WI_18_Single_Point_Davit_Procurement_Specification_-_Rev_1_Final_May_2015.docx

5/26/2015 Revision B Statement of Work INSPECTION and OVERHAUL of Appleton Marine – Davit, Single Point Slewing Arm – Model RAD30-15.5

1. Scope: This description covers the inspection, overhaul, upgrade, test, certification, preservation, packaging and marking of the item described below:

1.2. Government Furnished Equipment/ Information (GFE/GFI)

A. Crane, Electro-Hydraulic: 3810-01-495-8710 B. Conex shipping container 20 ft.

C. Coast Guard Technical Publication 3562 Tab 583B – Technical Manual for Davit, Single Point Slewing Arm – RAD 30-15.5, [BMD 477]

1.3. The complete RAD 30-15.5 davit unit consists of a structural davit assembly with Constant Tension winch and a Rotek bearing [which bolts atop a supporting pedestal], plus a deck mounted control console assembly, and supporting hydraulic accumulator, reservoir and hand pump which bolt to the supporting pedestal. The davit unit being overhauled does not include the supporting pedestal, the wiring harness between the davit assembly and the control console, or the hydraulic power unit which powers the davit. The davit is packaged inside of a 20 foot Conex container which does not have a unique stock number (when empty).

1.4. The original configuration RAD30-15.5 BMD 477 Rev 2 davit with CT winch controls based on a proprietary electronic board shall be revised to configuration BMD 710 with new PLC based CT winch controls. Additional RAD30-15.5 davits built to configuration BMD 507 may also be requested to be revised to configuration BMD 710. For tracking purposes, the configuration BMD 710 davit will be assigned a new National Stock Number (2030-01-F15-4314).

1.5. The total overhaul process shall include a) a Receiving Report supplemented by Open-and-Inspect / Condition Found Reports (CFR) for components not otherwise identified as being replaced, b) replacement of specified subsystems and components [known to be obsolete], and specified baseline overhaul requirements [described herein], c) correction of any CFR items [negotiated for each davit], and d) factory testing to demonstrate performance. The contractor shall provide a firm fixed price for the reports, baseline overhaul, and factory testing; pricing for CFR response items will be separately negotiated for each davit as a CLIN of this contract. The requirements described herein are intended to restore the davit including all sub-components to a like-new condition with an operational performance equal to that of a new davit. These requirements are not intended to replace any procedures, controls, examinations or tests normally employed by the contractor to assure the quality of the product.

1.6. It is the intent of this contract to install a Constant Tension Winch and constant tension winch controls based on the successful winch and control system previously provided to the Government on APPLETON davit model FB20-21. The winch and control system shall utilize FB20-21 components already supported, to the extent practicable.

1.7. The Contractor shall provide a modified technical publication, based on the original BMD 477 configuration, as amended to reflect the BMD 710 configuration. The Coast Guard will promulgate the Technical Publication under a new document number. The Contractor shall provide Provisioning and Technical Documentation for new components not previously documented for the BMD 477 configuration.

2. Applicable Documents

2.1. Document availability – To obtain copies of documents see section 6.

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

2.2.1. Coast Guard Drawings and Documents

A. Coast Guard Technical Publication 3562-583-B, Technical Manual for Davit, Single Point Slewing Arm – RAD 30-15.5, [BMD 477] B. Coast Guard Technical Publication 3720-583-A, Technical Manual for Davit, Single Point Slewing Arm – RAD 30-15.5. [BMD 507] C. Coast Guard Technical Publication 3554-556-D, Hydraulic Power Unit.

