Specifications_for_Overhaul_of_L-3_AIS_TRANPONDERS_10-12-12_(FINAL).pdf

REVISION No. CHANGE NO. .

Repair and Overhaul of L-3 PROTEC AIS

TRANSPONDER

R-451-0638

ORIGINATED BY: PBPL-ELEX Team DATE OCT 12, 2012 .

UPDATED BY: DATE .

ORIGINATOR’S COMMAND Surface Forces Logistics Center (SFLC) .

DEPARTMENT / DIVISION Patrol Boat Product Line (PBPL) / ELEX .

INTERNAL REVIEWER ETC W. H. Mann DATE OCT 03, 2012 .

SFLC QA APPROVAL LT B. R. Clemons DATE OCT 03, 2012 .

SWORB APPROVAL DATE .

1.0 SCOPE

1.1. General – This overhaul specification sets forth the requirements for the receipt, cleaning, disassembly, inspection, condition/test reports, overhaul, reassembly, testing, preservation, packaging, packing, marking and bar-coding of the PROTEC AIS Transponders used fleet wide on all Coast Guard vessels.

1.2. Government Furnished Property (GFP) – The listed item is managed by the Coast

Guard Surface Forces Logistics Center at Curtis Bay, MD.

a. National Stock Number: NSN: 6610-01-536-2446 Item Name: PROTEC AIS Transponder Part Number: AISA100094, AISA100090 or AISA300090 Manufacturer: L-3 Aviation Recorders Application: Fleet wide AIS

1.2.1. Descriptive Data – PROTEC AIS Transponder

a. All references to AIS Transponder shall include all internal parts. The cost estimate and overhaul shall include these items.

2.0 APPLICABLE DOCUMENTS

2.1. General – The documents listed in this section are specified in sections 3, 4, and 5 of this repair/overhaul 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 ensure the completeness of this list, document users are cautioned that they must meet all specified requirements cited in sections 3, 4, and 5 of this specification, whether or not they are listed.

2.1.1. Government Documents – The following specifications, standards, publications, and handbooks form a part of this repair/overhaul specification to the extent specified herein. Unless otherwise specified, the versions in effect are those listed in the GSA Index of Federal Specifications, Standards and Commercial Item Descriptions or the current Department of Defense Index of Specifications and Standards (DODISS), and supplements thereto, cited in the solicitation or contract.

2.2. Coast Guard Documents – The following documents form a part of this repair/overhaul specification to the extent specified herein. The documents listed shall be by title and effective date unless otherwise documented.

2.2.1. Specifications

a. USCG-SFLC SPECIFICATION D-000-0100 Rev. G, Change 1, Dated 03/06, Bar Coding for USCG Surface Forces Logistics Center material.

2.2.2. Technical Publications

a. TP: E-441-076 AUTOMATIC IDENTIFICATION SYSTEM (AIS) PRO

TEC, Rev 08, Dated 01/09

b. TP: E-441-081 PROTEC – (AIS) QUICK INSTALLATION MANUAL, Initial Issue, Dated 06/04

c. TP: E-441-081 PROTEC - (AIS) WITH BLUE FORCE TRACKING -

INSTALLATION & OPERATION MANUAL, Rev 11, Dated 06/09

d. TP: E-441-081 PROTEC - (AIS) - "STEDS" PROGRAMMING

PROCEDURES, Initial Issue, utilizing “STEDS” Version 1.6.43

Note: All OEM specific repair manuals. Repair manuals not held by USCG due to proprietary property.

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

2.3.1. Federal Specifications

a. IMO MSC.74(69) Annex 3, IEC 61993-2

b. ITU.RM.1371-1

2.3.2. Military Specifications

a. FIPS 140-2 Validation Certificate (Encryption Certification)

1. Certificate No. 1096

b. MIL-STD-2073-1E, Version C, Dated 10/96, Standard Practice for Military

Packaging

c. MIL-STD-129 P, Version P, Dated 09/07, Marking for Shipment and Storage

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

2.4.1. American National Standards Institute (ANSI)/ National Conference of Standards

Laboratories (NCSL)

a. ANSI/NCSL Z540-1-1994 Dated 08/94, Calibration Laboratories and Measuring and Test Equipment – General Requirements.

