-01-118-6394 19 Work Item 4: 270’ Fuel Transfer Pump Overhaul, 4320-01-118-6395 23 Work Item 5: 270’ A/C Chill Water Pump Unit Overhaul, 4320-01-121-9680 27 Work Item 6: 270’ Auxiliary Sea Water Pump Unit Overhaul, 4320-01-122-3852 31 Work Item 7: 270’ JP-5 Transfer Pump Overhaul, 4320-01-183-9557 35 Work Item 8: 270’ Fire Pump Unit Overhaul, 4320-01-481-4914 39 Work Item 9: 270’ Sewage Discharge Pump Unit, Overhaul 4320-01-131-0841 42 Work Item 10: 270’ In-Port ASW Pump Unit Overhaul, 4320-01-339-6786 46 Work Item 11: 270’ Reverse Osmosis HP Pump Overhaul, 4320-01-521-7356 50 Work Item 12: 270’ Potable Water Service Pump Unit Overhaul, 4320-01-535-4782 55 Work Item 13: 270/378 Sewage Discharge Pump Unit Overhaul, 4320-01-112-0008 59 Work Item 14: 270’ FWD/AFT Waste Water Pump Unit Overhaul, 4320-01-131-6912 62 Work Item 15: 270’ Chilled Water Circ Pump Unit Overhaul, 4320-01-554-3286 66 Work Item 16: 270’ Bilge and Ballast Pump Unit Overhaul, 4320-01-318-0826 70 Work Item 17: 210’ Sewage Vacuum Ejection Pump Unit Overhaul, 4320-01-519-3163 74 Work Item 18: 210’ Fuel Oil Transfer Pump Overhaul, 4320-01-230-6221 78 Work Item 19: 210’ Fire Pump Overhaul, CW 4320-01-225-7493 82 Work Item 20: 210’ Fresh Water Transfer Pump Unit Overhaul, 4320-01-203-5819 86 Work Item 21: 210’ Bilge Pump Unit Overhaul, 4320-01-206-2611 90 Work Item 22: 210’ Reverse Osmosis LP Pump Unit Overhaul, 4320-01-422-0469 93 Work Item 23: 210’ Sewage Discharge Pump Unit Overhaul, 4320-01-273-9350 97 Work Item 24: 210’ Reverse Osmosis HP Pump Overhaul, 4320-01-503-5378 101 Work Item 25: 210’ Fresh Water Service Pump Unit Overhaul, 4320-01-199-9751 106 Work Item 26: 210’ JP5 Service Pump Overhaul, 4320-01-227-8866 110 Work Item 27: 210’ Fire Pump Overhaul, CCW 4320-01-566-2626 114

Consolidated list of References iii-iv General Requirements 5-11 ii Consolidated List of References

The below-listed documents form a part of this specification to the extent specified herein. Approval/publication dates or revision dates/numbers are also identified, to ensure that same document versions are used at time of specification writing and during contract execution.

All Coast Guard drawings, technical publications, and standard specifications will be provided to contractors by the Coast Guard at an appropriate time, or upon request, free of charge. Other Government documents may be accessed – free of charge – as follows:

· MIL/DOD/CID Specifications: http://www.assistdocs.com/search/search_basic.cfm

· Commandant Instruction Manuals: http://www.uscg.mil/directives/default.asp

· Public Laws, Code of Federal Regulations, U.S Codes, and other Federal Government laws:: www.gpoaccess.gov The Government is aware of the following internet web links where contractors may procure commercial specifications:

· American Welding Society (AWS): http://www.awspubs.com/index.php

· ANSI, ASTM, IEEEE, NFPA, ASME, SAE Standards: http://www.techstreet.com/

· NFPA: http://www.nfpa.org

· SSPC Standards and pictorial guides: http://shopping.netsuite.com/sspcmarketplace

COAST GUARD DRAWINGS:

Not applicable.

COAST GUARD PUBLICATIONS:

Surface Forces Logistics Center Standard Specification 3020 (SFLC Std Spec 3020), Jan 2009, Overhaul AC Electrical Motors In-Shop.

Surface Forces Logistics Center Specification D-000-0100 Rev G, Change 1 Dated 03/06/2006, Bar Coding for USCG Surface Forces Logistics Center Material.

OTHER REFERENCES:

Federal Standard, FED-STD-595C, dated 01/16/2008, Colors Used in Government Procurement.

ASTM International (ASTM) D3951, Reapproved 2004, Standard Practice for Commercial Packaging.

Code of Federal Regulations, Title 40, Chapter I, 2008, Environmental Protection Agency.

International Standard Organization (ISO) 2953, 1999, Mechanical Vibration, Balancing Machines, Description and Evaluation .

MIL-PRF-81309F dated 05/16/2005, type 2, class 1 or 2, Corrosion preventive compounds, water displacing, ultra-thin film.

MIL-D-3464E dated 04/1987- Desiccants, Activated, Bagged, Packaging use and static dehumidification.

MIL-PRF-131K Type 1, dated 28 Aug 1998- Barrier materials, water vapor proof, greaseproof, flexible, heat sealable.

The Society for Protective Coatings (SSPC) Surface Preparation Specification No.3 (SSPC-SP 11), 2004, Power Tool Cleaning to Bare Metal.