D. Coast Guard Technical Publication 4924-583-A, Folding Boom Crane, 270’ WMEC (A) and (B) Class Cutters, 2010.

E. SFLC Standard Specification 6310, Requirements for Preserving of Ships Structures.

F. SFLC Technical Standard TS 085, Engineering Drawings, 6/11/2013.

G. SFLC Technical Standard TS 085-1, Illustrated Parts Breakdown (IPB), 7/17/2013.

H. SFLC Technical Standard TS 305, Electrical and Electronic Designating and Marking, 3/17/2014.

I. SFLC Technical Standard TS 505-2, Hoses and Expansion Joints, 7/17/2013.

J. SFLC Specification D-083-351, Data for Provisioning, 2000 edition.

K. SFLC Specification D-084-481, Preservation and Packaging, Engineering Change Unit, 2012 edition.

L. SFLC Specification D-085-482, Drawings for Auxiliary Machinery, 2006 edition.

M. SFLC Specification D-086-483, Technical Publication Requirements for Auxiliary Machinery, 2006 edition.

N. COMDTINST M9085.1C, Naval Engineering Computer Aided Design Standards.

2.2.2. Specifications, Federal

A. Federal Standard, FED-STD-595B and change notice 1, Colors used in government procurement.

B. DI-GDRQ-81224, Functional Flow Diagram (Data Item Description), 1991.

C. DI-IPSC-81435, Software Design Description (Data Item Description), 2013.

D. DI-MGMT-81648, Condition Found Report (Data Item Description), 2004.

E. DI-NDTI-80809B, Test-Inspection Report (Data Item Description), 2014.

F. DI-NDTI-81583, Equipment Inspection and Testing Report, 2006.

2.2.3. Standards, Military

A. MIL-STD-419E, Cleaning and Protecting Piping, Tubing and Fittings for Hydraulic Power Transmission Equipment.

B. MIL-STD-1310H, Shipboard Bonding, Grounding and Other Techniques for Electromagnetic Compatibility and Safety, 2009.

C. MIL-STD-1399 Section 300B, Interface Standard, Electric Power, Alternating Current, 2008.

D. MIL-STD-2003 series, Electric Plant Installation Standard Methods for Surface Ships, 2003.

E. MIL-DTL-24643, Rev C, Cables, Electric, Low Smoke Halogen-Free, for Shipboard Use, 2011.

F. MIL-DTL-24695C - Valve sampling and bleed, 2012.

G. MIL-DTL-24695/1B - Valve, vent and test, hydraulic service, 2012.

H. MIL-DTL-24695/2B – Vent and Test valve hose assembly, 2012.

I. MIL-DTL-24695/3B – Valve, hose assembly and adapter, 2012.

J. MIL-DTL-81940/4B Valve, sampling and bleed, hydraulic 3000 psi, non-aircraft applications, 2011 edition.

K. MIL-DTL-15024F, Rev F, Plates, Tags, and Bands for Identification of Equipment, 2014.

L. MIL-STD-12, Rev D, Abbreviations for Use on Drawings and in Specifications, Standards and Technical Documents (S/S by ASME-Y14.38M), 1998.

2.2.4. Code of Federal Regulations (CFR)

A. Code of Federal Regulations (CFR), Title 46 (Shipping), Chapter I, Subchapter F, Part 56 and 58.

B. Code of Federal Regulations, Title 46 (Shipping), Chapter II, subchapter J.

2.3. 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 Index of Specifications and Standards (DODISS).

2.3.1. American Society of Mechanical Engineers (ASME)

A. ASME Y14.5, Dimensioning and Tolerancing, 2009.

B. ASME-Y14.38M, Abbreviations and Acronyms for Use on Drawings and Related Documents, 2013.

2.3.2. American Society of Testing and Materials (ASTM)

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

B. ASTM D4174-89 (re-approved 1999) Standard Practice for Cleaning and Purification of Petroleum Fluid Hydraulic Systems C. ASTM A-312, Standard Specification for Seamless and Welded Austenitic Stainless Steel Pipes

2.3.3. American Petroleum Institute (API)

A. API-9A Specification for Wire Rope, 1995.

B. API-2C 7.4 Specification for Offshore Pedestal Mounted Davits, 6th Ed., 2004.

2.3.4. Institute of Electrical and Electronic Engineers (IEEE) A. IEEE Std 45, Recommended Practice and Electrical Installation on Shipboard, 2002.