2.4.2. American Society for Quality Control (ASQC)

a. ANSI/ASQC Z1.4-1993, Dated 01/93, Sampling Procedures and Tables for

Inspection by Attributes.

b. ANSI/ASQC Q9001-1994, Dated 01/94, Quality Systems – Model for Quality Assurance in Design, Development, Production, Installation, and Servicing.

c. ANSI/ASQC Q9002-1994, Dated 01/94, Quality Systems – Model for Quality

Assurance in Production, Installation, and Servicing.

d. ANSI/ASQC Q9003-1994, Dated 01/94, Quality Systems – Model for Quality Assurance in Final Inspection and Test.

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

2.6. Order of Precedence – In the event of a conflict between the text of this repair/overhaul specification and the references cited herein, this specification shall take precedence, unless otherwise specified herein. Nothing in this specification, however, supersedes applicable laws and regulations unless a specific exemption has been obtained.

3.0 REQUIREMENTS

3.1. General – Contractor shall provide all labor and materials to perform repair/overhaul services on the L-3 Aviation Recorders PROTEC AIS Transponder, listed in section 1.2 and in accordance with all applicable documents listed in section 2.0 and this specification.

3.2. Responsibility for GFP – Contractor shall provide protective storage for the GFP when not in use, and safe handling when in use.

3.2.1. The storage area shall at a minimum be closed on all sides, protected from the weather and locked when the equipment is not in use or being serviced.

3.3. Arrival Inspection – Contractor shall conduct an arrival inspection to determine the

PROTEC AIS Transponder conforms to the description in section 1.2.

3.3.1. The assembly delivered for repair/overhaul services is intended to be a complete L-3 Aviation Recorders PROTEC AIS Transponder.

3.3.2. The Contractor shall notify the Contracting Officer via Government Property

Discrepancy Report within ten (10) calendar days of receipt verifying the units received are correct and identify any missing components, incorrect items or, otherwise questionable conditions that may hinder the repair/overhaul process or the make and/or model delivered for repair/overhaul services do not conform to the intended make and/or model cited in section 1.2.

a. If after arrival inspection the item received is not as listed in section 1.2 the

Contractor shall prepare the item for shipment back to SFLC Baltimore, MD in accordance with the Contracting Officer’s instructions.

3.4. Initial Disassembly, Inspection and Estimate (Repair/Overhaul) – Contractor shall disassemble, clean and inspect the AIS Transponder to obtain the overall condition and determine the estimated cost of a repair/overhaul. A detailed Open and Inspect Report (OIR) and repair plan including replacement parts, materials, labor, overhaul, testing, preservation, packaging, packing, marking, and bar-coding shall be submitted to the Contracting Officer for approval within 60 calendar days of receipt. Repair/Overhaul is intended to restore the AIS Transponder to a condition that is equal to that of a new L-3 Aviation Recorders PROTEC AIS Transponder Part Number: AISA100094, AISA100090 or AISA300090. Contingency replacement parts shall be listed, priced and submitted with the initial inspection report and estimate. No further work shall be accomplished until the report is approved in writing by the Contracting Officer.

a. The OIR and repair plan shall consist of, at a minimum, the following information:

1. Date of Inspection

2. Identification of base units by serial number, part number and stock number.

3. Condition of shipping crate and any cost for repair or replacement.

4. Pricing for standard repair/overhaul.

5. List and pricing of any replacement parts, if required.

6. Repair/Overhaul labor hours

7. Labor rate.

8. Comments if any pertaining to unusual observations during inspection and disassembly.

3.5. Replacement Parts – All replacement parts used for this specification shall be new Original Equipment Manufacturer (OEM) parts. Reclaimed, recycled or aftermarket parts are not acceptable and shall not be used. The repair/overhaul facility or any sub-contractors shall not manufacture parts to be used on repaired/overhauled assemblies.

3.5.1. Label Plates: A new label plate shall be used if the original plate is not legible or in poor condition. The label plate shall contain AIS Transponder unit make, model number, part number and serial number.

3.6. AIS Transponder Disposition – The Coast Guard shall determine the disposition of any

AIS Transponder unit delivered to the repair/overhaul facility that is found to be not suitable for repair/overhaul for whatever reason.