National Conference of Standards Laboratories (NCSL) Z540-3-2006, dated 2006, Requirement for the Calibration of Measuring and Test Equipment.

American Society for Quality (ASQ) Q90001-2008, dated 2008, Quality Management Systems-Requirements.

American Society of Mechanical Engineers, ASME international – PTC 8.2 Centrifugal Pump, dated 1990.

American National Standards Institute (ANSI)/HI 3.6 Rotary Pump Tests, dated 2000.

General Requirements

1. SCOPE

1.1 Intent: This section describes the requirements which the Contractor shall follow applicable to all pump/pump units inducted for overhaul under this Contract. Additional specific requirements applicable to a designated model/unit are addressed in the applicable individual Work Items (WI) within this specification package. These General Requirements in conjunction with the applicable WI make up the overall Contractor repair/overhaul requirements for each pump/pump unit.

2. REFERENCES

COAST GUARD DRAWINGS

None

COAST GUARD PUBLICATIONS

Surface Forces Logistics Center Specification D-000-0100 Rev G Dated 06/2006, Bar Coding for USCG Surface Forces Logistics Center Material.

OTHER REFERENCES

Code of Federal Regulations (CFR), Title 40, Chapter I, 2008, Environmental Protection Agency.

National Conference of Standards Laboratories (NCSL) Z540-3-2006, dated 2006, Requirement for the Calibration of Measuring and Test Equipment.

MIL-PRF-81309F dated 05/16/2005, type 2, class 1 or 2, Corrosion preventive compounds, water displacing, ultra-thin film.

MIL-D-3464E dated 04/1987- Desiccants, Activated, Bagged, Packaging use and static dehumidification.

MIL-PRF-131K Type 1, dated 28 Aug 1998- Barrier materials, water vapor proof, greaseproof, flexible, heat sealable.

ASTM International (ASTM) D3951, Reapproved 2004, Standard Practice for Commercial Packaging.

American Society for Quality (ASQ) Q90001-2008, dated 2008, Quality Management Systems-Requirements.

3. REQUIREMENTS

3.1 General:

3.1.1 Contractor Repair Process: The Contractor shall conform to all requirements specified throughout this specification during performance of this contract. 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.

3.1.2 Repair to Original Equipment Manufacturer (OEM) Specifications: Unless otherwise specified in the individual WI, the inspection, repair/overhaul, and testing of each pump/pump unit shall be accomplished in accordance with the OEM procedures, specifications, references and standard practices.

3.2 Repair Parts: All replacement parts utilized in each overhaul shall be new OEM approved parts. Reclaimed, recycled or aftermarket parts are not acceptable and shall not be used. Commercial parts such as seals and ball/roller type bearings and couplings which are not manufactured by the pump or motor manufacturer shall be identified by their marking or the OEMs technical publications for identification purposes. Commercially available items such as these are generally interchangeable between different manufacturers and may be substituted as long as they are equal in all respects. Only in the case where the part cannot be identified shall it be ordered directly through the pump manufacturer and by their part number.

3.2.1 Gaskets: All new gaskets shall be made of non-asbestos materials. All pump/pump units will be packaged with new gaskets needed for installation of the pump/pump unit by the ship’s crew. The new installation gaskets will be labeled and enclosed in protective waterproof packaging with cardboard backing to prevent the gaskets from bending.

3.2.2 Zerc Fittings: All ferrous metal zerc fittings or pipe plugs called out in the bill of material shall be substituted with like items made of non-magnetic grade stainless steel. All pipe plugs shall be installed with a non hardening thread sealer. Zerc fittings shall have a protective plastic cap installed on each fitting.

3.2.3 Label Plates: Renew all original data or label plates after completing pump external preservation. A separate label plate made of similar material as the original label plate shall be attached to the pump stating the Contractor’s name, contract number and date of overhaul.

3.3 Billable Costs: The Contractor shall provide all labor and materials to perform the overhaul services as described in the WI for each pump/pump unit.

3.4 Inspections: The Contractor shall submit “Receiving and Preliminary Inspection” reports as follows.

3.4.1 Receiving Inspection: The Contractor shall submit a “Receiving Inspection Report” to the government within 3 days of receiving a pump/pump unit. The report will document that the make, part number, model and/or inlet/outlet size delivered for overhaul conform to the pump/pump unit cited. This report will also include digital photographic documentation of the crate and its contents.

3.4.2 Preliminary Inspection: The Contractor shall conduct a preliminary disassembly and inspection of the pump/pump unit and its shipping container in accordance with pump/pump unit OEM procedures, specifications, references, and standard practices addressed in each WI. A Condition Found Report (CFR) shall be submitted within 10 days of the completion of the “Receiving Inspection Report” detailing the Contingency Repair parts recommended for replacement and a total repair cost. This report will document the item name, NSN, manufacturer part number, serial number and the date of inspection. The contractor may not proceed with any repairs or parts replacements (mandatory or contingency) without authorization by the government. This authorization if given will be made following the government review of the CFR.

3.5 Beyond Economical Repair: The government reserves the right to dispose of the pump/pump unit if the pump/pump unit is BER. The contractor will dispose of the unit at a predetermined cost to the government. The contractor shall provide a scrap credit to the government or a price to discard any pump/pump unit Beyond Economic Repair.