B. IEEE Std C37.24, Guide for Evaluating the Effect of Solar Radiation on Outdoor Metal-Enclosed Switchgear, 2003.

2.3.5. International Electrotechnical Commission (IEC)

A. IEC Standard 61131-03, system Hardware and Software Technical Requirements, Edition 3.0, 2013.

2.3.6. International Maritime Organization (IMO)

A. Safety of Life at Sea (SOLAS) IMO Life Saving Appliance (LSA) Code (2003)

2.3.7. International Standards Organization (ISO)

A. ISO 4406, Hydraulic Fluid Power-Fluids-Method for Coding the Level of Contamination by Solid Particles, 1999.

2.3.8. American National Standards Institute (ANSI)

A. ANSI/ASQC Q9001-2008 – Quality Management Systems - Model for Quality Assurance in Design, Development, Production, Installation, and Servicing Requirements.

B. ANSI/NCSL Z540.3-2006, Requirements for the Calibration of Measuring and Test Equipment.

C. ANSI/ISA 18.1, Annunciator Sequences and Specifications 1992.

2.3.9. American Welding Society (AWS)

A. AWS D1.1-96, DATED 1996, Structural Welding Code, Steel.

2.3.10. Society of Automotive Engineers (SAE)

A. Metals and Alloys in the Unified Numbering System, 2004.

B. SAE J-1780, Hydraulic System Diagrams and Associated Tables for Marine Vehicles, 2004 edition.

C. SAE-J1942, Hose and Hose Assemblies for Marine Applications, 2002.

D. SAE-J1942-1, Qualified Hoses for Marine Applications, 2010.

E. SAE J514, Hydraulic Tube Fittings, 2004.

2.3.11. Society of Naval Architects and Marine Engineers (SNAME) A. T&R Bulletin 3-39, Guide for Shop and Installation Tests, 1985.

2.3.12. Underwriters Laboratory (UL)

A. UL 508 – Industrial Control Equipment, 2013.

2.4. Order of Precedence. In the event of any conflict between this statement of work and references sited herein, this statement of work shall take precedence.

3. Requirements

3.1. General – The inspections and overhaul shall be performed in accordance with the existing davit Tech Pubs (3562-583-A, 3562-583-B, 3720-583-A, 3554-556-A, and 3554-556-D) and this statement of work.

3.1.1. The Contractor shall provide all labor, equipment, special tools and materials.

3.1.2. All replacement parts shall be new original equipment manufacturer (OEM) replacement parts. Reclaimed or recycled parts are prohibited.

3.1.3. Certification of material and components shall be provided as indicated throughout this statement of work.

3.1.4. Before removal or disassembly of components, each item shall be tagged or match marked to assure proper re-assembly.

3.1.5. The contractor shall provide adequate storage and protection for the GFE/GFM.

3.1.6. Welding shall be in accordance with AWS D1.1.

3.1.7. Components requiring test certification shall be inspected, overhauled and certified by the OEM or their authorized service center.

3.1.8. The original BMD 477 configuration davit was fabricated to requirements based on earlier editions of API-2C and SOLAS, with exceptions. The BMD 710 configuration davit shall structurally and functionally meet the intent of the original design. Where structural modifications are required, the Contractor shall provide calculations and validate that the replacement or modified structures meet the original requirements. Complete certification of the davit assembly to the new standards is not required.

A. If a replacement structural davit frame is constructed, or if structural repairs or modifications to the davit weldments are required, then as part of factory testing the davit frame shall be given a static load test.

3.2. Inspection

3.2.1. Receiving Report. Upon receipt of the davit, the contractor shall inspect and inventory the davit assembly and submit a report of the below finding to the Contracting Officer. Receiving report shall be in accordance with DI-NDTI-81583 A. The general condition of the shipping containers and davit assembly as received.

B. Davit model and serial number.

C. Note any missing or damaged parts/components.

D. Digital pictures shall be taken of any damage. Digital pictures shall be submitted with CFR(s).

3.2.2. Disassembly and Inspection: The Contactor shall disassemble the mechanical, electrical and hydraulic systems on the davit, sufficient to conduct a thorough inspection of the components and structure to determine [for those items not already identified as being replaced] suitability for overhaul or replacement for long term use. In particular:

A. Hydraulic piping and manually operated valves shall be examined for corrosion.

B. The structure shall be examined for corrosion, twist and deformation.

C. The control stand shall be examined for condition.

D. The slewing system drive-train shall be inspected for wear and condition. The gearboxes shall be opened and inspected for internal condition. The contractor shall replace the Rotek bearing and gear teeth with new (Appleton part number YMD-6466 or Rotek part number A13-24E2).