3.6.1. If the Contracting Officer deems the AIS Transponder beyond economical repair/overhaul. The following shall be used to dispose of the AIS Transponder at the Contracting Officer’s discretion:

a. Reassemble, repackage, mark “Condition S” and return the AIS Transponder to USCG SFLC Baltimore, MD as scrap.

3.7. Testing Requirements – After completion of repair/overhaul, Contractor shall conduct an operational test of the AIS Transponder in accordance with OEM testing requirements per the Manufacturers Technical/Service Manuals. All testing shall be accomplished using Contractor supplied calibrated test equipment.

3.8. Inspection and Test Report – If the Contracting Officer deems an onsite evaluation to be necessary, a detailed inspection and test report shall be submitted to the Contracting Officer via a modified OIR for approval prior to scheduling SFLC quality assurance personnel. The inspection and test report shall contain the following information as a minimum:

a. Contractor name, address and telephone number.

b. Contract number and delivery order number as applicable.

c. AIS Transponder model, serial number, & bar code.

d. Date of test

e. Description and results of each test conducted.

f. Name of the person conducting the testing.

g. Test equipment used, nomenclature, serial number, and calibration date.

3.8.1. The inspection report shall depict the condition of the AIS Transponder after all work has been completed.

3.8.2. All defects, if any, even those deemed acceptable, shall be documented on the inspection report.

a. Acceptable defects include but not limited to: cosmetic defects such as scuffing on casing.

b. Acceptable defects are subject to approval by the Contracting Officer.

3.8.3. Contractor shall provide written certification that the AIS Transponder was reconditioned to the same standards as new. One copy shall be placed in the package with the AIS Transponder in a water proof envelope and one copy shall be provided to the Contracting Officer.

3.9. Calibration – All test equipment shall be calibrated and have a current calibration sticker attached. Calibration shall be traceable to ANSI Standards and shall be made available upon request by Contracting Officer as per Section 6.1.2.d.

3.10. Assembly – The repaired/overhauled AIS Transponder shall be delivered to the Coast

Guard completely assembled, clean and ready for installation. The Contractor shall preserve, package, pack, mark and bar-code each AIS Transponder in accordance with section 5.0 of this specification.

3.10.1. Contractor shall supply a waterproof instruction sheet containing the manufacturer’s set up procedure. The sheet shall be placed with the AIS Transponder inside a polyurethane bag.

3.11. Notifications and Inspections – Contractor shall notify the Contracting Officer no less than ten (10) calendar days prior to any required inspections and/or monitored testing required herein by Coast Guard Quality Assurance (QA) personnel.

4.0 QUALITY ASSURANCE

4.1. General – 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, meet the requirements of ASQ-Q9003 and be available for review by the Coast Guard.

4.2. Records – Contractor shall maintain records of all inspections and tests. The records shall indicate the nature and number of performed observations, the number and type of deficiencies found and the corrective action taken.

4.3. Calibration System – Contractor, as well as any subcontractors, shall maintain a test equipment calibration program in compliance with NCSL Z540.3. The program shall be documented and traceable to the National Institute of Standards and Technology (NIST).

4.3.1. The calibration system records shall be maintained for inspection for the duration of any contract referencing this overhaul specification.

4.4. Responsibility for Inspection – Contractor shall be responsible for the performance of all inspection requirements specified herein. Contractor shall provide space, personnel and test equipment to conduct all inspection requirements. All inspection and testing shall be performed at the Contractor’s facility prior to the Coast Guard’s acceptance of the contracted items. The Coast Guard reserves the right to have a Government designated Quality Assurance Representative on hand to witness, verify, or have performed any of the inspections set forth herein where such inspections are deemed necessary to assure that supplies and services conform to prescribed requirements.

Contractor shall notify the Contracting Officer prior to the scheduled commencement of any inspections required by this repair/overhaul specification, to allow for observation of testing when the Contracting Officer deems it necessary.