3.6 Photo Documentation: The Contractor shall include digital photo documentation in the “Receiving Inspection Report” to the Contracting Officer of the crate upon arrival and the contents of the crate.

3.7 Status Report: The Contractor shall submit a monthly status report on a government approved spreadsheet via email to the CG KO and the COR. All pumps/pump units shall be listed with the current repair status. The excel spreadsheet shall contain the following column headings.

a. Delivery order number

b. Work Item number

c. Part number

d. Serial number

e. National Stock Number (NSN)

f. Date pump/pump unit received

g. Date pump/pump unit CFR is submitted for approval of “Contingency Parts” replacement.

h. Date material ordered.

i. Date material received.

j. Date of Quality Assurance final inspection

k. Date pump/pump unit shipped

l. Comments/remarks

3.8 Quality Assurance: The Contractor shall maintain an inspection system per American Society for Quality (ASQ) Q90001-2008 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 and as specified in paragraph 3.11 and individual work items.

3.9 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.

3.10 Calibration System: The Contractor, as well as any sub-contractors, shall be required to maintain a measuring and test equipment calibration program in compliance with the National Conference of Standards Laboratories (NCSL) Z540-3. The program shall be documented and traceable to the National Institute of Standards (NIST).

3.11 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 to conduct all required inspections. 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 or tests that are deemed necessary to assure that supplies and services conform to the prescribed requirements. It is the Coast Guard’s intent for the Coast Guard Quality Assurance Representative (QAR) to have the discretion to witness and or verify inspections and tests of all pumps overhauled by the Contractor. Any inspection scheduling issues that may occur that would impede progress may only be waived by the CG KO.

3.12 Responsibility for Compliance: The Contractor shall meet the provisions of section 3 of this specification. The inspections set forth in this specification shall become part of the Contractor’s overall inspection system and 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.

3.13 Quality System: The Contractor shall maintain an inspection system for tools and equipment which shall insure that each item performs in accordance with the National Conference of Standards Laboratories (NCSL) Z540-3. The inspection system shall be documented and available for review by the Coast Guard.

3.14 Tests & Inspections: The inspections/tests required, here and in the appropriate subsection in the individual WI 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. The Contractor shall submit a written Test Report for each test and inspection.

3.15 Notifications of Inspections/Tests: The Contractor shall notify the Contracting Officer at least ten calendar days prior to accomplishing the following inspections and tests:

a. WFT/DFT readings

b. Motor winding resistance check

c. Motor certification

d. Pump rotation and impeller direction verification

e. Proper pump orientation as per the OEM tech pub

f. Hydrostatic test

g. Operational test (note results including meter and gauge readings in Test Report)

h. OEM installation/alignment, parts and service manuals verified packed with the pumps

i. Verify PP&M requirements

j. Disposal of mandatory replacement parts

3.16 Warranty: Contractor’s standard pump warranty shall apply. A notice of warranty shall be enclosed in a water proof enclosure describing warranty terms and Point of Contact for warranty issues.

3.17 Preservation, Packing and Marking (PP&M): Each pump/pump unit shall be preserved, packaged and marked in accordance with Sections 3.20, 3.21.1, 3.21.2, 3.21.3, 3.21.4, 3.22, 3.23 and 3.24 of this specification.

3.18 Assembly: The overhauled pump/pump unit shall be delivered to the Coast Guard completely assembled and in a ready to operate condition and configuration.

3.19 Recommended Grease: A decal or permanent type label shall be affixed to the side of the pump/pump unit informing the user of the manufacturer’s recommended amount and type of grease to be used.

3.20 Preservation: An overhauled pump/pump unit is typically intended for warehouse storage and not for immediate installation. Therefore, the Contractor shall ensure that the overhauled pump/pump unit undergoes the following preservation requirements.

3.21.1 The pump shall be drained and completely dried of all test fluid. Each pump shall be fogged with a MIL-C-81309E Type II corrosion protection such as Corrosion X. The inlet and outlet openings shall have plastic plugs to seal off the housing and the plugs taped in place using duct tape. Any sharp edges or protruding parts shall be covered to protect the packaging bag from tears.

3.21.2 Any ferrous metal surface and all unpainted surfaces shall have a thin coat of rust inhibitor per MIL-PRF-81309F applied.

3.21.3 Each pump/pump unit shall be placed into a protective heat sealable bag per MIL-PRF-131K, Type 1. The pump base shall be fastened to the skid mounted shipping container. Areas where the fasteners penetrate the sealing bag shall have either a rubber gasket or 100% silicone rubber shall be used to seal the bag from moisture.

3.21.4 Prior to sealing the bag opening, a minimum of 48 UNITS of self contained dehydrated desiccant per MIL-D-3464E shall be placed inside the bag. Using a vacuum, remove as much air possible and heat seal the bag opening.