E. The rigging system, including shall be examined for condition.

F. The condition of the reusable shipping container shall be evaluated

3.2.3. Component Cleanliness: Serviceable components shall be disassembled in accordance with the existing davit Technical Publication (GFE) and any applicable manufacturer’s instructions. Clean all components of grease, oil and other contaminants in preparation for inspections.

3.2.4. Non-Destructive Testing (NDT): A certified level II inspector shall perform all inspections. Inspector qualification and certification shall be certified by a nationally recognized third party agency. Copies of certification and equipment calibration shall be current per the relevant document and provided to the Coast Guard, Quality Assurance Representative (QAR).

A. Protect all necessary machined surfaces by the use of blanks, plugs or wrapping to preclude damage during NDT. The surfaces of all components shall be prepared in accordance with the guiding document for the NDT method being performed.

B. Visually inspect all structural component welds for visible signs of corrosion, stress, fatigue, distortion, bends and cracks, and imperfections.

C. Perform NDT inspections of all structural welds identified as critical or suspect, and all weight-bearing components of the davit assembly using the most appropriate NDT method. Load bearing components include but are not limited to: pins, pin holes, sleeves, sheaves, shackles, lifting ring, eyes, pads, struts, turnbuckles, links, swivels, gears, shafts, keyways, threads, brake drums/disc, foundations and structural mounting fasteners. The appropriate test and inspection method shall be determined based on the most economical method and by the components material make up. The criteria for acceptance or rejection of parts shall be determined in accordance the guiding NDT document.

D. NDT Reports: The contractor shall provide copies of inspection reports for review by a QAR. Items that fail inspection shall either be recommended for repair or replacement or noted in the CFR report. The data supplied within the NDT reports shall be detailed as identified in the NDT guiding document.

3.2.5. Condition Found Report (CFR). Upon the completion of the davit disassembly and all inspections, a CFR and cost proposal to address the CFR items shall be prepared and submitted to the Contracting Officer. The CFR shall include the information contained in DI-MGMT-81648. The CFR and cost proposal shall include the following A. Details of all disassembly and inspection findings. It is expected that several reports shall be required to cover the entire system components. The reports shall be individually grouped by the type of service: hydraulic, electrical, mechanical.

B. Components that are determined to be more economical to replace vice repair shall be addressed. The rational for each decision shall be explained in detail.

C. A list of all parts needed to complete the overhaul to include part number, quantity and price shown in U.S. currency.

D. A proposal to repair or renew items that were identified in the receiving report.

E. A list of all upgrades that have not been identified or completed to bring the davit up to the most current davit configuration.

F. The total cost to address the CFR items; (Note: the total cost will be the fixed price overhaul / upgrade plus the CFR items.)

G. Color pictures of damaged, corroded components or other issues shall be included.

3.2.6. Authority To Proceed: The Contractor shall not proceed with the overhaul until authorized by the Contracting Officer. The Contracting Officer will provide specific guidance and authorization as to what work or material shall be performed or provided. Once authorization is given to proceed as directed, the Contractor shall have the davit completely overhauled, assembled, tested, inspected, prepared and ready for shipment.

3.3. Constant Tension Winch

3.3.1. The Contractor shall provide and install a new constant tension winch and new winch control valve.

3.3.2. Winch:

A. The winch assembly shall be built to APPLETON drawing AMD-1974. The winch itself shall be common to the APPLETON FB20-21 davit, but shall be driven by a hydraulic motor selected for this application.

B. The winch assembly shall have a Working Load Limit (WLL) of not less than 6000 lbs at 90 fpm. The winch assembly shall be capable of operating at sea in advanced sea states; the winch assembly shall be capable of lifting, lowering and holding a load of 7500 lbs (1.25*WWL) at no specified speed, without adjustment to pressure settings. The winch assembly shall be fitted with a disk brake system rated for not less than 9000 lbs (1.5*WWL).

C. The winch assembly shall be fitted with a Constant Tension feature, with separately adjustable drive. In the Constant Tension mode, the winch shall be capable of yo-yo operation under minimal load at up to 500 fpm; the constant tension level shall be adjustable by the davit operator. The boat coxswain shall be capable of pulling against and overhauling the CT winch drive in order to attach or release the davit hook.