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 requirement in this 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. Inspections & Tests – The inspections & tests required herein are the minimum necessary and are not intended to replace any controls, examinations, or tests normally employed by the Contractor to assure the quality of the product. The following inspections and documentation may be witnessed or observed by an SFLC Quality Assurance Representative IAW section 3.0 of this repair/overhaul specification at the discretion of the Contracting Officer:

a. Test requirements as described in section 3.7.

b. Calibration certificates as listed in section 3.9.

c. Inspection of preservation, packing, packaging, marking and bar-coding in accordance with section 5.0.

4.7. Failure Responsibility – If an AIS Transponder fails to pass inspection or test after completion of repairs/overhaul listed in the initial OIR, the Contractor shall report the failure via a modification to the original OIR and their recommended fix to the Contracting Officer.

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

4.8. Warranty – The Contractor’s standard new AIS Transponder warranty applies as per section 3.4.

4.9. Packing and Packaging Inspection – If deemed necessary, the Contracting Officer shall be notified ten (10) days prior to the packing, packaging, marking and bar-coding of the repaired/overhauled AIS Transponder.

5.0 PRESERVATION, PACKAGING, PACKING, MARKING AND BAR-CODING

5.1. General – Each repaired/overhauled AIS Transponder shall be cleaned, preserved, packaged, packed, marked and bar-coded as specified herein.

5.1.1. A copy of the test data record sheet (see 3.8.3) shall be included in the container.

5.1.2. If the Contracting Officer does not elect to have a Coast Guard Quality Assurance

Representative perform on site inspection of the preservation, packing, packaging, and marking, the Contractor shall document the process using digital pictures, and shall submit those pictures to the Contracting Officer for review and acceptance prior to shipping if deemed necessary.

5.2. Preservation – Each repaired/overhauled AIS Transponder will be placed in warehouse storage and not for immediate installation. The repaired/overhauled AIS Transponder shall be individually preserved and wrapped for protection against moisture and deterioration for a period of two (2) years minimum.

5.2.1. Electronic equipment susceptible to damage by environmental field forces.

Sensitive electronic devices and other items susceptible to environmental field force damage (electrostatic fields, electromagnetic fields, or magnetic fields, or combinations of these fields) shall be protected in accordance with MIL-STD- 2073-1E as referenced in section 2.3.2.

5.3. Packaging and Packing – All items repaired/overhauled shall be individually packaged and returned in new OEM provided packaging.

5.3.1. Contractor shall put a waterproof instruction sheet describing the manufacturer’s set up procedures in a polyurethane bag in accordance with section 3.10.1.

5.3.2. Intermediate and exterior packing. Unit packs shall be packed in exterior shipping containers, meet common carrier acceptance and provide safe delivery to destination.

5.4. Marking – The marking described herein shall be placed in the upper left-hand side of the two longest sides of each box (on opposite ends) and include the requirements of section 5.5 of this specification. Markings shall be such that the lettering is highly contrasted from the marking field.

5.4.1. These markings shall consist of the NATIONAL STOCK NUMBER, ITEM

NAME, PART NUMBER, CONTRACT NUMBER, GROSS WEIGHT (in lbs.,) condition code i.e. CONDITION “A”, unit of issue with quantity (1-EA) and the words COAST GUARD SFLC MATERIAL.

a. The markings shall be in the format as follows:

STOCK NUMBER: NSN: 6610-01-536-2446

ITEM NAME: PROTEC AIS Transponder PART NUMBER: AISA300090 (as applicable)

SERIAL NUMBER: (as applicable)

CONTRACT NUMBER: SEE CONTRACT

SHIPPING WEIGHT: CONTRACTOR PROVIDE

CONDITION CODE CONDITION “A”

QUANTITY & UNIT OF ISSUE 1 - EACH

COAST GUARD SFLC MATERIAL

5.4.2. MULTIPAK – If the preserved and packaged item is combined in a container with other like items the marking on this “multi-pack” shipping container shall consist of the STOCK NUMBER,ITEM NAME, CONTRACT NUMBER, SHIPPING WEIGHT (total), condition code and the words COAST GUARD

SFLC MATERIAL.

a. The markings shall be in the format as follows:

STOCK NUMBER: NSN: 6610-01-536-2446

ITEM NAME: PROTEC AIS Transponder PART NUMBER: AISA300090 (as applicable) SERIAL NUMBER: (as applicable)