3.22 Packing: Each pump/pump unit shall be individually packed in its own enclosed framed in wooden container using 2 x 4’s for framing and ½” plywood for the remainder. All corners shall have 14 gauge 1 ½ x 1 ½” slotted angle on all 8 corners of the outside of the crate. Material shall be galvanized. The crates shall have 2 zinc plated 3 3/8” x 2 7/8” surface mount folding pull handles placed one on each side of the crates with a 1/8” steel backer plate on the inside of the crate lid. The pump/pump unit shall be securely bolted to a skid base using 2 x 6 solid lumber bolted to 4 x 4’s. The 4 x 4’s shall facility fork lifting on the side of the crate marking and the lid or cover shall be attached using 3 lag bolts on each side. The lag bolts shall then have a 2” square paint red around the bolt to make lid removal identification easy. A 3/4 “Red stencil shall be painted on both sides with the words “remove lag bolts in RED then lift lid”. The container shall be framed on the inside using solid wood as framing material. The container shall be capable of protecting the pump/pump unit from damage during multiple shipments by commercial carrier per ASTM D3951.

3.23 Marking: Each preserved and packed pump/pump unit shall be stenciled in the upper left-hand corner of the two longest sides (two opposite sides if square) of each box. The stencil marking shall be ¾ -1” inch in height. Markings shall be black characters on white enamel painted background. All previous markings and quality assurance decals shall be removed from a reusable shipping container prior to the application of any new markings.

3.24 Bar Coding: The Contractor shall attach bar code labels on all shipping containers for each pump/pump unit returned to the Coast Guard. Bar code labels shall be in accordance with USCG-SFLC Specification D-000-0100 Rev G Dated 03/2006, Bar Coding for USCG Surface Forces Logistics Center Material.

3.25 Shipping: Unless otherwise directed by the KO, the contractor shall return repaired pumps/pump units to:

3.26 Hazardous Waste Disposal: The Contractor shall be responsible for proper disposal of all hazardous wastes generated by work under this contract, i.e. asbestos gaskets, test fluids. Label and package all hazardous wastes in accordance with all applicable Federal, state, and local laws and regulations. In addition, comply with CFR title 40 part 262, applicable to handling and disposal of hazardous waste.

4. NOTES

4.1 Terms and definitions:

a. The word “pump” does not include an electric motor and/or primary drive unit.

b. The word “pump unit” includes an electric motor and/or primary drive unit.

c. BER - Beyond Economical Repair.

d. PP&M - Preservation, Packing, & Marking.

e. KO - Contracting Officer.

f. NA - Not Available.

g. QAR - Quality Assurance Representative

h. COR - Coast Guard Contracting Officer’s Representative

i. WI - Work Items

j. QA - Quality Assurance

WORK ITEM 1: 270’ EDG Sea Water Cooling Pump Unit Overhaul

NSN 4320-01-118-5085

Dresser Pump, P/N NY671190-MODEL-D1131

1. SCOPE

1.1. Intent: This work item describes the requirements for the Contractor to disassemble, overhaul, assemble, paint, test, prepare for delivery, and shipment of the designated Emergency Diesel Generator Seawater Cooling Pump Unit. This WI shall be used in conjunction with the “General Requirements” included in this specification package.

1.2. Government-Furnished Material: None.

1.3 Mandatory Replacement Parts:

732A500AF-P25

25PC02XP

1.3.1 Contingency Replacement Parts:

2.0 REFERENCES

COAST GUARD DRAWINGS

Not applicable.

COAST GUARD PUBLICATIONS

Not applicable.

OTHER REFERENCES

The Society for Protective Coatings (SSPC) Surface Preparation Specification No.3 (SSPC-SP 3), 2004, Power Tool Cleaning.

Federal Standard, FED-STD-595C, dated 01/16/2008, Colors Used in Government Procurement.

American Society of Mechanical Engineers, ASME international – PTC 8.2 Centrifugal Pump, dated 1990.

3.0 REQUIREMENTS

3.1 General: The Contractor shall disassemble, overhaul, assemble, paint, test, prepare for delivery, and ship the designated seawater cooling pump unit assembly. The Contractor shall accomplish the specified requirements of this WI in conjunction with the “General Requirements” included in this specification package for each designated pump/pump unit. The Contractor shall refer to OEM Technical Publications for guidance in accomplishing this WI.

3.2 Quality Product: The overhaul requirements described herein are considered to be the minimum acceptable and are not intended to replace any procedures, controls, examinations or tests normally conducted by the Contractor to assure the quality of the product.

3.3 Inspection Reports: The Contractor shall receive, open and inspect each pump unit in accordance with the “General Requirements” in this specification package regarding required inspection reports.

3.4 Motor Overhaul: The drive motor supplied shall be reconditioned to a like new condition in accordance with the OEM technical specifications.

3.5 Verify specifications: The following items shall be inspected to confirm proper dimension, tolerance and run-out in accordance with the manufacturer’s recommendation

A. Rotors B. Rotor Shafts C. Drive and Driven Shafts D. Bearing Housings E. Shaft Sleeves F. Impellers G. Volutes H. Gears

All discrepancies shall be documented and submitted on a CFR within 10 days of submitting the Receiving Report and include specific details along with recommended repair procedures and price quoting.

3.6 CG Inspection: The Contractor shall provide at least a ten day advance notice to the KO prior to conducting pump unit tests and inspections in preparation for CG QAR inspections. All inspection and test results shall be made available for review by the QAR upon request.