3.4. Overhaul Requirements.

3.4.1. General. As part of the overhaul of the davit, the following devices shall be replaced:

A. All directional control and flow control valves.

B. All hydraulic motors C. Hydraulic accumulator.

D. Hydraulic hand pump.

E. Hydraulic hoses.

F. All electrical control switches, wire and cabling.

G. All anti-two-block, swing limit, slack wire and related switches.

H. Floodlight on the crane.

3.4.2. Additional Replacement Parts. The following shall all be replaced with new parts during the overhaul:

A. Gaskets, seals, O-rings, backup ring, circlips, tension pins, cotter pins, disposable air breathers, springs, and bearings (sealed bearings shall be utilized where no grease nipple exist), deck grates and hardware.

B. Non-structural fasteners (such as nuts, bolts, washers etc.) that are exposed to marine environment shall be made of 300 series stainless steel C. All structural fasteners, nuts and locking devices, such as setscrews and pins, shall be renewed.

D. All grease nipples shall be made of 300 series stainless steel2.3.10.A and have protective plastic caps installed.

3.4.3. SOLAS hook. The contractor shall provide a replacement Cranston – Eagle SOLAS davit hook (part number APR 356-CB) for installation on the davit at the end of overhaul.

3.4.4. Electrical:

A. Electrical equipment shall meet the design, performance, application and installation requirements of IEEE-STD-45 and 46 CFR Subchapter J.

B. Electrical motors and generators shall be in accordance with NEMA (National Electric Manufacturer’s Association) standard MG1.

C. Electrical systems and components shall be designed to operate on Type I 115 VAC, single phase, 60 Hertz, ungrounded ships service power in accordance with MIL-DTL-1399-300B. The console will be provided with 115 VAC source of supply from the cutter.

D. Cable installations shall meet the requirements of MIL-STD-2003. All cables shall be installed from the bottom of the enclosure, controller or junction box.

E. Equipment shall be Class B or C bonded to cutter’s structure in accordance with MIL-STD-1310H. IEEE Std 45 has the same requirements but it is called equipment grounding. Compliance with either standard is acceptable.

F. Electrical cable shall be low smoke, zero halogen in accordance with MIL-DTL-24643.

G. Electrical cable exposed to the weather shall be waterproof.

H. Electrical cable exposed on weather decks shall be protected from mechanical damage by conduit or other means in accordance with the recommendations of IEEE-STD-45, paragraph 25.4 cable protection.

I. Electrical enclosures shall be visually inspected for watertight integrity and corrosion. Door seals, gaskets and cable connection seals shall be renewed.

J. All non-repairable components such as switches, coils, heaters, lamps, sensors, transformers, fans, relays, power supplies and controllers shall be replaced. Any components replaced shall be identified in the CFR.

K. Repairable / Adjustable components such as switches, contactors, relays, thermostats, processors and pressure switches shall be replaced. Any components replaced shall be identified in the CFR. Final adjustments shall be made during the equipment testing / pre-delivery process.

L. Cable tags shall be in accordance with MIL-DTL-15024F.

M. Cable and wiring designation shall be in accordance with TS 305 or established cutter specific cable and wiring designations.

N. The floodlight shall be a dimmable white LED lighting unit with a protective reflector cone. The floodlight fixture shall provide at least 7500 lumens with a color temperature between 3500K to 5000K. The beam angle shall be between 25° and 35°. The floodlight fixture shall be IP66 or better. Provisions shall be made on the console for dimming of the floodlight.

3.4.5. Controls:

A. The davit controller shall utilize a PLC (Programmable Logic Controller).

B. The PLC control system software language, functions, syntax and semantics shall be developed in accordance with IEC 61131-03.

i. System software shall utilize only use Ladder Logic (LD) or Functional Block Diagram (FBD) logic in accordance with IEC 61131-03.

