Roll-Royce_Kamewa_water_jet_FF375S.pdf

USCG-SFLC

09 MAY 2013

REVISION NUMBER ______

ROLLS-ROYCE OVERHAUL / RECONDITION SPECIFICATION FOR

WATER JET FF375S COMPONENTS

ORGINATED BY: MKC TOM ANDERSON DATE: 09MAY2013

UPDATED: ________

ORIGINATOR’S COMMAND

DEPARTMENT / DIVISION SBPL-CEO

INTERNAL REVIEWER DATE

SWORB APPROVAL DATE

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ROLLS-ROYCE OVERHAUL / RECONDITION SPECIFICATION

1.0 SCOPE

1.1. General -This document sets forth the requirements for the overhaul / recondition of the following parts to Original Equipment Material (OEM) specifications, and standards:

(P/N=Part Number, S/N=Stock Number)

a. Reversing Cylinder P/N 10121038 S/N 2010-01-590-4296

b. Impeller Housing P/N 37500315 S/N 4320-01-590-7310

c. Impeller P/N 5481295 S/N 4140-01-590-4289

d. Guide Vane Chamber P/N 37618602 S/N 2990-01-590-4492

e. Steering Nozzle P/N 37501113 S/N 2010-01-590-4266

f. Reversing Bucket (PORT) P/N 37506818 S/N 2010-01-590-4535

g. Reversing Bucket (STBD) P/N 37506814 S/N 2010-01-590-4246

h. Bearing Housing P/N 45001815 S/N 3130-01-590-4525

The above parts shall be opened, disassembled, inspected, reported, overhauled / reconditioned, tested, serialized, preserved, packaged, marked, tracked and shipped back to the U.S Coast Guard Yard Baltimore, MD.

2.0 APPLICABLE DOCUMENTS

2.1. Document Availability – To obtain the referenced documents see section 3.8

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 current Department of Defense Single Stock Point (DODSSP) for military specifications, standards, and related publications.

2.3. Military Specifications

a. MIL-STD-2073-1E, Dated May 2008, Standard for Military Packaging

2.4 Commercial Documents – The Following documents form a part of this specification to the extent specified here. The documents shall be the version listed by number and date from the referenced industry organization. Commercial documents may be listed in the Department of Defense Single Stock Point (DODSSP)

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a. American National Standards Institute (ANSI)/ National Conference of Standards Laboratories (NCSL)

b. ANSI/NCSL Z540, Dated 2006, Requirements for the Calibration of Measuring and Test Equipment

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

d. ANSI/EASA AR100, Dated 2006, Recommended Practice for the Repair of Rotating Electrical Apparatus

e. American Society for Testing and Materials (ASTM)

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

2.5.1 Departure from Specification - Departure from this specification shall not be allowed unless approved by the Coast Guard Contracting Officer.

a. If the contractor finds it necessary to implement change or depart from applicable specifications, they shall request permission.

b. Request for change by contractors shall clearly describe the changes proposed, the reasons for and advantages of the changes proposed, and the contract’s price increase or decrease (if any) that would result.

3.0 REQUIREMENTS

3.1. General - The contractor shall open, disassemble, inspect, report, recondition / overhaul, test, serialize, preserve, package, mark, track and ship each part within 45 days of receipt date. The contractor shall provide all labor, equipment, special tools, parts and materials required to accomplish the following:

a. Receive a part listed in section 1.1

b. Overhaul / Recondition the part to like new condition

c. Perform Final Inspection

d. Perform internal Preservation if applicable

e. Perform External Preservation if applicable

f. Apply Serial Number / Information

g. Package For Shipping

h. Preserve and Properly Label Shipping Container

i. Ship back to Surface Forces Logistics Center

Receiving Room- BLDG. 88 2401 Hawkins Point Road Baltimore, MD 21226

3.2. Government Furnished Property – The Government reserves the right to supply Government Furnished Property (GFP) at anytime during the existence of this contract. The contractor shall provide protective storage for the GFP when not in use, and safe handling when in use.

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3.2.1. The storage area shall at a minimum be closed on all sides, dry, and locked when unattended.