3.7 Replacement Parts: Section 1.3 lists “Mandatory Replacement Parts” in this work item. Section 1.3.1 lists any “Contingency Parts” that may need replacement. Before any “Mandatory or Contingency Parts” are replaced the Contractor must submit a CFR listing the “Contingency” parts being recommended for replacement and the reason for replacement. This CFR must be submitted within 10 days of the “Receiving Report”. The contractor may not proceed with any repairs or part replacement until the government provides authorization to proceed.

3.8 Pump/Pump Unit: Pump Unit.

3.9 Pump Assembly: The Contractor shall assemble the pump/pump unit in accordance OEM Technical Publications.

3.10 Pump/Pump Unit QA Tests: After assembly of the pump, the Contractor shall accomplish the tests listed below for each designated pump/pump unit. At the Coast Guard’s discretion, a CG QAR will witness or verify inspections and tests conducted by the Contractor to prove satisfactory operating condition. The Contractor shall provide all labor, material and place of service to conduct the tests.

3.11 Rotation Test: To ensure the pump turns freely, the pump shaft shall be rotated a minimum of five revolutions by the use of a strap wrench or other non-damaging tool. The Contractor’s QA representative shall inspect for smoothness of rotation and check for signs of binding or dragging. Pumps which have reversible impellers shall be inspected to confirm proper rotation. The Contractor shall investigate any questionable test results and correct as necessary.

3.12 Hydrostatic Test: The Contractor shall conduct a hydrostatic test of the overhauled pump unit using the OEM specified test fluid. The test shall be conducted to certify the integrity of the pump and seal area. The test shall be conducted at 150 percent of the rated working pressure or mechanical seal rating whichever is less. The test shall be conducted for a period of ten minutes and discontinued at any sign of leakage. The Contractor shall investigate and correct any leakage and retest the pump unit.

3.13 Operational Test: In addition to the hydrostatic test, pump units shall be operationally tested by the use of a test tank of compatible OEM recommended test fluid. Each operational pump unit test shall be conducted, recorded, and reported in accordance with Type B of ASME International PTC 8.2.

3.14 QA Test Documentation: The test results shall be documented on a report in accordance with ASME International PTC 8.2 and provided to the CG KO. A copy of the test report shall be packed with each pump unit and a copy shall available for the QAR inspection.

3.15 Paint: The Contractor shall prepare the exterior pump housing for preservation in accordance with SSPC-SP-3. The Contractor shall apply primer and finish coats of paint to the entire pump/pump unit external housing (excluding flange faces). The primer coat shall be 5-6 mils dry film thickness (DFT) of any rust preventive metal primer suitable for use with the finish coat. The finish coat shall be 3-6 mils DFT of silicone alkyd enamel, Type II or III, Class I or II. The color shall be Dark Green, color number 14062 per Federal Standard, FED-STD-595C. Total paint thickness shall be a minimum of 8-12 mil DFT. The pump/pump unit shall be painted after all tests are complete.

3.16 Quality Assurance: See General Requirements.

3.17 Preservation, Packaging & Marking: See section 3.17 of the General Requirements.

4. NOTES: Not applicable

WORK ITEM 2: 270 MDE/RG Lube Oil Transfer Pump Unit Overhaul

NSN 4320-01-106-7631

Curtis-Wright Electro-Mechanical, P/N 9210

1. SCOPE

1.1. Intent: This work item describes the requirements for the Contractor to disassemble, overhaul, assemble, paint, test, and mark the shipping container for a designated Lube Oil Transfer Pump assembly. This WI shall be used in conjunction with the “General Requirements” included in this specification package.

1.2. Government-Furnished Property: None.

1.3 Mandatory Replacement Parts:

1.3.1 Contingency Replacement Parts:

2. REFERENCES

COAST GUARD DRAWINGS: Not applicable.

COAST GUARD PUBLICATIONS: Not applicable.

OTHER REFERENCES:

The Society for Protective Coatings (SSPC) Surface Preparation Specification No.3 (SSPC-SP3), 2004, Power Tool Cleaning.

The Society for Protective Coatings (SSPC) Surface Preparation Specification No.3 (SSPC-SP 11), 2004, Power Tool Cleaning to Bare Metal.

Federal Standard, FED-STD-595C, dated 01/16/2008, Colors Used in Government Procurement.

American National Standards Institute (ANSI)/HI 3.6 Rotary Pump Test, dated 2000.

3. REQUIREMENTS:

3.1 General: The Contractor shall disassemble, overhaul, assemble, paint, test, prepare for delivery, and ship the designated lube oil transfer pump/pump unit assembly. The Contractor shall accomplish the specified requirements of this WI in conjunction with the “General Requirements” included in this specification package for each designated pump/pump unit. The Contractor shall refer to OEM Technical Publications for guidance in accomplishing this WI.

3.2 Quality Product: The overhaul requirements described herein are considered to be the minimum acceptable and are not intended to replace any procedures, controls, examinations or tests normally conducted by the Contractor to assure the quality of the product.

3.3 Inspection Reports: The Contractor shall receive, open and inspect each pump and adhere to the “General Requirements” in this specification package regarding any required inspection reports.

3.4 Motor Overhaul: The drive motor supplied shall be reconditioned to a like new condition in accordance with OEM Technical Specifications.