C. Industrial electrical control devices including the PLC control panel shall be a UL 508 listed.

D. Industrial control and systems shall be in accordance with NEMA (National Electric Manufacturer’s Association) ICS-1.

E. The PLC shall have built-in test (BIT) capability. Self-test shall be automatically performed each time the system is turned on. The system shall perform continuous fault detection during normal operation. The system shall permit an operator initiated test to be performed at any time to check system performance via the operator interface. Fault isolation shall be performed by the BIT to the Lowest Replaceable Unit (LRU) level. An LRU shall be defined as the lowest subassembly of any component of the system which can be replaced n the field (shipboard) in order to affect complete system repair (i.e. restore normal system operation).

F. The PLC shall have multiple layers of password protection. Unit personnel shall have access to PLC ladder logic for troubleshooting purposes. All passwords will be provided to the KO. USCG land-based support shall have the ability to access and modify all layers of controller logic including developmental levels.

G. Constant Tension Winch Controls.

i. The Contractor shall provide and install a new constant tension winch PLC based control system with associated sensors and displays.

H. Console: The Contractor shall modify the original equipment console to incorporate the replacement control system electronics, provide the davit operator with joy-stick operated controls, and display critical alarms. CT winch controls shall function and transition similar to the CT winch controls on the APPLETON FB20-21 series davit. See TP 4924-583-A.

i. The console shall be designed for operation by 5th percentile female through 95th percentile male operators, in accordance with ASTM F1166, wearing arctic gloves and standing behind the console, looking forward and outboard at the davit and boat being launched or recovered.

ii. If the console requires replacement, the replacement console shall retain the footprint and bolting installation pattern as the original unit.

iii. The PLC control system shall be mounted internal to a water-tight NEMA 6P, 316L stainless steel enclosure, which shall be incorporated into the free-standing control console. The control system shall be capable of operation in all ambient conditions from -20 degrees F to 120 degrees F, and 100 percent humidity. Console will be exposed to solar load on the weather deck; Console enclosure shall be selected to minimize the effects of solar radiation on outdoor enclosures. IEEE C37.24 can be used as guidance to reduce the effects of solar load.

iv. The control system shall have a flat, touch pad display device (similar to part number CR1050) to display digital operating information and alarms. The display shall be:

a. at least IP66 waterproof.

b. 600 Nits or better brightness for sunlight readability.

c. anti-glare.

d. UV resistant.

v. The console shall also be fitted with an adjustable shade / hood device to permit view and operation of the display screen in full sunlight.

vi. The inside of the console hood shall be fitted with a dimmable white LED lighting device to provide for night time operation. On/off control of the light shall also be provided. The lighting shall not be a source of blinding light to personnel with night vision goggles in a cutter boat being launched or retrieved.

vii. All indicator lights on the weather deck and console shall be capable of being dimmed. One dimming control device shall be provided on the control panel.

a. The local davit display shall provide at least the following parameters:

(1). Winch speed (2). Winch load (3). Set-up information (4). Diagnostic information (5). Hydraulic pressure (6). Hydraulic oil temperature

b. The PLC display shall provide a display page for audible and visual alarms of the Hydraulic Power Units (2 ea) which support the davit. See Technical Publications 3554-556D, 4924-583A, Appleton drawings BMD 479 and CMD 545. Audible and visual alarms shall include at least the following:

(1). HPU 1 high oil level / low oil level (consolidated) (2). HPU 1 motor overload and low oil pressure (consolidated) (3). HPU 1 filter alarms (3, consolidated) (4). HPU 2 high oil level / low oil level (consolidated) (5). HPU 2 motor overload or low oil pressure (consolidated) (6). HPU 2 filter alarms (3, consolidated) (7). Anti two-block

The government will provide the alarm control signals to the console as part of the installation contract.

c. Operator shall be capable of silencing, acknowledging and resetting alarms in accordance with sequences in ISA 18.1.

d. The contractor shall provide an alarm sequence diagram and table in accordance with ISA 18.1 that defines the alarm sequences including the silence acknowledge and reset pushbutton functions. .

e. The alarm function shall call attention to an abnormal process or operating condition by the use of individual illuminated visual displays and audible devices.

f. An acknowledge function shall be provided. The acknowledge pushbutton when activated shall provide manual response to the receipt of an alarm or new alarm by the operator. The visual alarm shall continue or change blinking pattern until alarm is cleared. Other new alarms shall re-initiate the alarm sequence.