3.3. Internal Inspection – For any part overhauled / reconditioned that exceed 65% of the replacement value; a report must be completed using (Appendix A), and shall be submitted to the COTR for authorization to dispose or return.

3.4. Overhaul / Recondition Parts – The contractor shall use only Rolls-Royce OEM parts and service techniques which meet the OEM specifications and standards. All parts shall be inspected for critical dimensions and wear limits and replaced as authorized by the Contracting Officer (C.O.) to meet OEM recondition / overhaul specification and parameters.

3.5. Technical Representative Services – When requested by the Contracting Officer, the

Contractor shall provide OEM certified personnel for discussion on anything pertaining to this contract, work performed, including warranty, repairs and advice with technical problems. Troubleshooting and repair of technical problems may require Contractor personnel to travel to Coast Guard units. In correcting technical problems the Contractor shall abide by the following:

3.6.1. Technical Services Performed Onsite – The Contractor shall perform all services onboard the USCG vessel unless otherwise directed by the Contracting Officer.

Locations – The services shall primarily be required in vessel homeports located throughout the continental United States, Hawaii and Alaska.

Contractor Response – The Contractor shall be required to contact the designated location needing technical assistance within 24 hours after notification by the Contracting Officer. The Contracting Officer shall establish the dates the Technical Representative is required.

The results of the Representative's findings shall be provided in writing within 48 hours of arrival. Approval to perform repairs will be made by the Contracting Officer after evaluation from the USCG Contracting Officer’s Technical Representative.

3.8. Documentation – This specification sets forth the requirements for the following documentation.

a. Cumulative Tracking Report, in accordance with Appendix A

b. Warranty Report for Coast Guard unit Appendix B

c. “F” Condition Coast Guard unit Shipping Report Appendix C

d. Mandatory Parts Replacement and Special Instruction Appendix D

e. Serial Number Reconditioned Parts Appendix E

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3.10. Cumulative Tracking Report – The contractor shall maintain and submit, by the 15th of each month, to the COTR, the Cumulative Tracking Report, Appendix A, for all parts received and in possession of pertaining to this contract.

3.11. Warranty - A warranty of twelve months from date of installation. The inception date of the warranty will commence on the date of installation of the unit into the vessel. The inception date may be delayed without additional preservation of the unit for twenty four months of storage. Storage commences upon receipt of part at the designated Coast Guard facility warehouse. This warranty covers the entire reconditioned / overhauled part. The contractor shall work with SFLC’s Contracting Officers Technical Representative (COTR) to evaluate the contractors proposed duration of warranty repair time.

Following acceptance of a warranty claim by the contractor, in the event the Coast Guard decides the proposed warranty repair time compromises the Coast Guards mission and decides on removal and or replacement, the contractor shall coordinate and fund all necessary shipping arrangements for the failed part to be returned to the contractor’s facility for repairs and returned to the designated Coast Guard facility agreed upon after repairs have been completed.

The contractor shall repair / recondition the part to the condition level necessary for the contractor to honor a new full warranty. In the event that the work is found not to be warranted, the contractor shall stop work immediately and contact the Contracting Officer for authorization. In the event that full restoration or reconditioning of the part to full warrantable condition requires more extensive work than will be covered under the warranty, the contractor shall stop work immediately and contact the Contracting Officer for authorization.

The contractor shall submit to the Contracting Officer an inspection report for approval containing any parts and pricing for any work / repairs that are required that are not covered under warranty.

3.12. Notifications & Inspections – The contractor shall be responsible for notifying the Contracting Officer’s Contracting Officer’s Technical Representative (COTR) at least 10 calendar days prior to inspections or monitored testing required herein. At this time, prior to the arrival for inspection / testing, the contractor shall provide the exact inspecting / testing sheet with OEM specifications and parameters to the COTR via email attachment if applicable.

3.13. Failure Analysis - In the event of a failure, the Contractors “Technical Representative” shall determine the cause of casualty and corrective action. A report of the findings shall be submitted to the Contracting Officer.

4.0 QUALITY ASSURANCE

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4.1. General – The contractor shall maintain an inspection system, which shall insure that each item offered to the Coast Guard for acceptance, or approval conforms to the contract requirements and best commercial practices. The inspection system shall be documented, meet the requirements of ASQC-Q9003-1994 and be available for review by the Coast Guard.