3.5 Verify Specifications: The following items shall be inspected to confirm proper dimension, tolerance and run-out in accordance with the manufacturer’s recommendation

A. Rotors B. Rotor Shafts C. Drive and Driven Shafts D. Bearing Housings E. Shaft Sleeves F. Impellers G. Volutes H. Gears

All discrepancies shall be documented and submitted on a CFR within 10 days of submitting the Receiving Report and include specific details along with recommended repair procedures and price quoting.

3.6 CG Inspection: The Contractor shall provide at least a ten day advance notice to the KO prior to conducting pump unit tests and inspections in preparation for CG QAR inspections. All inspection and test results shall be made available for review by the QAR upon request.

3.7 Replacement Parts: Section 1.3 lists “Mandatory Replacement Parts” in this work item. Section 1.3.1 lists any “Contingency Parts” that may need replacement. Before any “Mandatory or Contingency Parts” are replaced the Contractor must submit a CFR listing the “Contingency” parts being recommended for replacement and the reason for replacement. This CFR must be submitted within 10 days of the “Receiving Report”. The contractor may not proceed with any repairs or part replacement until the government provides authorization to proceed.

3.8 Pump/Pump Unit: Pump Unit

3.9 Pump Assembly: The Contractor shall assemble the pump/pump unit in accordance OEM specifications.

3.10 Pump/Pump Unit QA Tests: After assembly of the pump, the Contractor shall accomplish the tests listed below for each designated pump/pump unit. At the Coast Guard’s discretion, a QAR will witness and or verify inspections and tests conducted by the Contractor to prove satisfactory operating condition. The Contractor shall provide all labor, material and place of service to conduct the tests.

3.11 Rotation Test: To ensure the pump turns freely, the pump shaft shall be rotated a minimum of five revolutions by the use of a strap wrench or other non-damaging tool. The Contractor’s QA Representative shall inspect for smoothness of rotation and check for signs of binding or dragging. Pumps which have reversible rotation shall be inspected to confirm proper rotation. The Contractor shall investigate any questionable test results and correct.

3.12 Hydrostatic Test: The Contractor shall conduct a hydrostatic test of the overhauled pump/pump unit using the OEM specified test fluid. The test shall be conducted to certify the integrity of the pump and seal area. The test shall be conducted at 150 percent of the rated working pressure or mechanical seal rating whichever is less. The test shall be conducted for a period of ten minutes and discontinued at any sign of leakage. The Contractor shall investigate and correct any leakage and retest the pump/pump unit.

3.13 Operational Test: In addition to the hydrostatic test, the pump shall be operationally tested by the use of compatible OEM recommended test fluid. Each operational pump test shall be conducted, recorded and reported in accordance with the American National Standards Institute (ANSI)/HI 3.6 Rotary Pump Tests to performance test type 3, level A.

3.14 QA Test Documentation: The test results shall be documented on a report in accordance with (ANSI)/HI 3.6 Rotary Pump Tests document and provided to the KO. A copy of the test report shall be packed with each pump/pump unit and a copy available to the QAR for review.

3.15 Paint: The Contractor shall prepare the exterior pump housing for preservation in accordance with SSPC-SP-3. The Contractor shall apply primer and finish coats of paint to the entire pump/pump unit external housing (excluding flange faces and shaft). The primer coat shall be 5-6 mils dry film thickness (DFT) of any rust preventive metal primer suitable for use with the finish coat. The finish coat shall be 3-6 mils DFT of silicone alkyd enamel, Type II or III, Class I or II. The color shall be black, color number 17038 per Federal Standard, FED-STD-595C. Total paint thickness shall be a minimum of 8-12 mil DFT. The pump/pump unit shall be painted after all tests are complete.

4 NOTES: Not applicable

WORK ITEM 3: 270’ JP-5 Service Pump Overhaul

NSN 4320-01-118-6394

Worthington Pump, P/N SZD-1BM3DIA

1. SCOPE

1.1 Intent: This work item describes the requirements for the Contractor to disassemble, overhaul, assemble, paint, test, prepare for delivery, and ship the designated JP-5 Service Pump. This WI shall be used in conjunction with the “General Requirements” included in this specification package.

1.2 Government-Furnished Material: None.

1.3 Mandatory Replacement Parts:

Assembly

1.3.1 Contingency Replacement Parts:

Assembly

Assembly

COAST GUARD PUBLICATIONS: Not applicable.

OTHER REFERENCES:

The Society for Protective Coatings (SSPC) Surface Preparation Specification No.3 (SSPC-SP3), 2004, Power Tool Cleaning.

Federal Standard, FED-STD-595C, dated 01/16/2008, Colors Used in Government Procurement.

American National Standards Institute (ANSI)/HI 3.6 Rotary Pump Test, dated 2000.

3. REQUIREMENTS

3.1 General: The Contractor shall disassemble, overhaul, assemble, paint, test, prepare for delivery, and ship the designated JP-5 service pump/pump unit. The Contractor shall accomplish the specified requirements of this WI in conjunction with the “General Requirements” included in this specification package for each designated pump/pump unit. The Contractor shall refer to OEM technical specifications for guidance in accomplishing this WI.

3.2 Quality Product: The overhaul requirements described herein are considered to be the minimum acceptable and are not intended to replace any procedures, controls, examinations or tests normally conducted by the Contractor to assure the quality of the product

3.3 Inspection Reports: The Contractor shall receive, open and inspect each pump in accordance with the “General Requirements” in this specification package regarding any required inspection reports.