g. A silence function shall be provided. A separate pushbutton shall be used to allow silencing of the alarm audible device without affecting the visual displays. The silence function should not acknowledge the alarm.

h. A manual reset function shall be provided. A separate pushbutton shall be used to return the annunciator to normal operation. Automatic reset that returns-to-normal operating conditions shall be used that requires no user operation when alarm is cleared.

viii. The control console shall be fitted with a red, protected, self-latching (maintained), twist-to-release, “Emergency Stop”, mushroom push-button greater than or equal to 40mm in diameter.

ix. The emergency stop button shall have normally closed contacts; operation (depression) of the button shall open the contacts.

x. The emergency stop button shall have a bezel (guard) to prevent inadvertent operation.

xi. Operation of the emergency stop button shall cause loss of power to the electrical controls within the console, but shall not darken lighting circuits.

xii. Manual resetting of the emergency stop button shall not cause automatic restart of davit operations.

xiii. Electrical contacts shall be provided to support installation of Emergency stop interruption devices (by the installing activity) on the HPUs.

xiv. The console shall not be fitted with a dead-man type operator switch.

3.4.6. Hydraulic Systems:

A. Hydraulic systems shall meet 46 CFR 58.30 Fluid Power and Control Systems, except as modified herein.

B. The hydraulic fluid shall be MOBIL DTE 10XL, ISO viscosity 46. The desirable fluid cleanliness to be maintained is ISO 4406 Code 19/17/14 or better. The allowable water contamination is 0.05% by weight, or better.

C. Hydraulic fluid to support the davit will be provided by existing Hydraulic Power Units, which shall provide pressure compensated fluid at 2800 psi.

D. All hydraulic tubing shall be tagged, removed and inspected for re-use. Tubing shall be flushed to ISO 4406 Code 18/16/13 or better, particularly case drains and pilot operators for brakes which normally see little flow. Connection seals or ferrule shall be renewed.

E. Replacement hydraulic piping, tubing and fittings shall be seamless stainless steel in accordance with ASTM A-312 with a design factor of at least 4.0. Tubing bends shall be preferred, where practical. Equipment interfaces and take-down joints for maintenance purposes shall be fitted with union type connections with O-ring seals or straight thread type connections with O-ring seal. Mechanical connections shall be swage and ferrule type; flared fittings shall not be used. National Pipe connections (NPT) or British Standard Pipe (BSP) tapered threaded connections shall not be used.

F. Piping shall be supported by commercial marine grade rubber lined type isolation hangers meeting MSS SD-89 or equivalent. Cadmium shall not be used.

G. Hydraulic control valves shall be modular and individually replaceable. Valves shall be manifold mounted, or mounted as a manifold assembly, which shall be structurally supported.

i. Hydraulic control valves and manifolds shall be specifically coated for corrosion control in an exposed marine environment; OEM coating systems alone are not acceptable. Marine grade high build epoxy or polysiloxane painting systems shall be used. Consideration shall be given to the use of supplementary corrosion control inhibitors; routine replacement of control valves and manifolds for “corrosion control” purposes is not desirable.

ii. Solenoid driven hydraulic control valves on the davit shall be housed within a box with cover to minimize normal exposure to marine spray or weather. The valves may be exposed to the weather when they are (infrequently) manually operated.

H. Hoses:

i. Hydraulic hoses shall meet the requirements of SAE J1942 and SAE J1942-1, and should not exceed 30 inches in length, except as necessary to support the movement or rotation of equipment. Hoses shall have an expected service life of at least 8 years, and shall have a waterproof cover resistant to ultraviolet light degradation. In addition, hoses or groups of hoses shall be fitted with removable protective cover to provide additional ultraviolet protection and prevent chaffing. Permanent fire type shielding that prevents hose inspection shall not be provided. Hose fittings shall be USN S31604 or S17400 series CRES and shall be permanently installed on the hose. The use of hydraulic hose connections with “O” ring seal connections is preferred. Hoses shall be field replaceable, without unshipping the crane. All hose assemblies shall be hydrostatically tested to 150% of the design pressure of the piping. All hoses shall be tagged; hoses in the weather shall be tagged on the outside of any cover. Tags shall be installed with metal strapping to prevent damage to hoses.