CONTRACT NUMBER: SEE CONTRACT

SHIPPING WEIGHT: CONTRACTOR PROVIDE

CONDITION CODE CODITION “A”

QUANTITY & UNIT OF ISSUE 1 - EACH

COAST GUARD SFLC MATERIAL

5.5. Bar Coding – The National Stock Number (NSN) shall also be bar coded in addition to the markings required above. Bar coded labels shall be in accordance with SFLC specification D-000-0100 Rev. G. The Bar Code Label can be applied separately or as part of the marking required in 5.4 of this specification.

a. The actual labels shall be Type "V", Grade "C", Style "2", Composition "a".

b. Each label shall contain encoded data for the National Stock Number.

5.6. Coast Guard Acceptance – Acceptance will be made at destination by a government representative. Acceptance will be contingent upon representative's verification of no damage in transit, correctness and completeness of order and Contractor’s conformance to preservation, packaging, packing, marking and bar-coding requirements.

6.0 NOTES

6.1. Government and 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 410-590-7143 (E.S.)

ATTN: Patrol Boat Product Line

6.1.2. Commercial Documents

a. Society of Automotive Engineers INC. (SAE)

400 Commonwealth Drive Warrendale, PA. 15096 412-776-4841

FAX 412-776-5760

b. American Society for Testing & Materials (ASTM) 1916 Race Street Philadelphia PA. 19103-1187 215-299-5585

FAX 215-977-9679

c. American Boat & Yacht Council (ABYC) 3069 Solomon’s Island Rd.

Solomon's Island, MD.

301-261-7150

d. American National Standards Institute (ANSI) 1430 Broadway New York, NY 10018 212-642-4900

e. American Society for Quality Control (ASQC) 611 East Wisconsin Avenue

Milwaukee Wisconsin 53202 800-514-1654

Deliverable List

ITEM DESCRIPTION UNIT PRICE UNIT EST

QTY

EXTENDED

PRICE

CLIN

NSN 6610-01-536-2446 - P/Ns AISA1000094, AISA100090 or AISA300090, Transponder - Open and Inspect charge per unit. Labor to inspect the condition of the shipping container, un-pack the Transponder, inspect for missing/unacceptable parts and prepare and submit the Inspection Report for approval. This is required for each Transponder inducted for repair in accordance with Specification R-451-0638 for the Repair of Electronic Equipment and Modules included as Attachment 1.

Number Loaded Shop of Hours x Labor Rate

_______ x

Unit = Price

125 $

CLIN

Open and Inspection Report submitted for Approval as stated in CLIN 0001.

1 Each - Not Separately Priced

CLIN

Beyond Economical Repair (BER) - Furnish necessary labor to re-pack any Transponder and prepare for shipment any Transponder determined by the Coast Guard to be BER.

Number Loaded Shop of Hours x Labor Rate

_______ x

1 $

CLIN

Labor - Labor cost to complete repair of each Transponder inducted for repair, including delivery in accordance with Attachments 1 and 2.

This price shall include all inspections, testing, test reports, preserving, packaging and marking of the Transponders in accordance with said Attachments.

Number Loaded Shop of Hours x Labor Rate

_______ x

125 $

Deliverable Schedule

CLIN Description Estimated Quantity/Unit

Within Days After Date of Contract

0001-4001 Labor to inspect & report condition of Transponder(s).

As required 45 calendar days after receipt of government property

0002-4002 Open and Inspection Report for Approval (OIR)

As required 60 calendar days after receipt of government property

0003-4003 Prepare of shipment and re-pack Transponder(s) not repairable (BER)

As required 30 calendar days after notification from the Contracting Officer

0004-4004 Delivery of repaired Transponder(s)

As required 60 calendar days after approval of the Inspection Report by the Contracting Officer

GFP furnished under this contract shall be:

NSN

Part Number Description Quantity Value Each

Estimated Weight Each

6610-01-536-2446 AISA1000094 Transponder 1 $4,121.00 5.6 lbs.

6610-01-536-2446 AISA100090 Transponder 1 $4,121.00 5.6 lbs.

6610-01-536-2446 AISA300090 Transponder 1 $5,751.00 5.6 lbs.