3.4 Motor Overhaul: Not applicable.

3.5 Verify Specifications: The following items shall be inspected to confirm proper dimension, tolerance and run-out in accordance with the manufacturer’s recommendation

A. Rotors B. Rotor Shafts C. Drive and Driven Shafts D. Bearing Housings E. Shaft Sleeves F. Impellers G. Volutes H. Gears

All discrepancies shall be documented and submitted on a CFR within 10 days of submitting the Receiving Report and include specific details along with recommended repair procedures and price quoting.

3.6 CG Inspection: The Contractor shall provide at least a ten day advance notice to the KO prior to conducting pump unit tests and inspections in preparation for CG QAR inspections. All inspection and test results shall be made available for review by the QAR upon request.

3.7 Replacement Parts: Section 1.3 lists “Mandatory Replacement Parts” in this work item. Section 1.3.1 lists any “Contingency Parts” that may need replacement. Before any “Mandatory or Contingency Parts” are replaced the Contractor must submit a CFR listing the “Contingency” parts being recommended for replacement and the reason for replacement. This CFR must be submitted within 10 days of the “Receiving Report”. The contractor may not proceed with any repairs or part replacement until the government provides authorization to proceed.

3.8 Pump/Pump Unit: Pump

3.9 Pump Assembly: The Contractor shall assemble the pump/pump unit in accordance OEM technical specifications and procedures.

3.10 Pump/Pump Unit QA Tests: After assembly of the pump, the Contractor shall accomplish the tests listed below for each designated pump/pump unit. At the Coast Guard’s discretion, a QAR will witness and or verify inspections and tests conducted by the Contractor to prove satisfactory operating condition. The Contractor shall provide all labor, material and place of service to conduct the tests.

3.11 Rotation Test: To ensure the pump turns freely, the pump shaft shall be rotated a minimum of five revolutions by the use of a strap wrench or other non-damaging tool. The Contractor’s QA Representative shall inspect for smoothness of rotation and check for signs of binding or dragging. Pumps which have reversible rotation shall be inspected to confirm proper rotation as which intended. The Contractor shall investigate any questionable test results and correct as necessary.

3.12 Hydrostatic Test: The Contractor shall conduct a hydrostatic test of the overhauled pump/pump unit using the OEM specified test fluid. The test shall be conducted to certify the integrity of the pump and seal area. The test shall be conducted at 150 percent of the rated working pressure or mechanical seal rating whichever is less. The test shall be conducted for a period of ten minutes and discontinued at any sign of leakage. The Contractor shall investigate and correct any leakage and retest the pump/pump unit.

3.13 Operational Test: In addition to the hydrostatic test, the pump shall be operationally tested by the use of compatible OEM recommended test fluid. Each operational pump test shall be conducted, recorded and reported in accordance with the American National Standards Institute (ANSI)/HI 3.6 Rotary Pump Tests to performance test type 3, level A.

3.14 QA Test Documentation: The test results shall be documented on a report in accordance with (ANSI)/HI 3.6 Rotary Pump Tests document and provided to the KO. A copy of the test report shall be packed with each pump/pump unit and a copy shall be available to the QAR for review.

3.15 Paint: The Contractor shall prepare the exterior pump housing for preservation in accordance with SSPC-SP-3. The Contractor shall apply primer and finish coats of paint to the entire pump/pump unit external housing (excluding flange faces and shaft). The primer coat shall be 5-6 mils dry film thickness (DFT) of any rust preventive metal primer suitable for use with the finish coat. The finish coat shall be 3-6 mils DFT of silicone alkyd enamel, Type II or III, Class I or II. The color shall be purple, color number 17142 per Federal Standard, FED-STD-595C. Total paint thickness shall be a minimum of 8-12 mil DFT. The pump/pump unit shall be painted after all tests are complete.

4 NOTES: Not applicable

WORK ITEM 4: 270’ Fuel Transfer Pump Overhaul

NSN 4320-01-118-6395

Worthington Pump P/N B7793014-1

1. SCOPE

1.1 Intent: This work item describes the requirements for the Contractor to disassemble, overhaul, assemble, paint, test, prepare for delivery, and ship the designated Fuel Oil Transfer Pump. This WI shall be used in conjunction with the “General Requirements” included in this specification package.

1.2 Government-Furnished Material: None.

1.3 Mandatory Replacement Parts:

1.3.1 Contingency Replacement Parts:

COAST GUARD DRAWINGS: Not applicable.

COAST GUARD PUBLICATIONS: Not applicable.

OTHER REFERENCES:

The Society for Protective Coatings (SSPC) Surface Preparation Specification No.3 (SSPC-SP3), 2004, Power Tool Cleaning.

Federal Standard, FED-STD-595C, dated 01/16/2008, Colors Used in Government Procurement.

American National Standards Institute (ANSI)/HI 3.6 Rotary Pump Test, dated 2000.

3.1 General: The Contractor shall disassemble, overhaul, assemble, paint, test, prepare for delivery, and ship the designated fuel transfer pump/pump assembly. The Contractor shall accomplish the specified requirements of this WI in conjunction with the “General Requirements” included in this specification package for each designated pump.