4.2. Records – The contractor shall maintain records of all inspections and tests. The records at a minimum shall indicate the nature and number of observations made, the number and type of deficiencies found, and the corrective action taken.

4.3. Calibration System – The contractor, as well as any subcontractors, shall be required to maintain a test equipment calibration program in compliance with ANSI/NCSL Z540, Dated 2006. The program shall be documented and traceable to the National Institute of Standards (NIST).

4.4. Responsibility for Inspection – The contractor shall be responsible for the performance of all inspection requirements specified herein. The contractor shall provide space, personnel, and test equipment for conducting all inspection requirements. All inspection and testing shall be performed at the contractor location, or at other facilities acceptable to the Coast Guard. The Coast Guard reserves the right to verify or witness, any of the inspections that are deemed necessary to assure that supplies and services conform to the prescribed requirements.

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

4.6. Tests & Inspections – The inspections / tests is the minimum required to meet OEM specification, parameters and standards. This inspection / test is not intended to replace any controls, examination, inspections or tests normally employed by the contractor to assure the quality of the overhaul / recondition.

5.0 PRESERVATION, PACKAGING & MARKING

5.1. Internal Preservation – Preservation in accordance with O.E.M. instruction.

5.2. External Preservation – After completion of the internal preservation, the part shall be prepared in accordance with O.E.M. instruction.

5.3. Packing Inspection- The contractor shall use new packing for each part. Include with each packaged part a copy of Appendix C and Appendix D.

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5.4. Marking – Each preserved and packaged item shall be stenciled in black print lettering.

5.4.1. This marking shall consist of the STOCK NUMBER, PART NUMBER, MODEL

NUMBER, ITEM NAME, CONTRACT NUMBER, DELIVERY ORDER

NUMBER, GROSS WEIGHT (in lbs), CONDITION CODE, QUANTITY, UNIT

OF ISSUE, AND LABELED; COAST GUARD SFLC MATERIAL. EXAMPLE:

Stock Number (4320-01-590-7310)

Part Number (37500315)

Model Number (FF375S)

Item Name (Impeller Housing)

Contract Number See Contract

Delivery Order Number See Delivery Order

Shipping Weight As Determined By Contractor

Condition Code Condition “A”

Quantity & Unit of Issue 1 – Each

And the Following:

U.S Coast Guard SFLC Material

Fragile – Do Not Damage

6.0 NOTES

6.1. Government & Commercial Document Sources

6.1.1. Government Documents

a. Department of Defense Single Stock Point for Military Specifications, Standards, and Related Publications (DODSSP Documents) Http://dodssp.daps.dla.mil/

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b. DOD & Navy Publications and Forms (Other Than DODSSP) Naval Publication and Forms Center 5801 Tabor Ave.

Philadelphia, PA 19120 215-697-2000

c. USCG Surface Forces Logistics Center 2401 Hawkins Point Road Baltimore, MD 21226-5000 410-762-6229 ATTN: Contracting Officer SBPL

6.1.2. Commercial Documents

a. Society of Automotive Engineers INC. (SAE) 400 Commonwealth Drive Warren dale, 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 National Standards Institute (ANSI) 1430 Broadway New York, NY 10018 212-642-4900

d. American Society for Quality Control (ASQC) 611 East Wisconsin Avenue Milwaukee, Wisconsin 53202

6.2. Appendices – The following Appendices form a part of this specification.

Appendix A: Cumulative Tracking Report Appendix B: Warranty Report for Coast Guard Units

Appendix C: “F” Condition Coast Guard Unit Shipping Report Appendix D: Mandatory Parts Replacement and Special Instruction Appendix E: Serial Number Reconditioned Parts

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6.3. Glossary

a. Field Unit – United States Coast Guard units located throughout the fifty (50) United States and it territories.

b. O.E.M. – Original Equipment Manufacturer

c. O.E.P.L. – Original Equipment Parts List

d. Exchange – Exchange of used parts for original equipment manufacturer (OEM) parts.

e. Recondition – to restore to a good or satisfactory condition; repair; make over with O.E.M. parts to O.E.M. specifications.

f. Overhaul- to make necessary repairs on; restore to serviceable condition with O.E.M.

parts to O.E.M. specifications.