3.2 Quality Product: The overhaul requirements described herein are considered to be the minimum acceptable and are not intended to replace any procedures, controls, examinations or tests normally conducted by the Contractor to assure the quality of the product.

3.3 Inspection Reports: The Contractor shall receive, open and inspect each pump in accordance with the “General Requirements” in this specification package regarding any required inspection reports.

3.4 Motor Overhaul: N/A.

3.5 Verify Specifications: The following items shall be inspected to confirm proper dimension, tolerance and run-out in accordance with the manufacturer’s recommendation

A. Rotors B. Rotor Shafts C. Drive and Driven Shafts D. Bearing Housings E. Shaft Sleeves F. Impellers G. Volutes H. Gears

All discrepancies shall be documented and submitted on a CFR within 10 days of submitting the Receiving Report and include specific details along with recommended repair procedures and price quoting.

3.6 CG Inspection: The Contractor shall provide at least a ten day advance notice to the KO prior to conducting pump unit tests and inspections in preparation for CG QAR inspections. All inspection and test results shall be made available for review by the QAR upon request.

3.7 Replacement Parts: Section 1.3 lists “Mandatory Replacement Parts” in this work item. Section 1.3.1 lists any “Contingency Parts” that may need replacement. Before any “Mandatory or Contingency Parts” are replaced the Contractor must submit a CFR listing the “Contingency” parts being recommended for replacement and the reason for replacement. This CFR must be submitted within 10 days of the “Receiving Report”. The contractor may not proceed with any repairs or part replacement until the government provides authorization to proceed.

3.8 Pump/Pump Unit: Pump.

3.9 Pump Assembly: The Contractor shall assemble the pump/pump unit in accordance OEM technical specifications and procedures.

3.10 Pump/Pump Unit QA Tests: After assembly of the pump, the Contractor shall accomplish the tests listed below for each designated pump/pump unit. At the Coast Guard’s discretion, a QAR will witness and or verify inspections and tests conducted by the Contractor to prove satisfactory operating condition. The Contractor shall provide all labor, material and place of service to conduct the tests.

3.11 Rotation Test: To ensure the pump turns freely, the pump shaft shall be rotated a minimum of five revolutions by the use of a strap wrench or other non-damaging tool. The Contractor’s QA Representative shall inspect for smoothness of rotation and check for signs of binding or dragging. Pumps which have reversible rotation shall be inspected to confirm proper rotation as which intended. The Contractor shall investigate any questionable test results and correct as necessary.

3.12 Hydrostatic Test: The Contractor shall conduct a hydrostatic test of the overhauled pump/pump unit using the OEM specified test fluid. The test shall be conducted to certify the integrity of the pump and seal area. The test shall be conducted at 150 percent of the rated working pressure or mechanical seal rating whichever is less. The test shall be conducted for a period of ten minutes and discontinued at any sign of leakage. The Contractor shall investigate and correct any leakage and retest the pump/pump unit.

3.13 Operational Test: In addition to the hydrostatic test, the pump shall be operationally tested by the use of compatible OEM recommended test fluid. Each operational pump test shall be conducted, recorded and reported in accordance with the American National Standards Institute (ANSI)/HI 3.6 Rotary Pump Tests to performance test type 3, level A.

3.14 QA Test Documentation: The test results shall be documented on a report in accordance with (ANSI)/HI 3.6 Rotary Pump Tests document and provided to the KO. A copy of the test report shall be packed with each pump/pump unit and a copy shall be provided to the QAR.

3.15 Paint: The Contractor shall prepare the exterior pump housing for preservation in accordance with SSPC-SP-3. The Contractor shall apply primer and finish coats of paint to the entire pump/pump unit external housing (excluding flange faces and shaft). The primer coat shall be 5-6 mils dry film thickness (DFT) of any rust preventive metal primer suitable for use with the finish coat. The finish coat shall be 3-6 mils DFT of silicone alkyd enamel, Type II or III, Class I or II. The color shall be yellow, color number 13538 per Federal Standard, FED-STD-595C. Total paint thickness shall be a minimum of 8-12 mils DFT. The pump/pump unit shall be painted after all tests are complete.

4. NOTES: Not applicable

WORK ITEM 5: 270’ A/C Chill Water Pump Unit Overhaul

NSN 4320-01-121-9680

Worthington Pump, P/N D-1131 3x1 1/2x6

1. SCOPE

1.1 Intent: The Contractor shall disassemble, overhaul, assemble, paint, test, prepare for delivery, and ship the designated A/C chill water pump/pump assembly. This WI shall be used in conjunction with “General Requirements” included in this specification package.

1.2 Government-Furnished Material: None.

1.3 Mandatory Replacement Parts:

1.3.1 Contingency Replacement Parts:

COAST GUARD PUBLICATIONS: Not applicable

OTHER REFERENCES:

The Society for Protective Coatings (SSPC) Surface Preparation Specification No.3 (SSPC-SP3), 2004, Power Tool Cleaning.

Federal Standard, FED-STD-595C, dated 01/16/2008, Colors Used in Government Procurement.

American Society of Mechanical Engineers, ASME international – PTC 8.2 Centrifugal Pump, dated 1990.

3.1 General: The Contractor shall disassemble, overhaul, assemble, paint, test, prepare for delivery, and ship the designated A/C chill water pump/pump assembly.