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APPENDIX A

CUMULATIVE TRACKING REPORT

SUBMIT BY THE 15TH OF THE MONTH

Part Number

Work Order

Delivery Order #

Date Received

Accepted Y/N

Percent Complete

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APPENDIX B

WARRANTY NOTICE

This item has a warranty for whichever comes first:

Twelve months of operation from installation

Two year storage from date SFLC received part from contractor

If any discrepancies are noted upon receipt

1. DO NOT REPAIR OR REPLACE!

2. CALL: USCG SURFACE FORCES LOGISTICS CENTER

CENTRAL ENGINE OVERHAUL

SMALL BOAT PRODUCT LINE (SBPL)

COMMERCIAL (410) 762-6089 / 6229

Have the following information ready when calling the (SBPL)

________ Date Received ________ Date Installed

________ Part Number ________ Vessel Home Port

________ Stock Number ________ Vessel Hull No

NOTES:

(1) Preventative Maintenance (PMS) should still be performed as per applicable Maintenance Procedure Cards (MPC’s). PMS does not void the warranty.

(2) If the above procedure is not followed, the warranty may be affected.

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APPENDIX C

FOR COAST GUARD UNITS ONLY

SHIPPING REQUIREMENTS FOR "F" CONDITION RETURNS

(“F” Condition = Broken, Used, Not ready for issue)

1. Call SBPL MTI Coordinator or visit http://10.38.65.78/WarehouseShipping/ApplicationHome.aspx for instructions.

2. Returned parts shall be crated and secured properly in the same package the new part came in.

3. Package is to be secured before shipping.

4. Change Package Marking from "A" Condition to "F" Condition (Black Marker).

5. Ensure any parts removed or swapped (if applicable) are reinstalled on the old part before shipping.

(Make the “F” Condition part complete as possible)

6. Any questions on these requirements please call the Central Engine Overhaul Warranty Phone Line @ 410-762-6089 / 6229.

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APPENDIX D

BEARING HOUSING ASSEMBLY

MANDATORY REPLACEMENT PARTS LIST

Manufacturer Rolls Royce Model Number FF375S Item Description Bearing Housing Assembly Part Number 45001815

No. Description Part No. Qty.

1 Plug 10203904S 04 2 Bolt Kit 93310025E 04 3 Cap 10203211 01 4 Mechanical Shaft Seal 10203870 01 5 Socket Head Screw 91208055 06 6 Seal Housing 45017001 01 7 O-Ring 10202631 01 8 Countersunk Screw 96305025 01 9 O-Ring 10202625 01 10 Gasket 41018801 01 11 Shaft Seal 10202590 02 12 Ball Bearing 10203480A 01 13 Bearing Cover 45004110 01 14 Gasket 45011611 01 15 Bearing Cover 45002010 01 16 Hexagon Nut 93416 12 17 Washer 912516 06 18 Stud Bolt 45002410 06 19 Lock Washer 10203012 01 20 Lock Nut 102 029 12 01 21 Shaft Sleeve 45002113 02 22 O-Ring 10202603 01 23 O-Ring 10202606 01 24 Lock Washer 10203008 01

Receive and Recondition Bearing Housing P/N 45001815. Add mandatory parts listed above, provide miscellaneous service below, and label as a kit using P/N 45008719.

Miscellaneous:

Torque plugs (4) 10203904

Press Shaft Seals (2) 10202590

Install Sealing (1) 41018801

Torque Allen Bolts (6) 91208055

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APPENDIX E

SERIAL NUMBER RECONDITIONED PARTS

1. Engrave or affix below information (A-E) that cannot easily be removed to overhauled assembly. This is so the item can be tracked for warranty purposes.

2. Example: Information from Section 1.1of this specification

a) (ITEM NAME) Reversing Cylinder

b) (PART NUMBER) P/N 10121038

c) (STOCK NUMBER) S/N 2010-01-590-4296

d) DATE OF OVERHAUL / RECONDITION

e) SERIAL NUMBER XXXX