a. All hoses on the davit assembly shall be replaced.

b. Hoses for field installation in the pedestal between the davit assembly and the accumulator / charge pump equipment, for field installation of the accumulator and charge pump, and for connection of supply and return to the shipboard piping shall be provided. The hose connections to shipboard piping shall be SAE 4-bolt flange type. Hoses internal to the pedestal shall be provided with supplementary cover protection to permit coiling and uncoiling within the pedestal during slewing. These hoses shall be sealed and packaged as part of the equipment for installation.

ii. Hose tags shall be a stamped, engraved or embossed aluminum strip tag with a coded Serial Number (S/N) in ¼ inch high letters. The S/N shall relate to the Hose List. Hoses shall be coded SPD (for single point davit) –HYD (for hydraulic) and –XX (sequential number within that service code.). “SPD-HYD-04” would be the 4th hydraulic hose on the davit. No additional information is required on the tag.

iii. The Contractor shall provide a complete hose list as a separate deliverable. A unique hose list shall be provided for each davit. The hose list, in sequential S/N order, shall identify the service for each hose, and shall be complete to permit fabrication and assembly of replacement hoses. The hose list shall include the S/N, description, “HYD” service, required design pressure, hydrostatic test pressure / test date / test facility, length (of the assembly), size, hose mfr and type, fitting A mfr part number and type, fitting B mfr part number and type, special features, and special notes. The hose list shall be packaged with the davit as a Unit Document, and a copy shall be provided to the government QAR. The unit will enter this data into a database program on the cutter.

a. The Contractor shall maintain the hydrostatic test records for review by the QAR, however the hydrostatic test data entered in the hose log shall serve as the official data transfer to the Coast Guard.

b. Where an individual hose is fabricated and provided to the Coast Guard as a replacement “part”, the hose shall be tagged and a 1 line hose log entry (complete with hydrostatic test data) shall be provided with the hose.

I. Gages – The hydraulic system shall be fitted with shock-resistant type gages and pressure transducers sufficient for normal operation of the system. Pressure gage dials shall be in psi units, with markings in 100 psi increments or smaller. Temperature gages shall be in degrees F, with markings in 1 degree increments or smaller. Gages shall be installed with isolation valves and damping devices. Temperature and thermocouple devices shall be installed with thermo-wells.

i. A pressure transducer shall be installed on the davit to read hydraulic pressure prior to the main directional control valve. The transducer shall provide a signal to the PLC.

ii. A temperature transducer shall be installed on the davit to read the hydraulic fluid temperature entering the directional control valve. The transducer shall provide a signal to the PLC.

iii. Certification documents shall be provided for gages and transducers. The documents shall be packaged with the davit assembly as Unit Documents, and a copy shall be provided to the government QAR.

J. Hydraulic Test Ports for the temporary installation of portable test ages, bleed valves and sampling valves shall be provided and permanently installed in parallel with gages and pressure transducers, and on both sides of all hydraulic motors so that:

i. a temporary gage can be installed to validate installed gages or pressure transducers,

ii. temporary gages can be installed to determine pressure drop across all hydraulic motors for diagnostic purposes,

iii. all areas of the system can be bled of air, and hydraulic oil samples can be taken.

K. The test ports shall permit attachment to and disconnection from the hydraulic system while under pressure, without leakage. The test ports shall be manufactured with stainless steel bodies. The test ports shall be functionally and mechanically interchangeable with Military Standard MIL-DTL-24695 test ports with reverse buttress threads. Hydrotechnik / Schroeder Industries Series 1215 stainless steel valves meet this specification.

i. The Contractor shall provide a test kit of at least two test gages (5000 psi), two each 2mm diameter hoses (MIL-DTL-24695/2B hoses with nominal 3 ft length), self-closing sampling valve (Circle Seal P14-500, rated for 3000 psi, meeting MIL-DTL-81940/4B), and appropriate adapters (MIL-DTL-24695/3B). The test kit shall be provided in a hinged carrying / shipping case with internal dividers. The case material and packing shall be resistant to hydraulic oil, and the case shall be stenciled “Hydraulic Oil Test Kit”.

ii. The Contractor shall utilize the test kit to verify the pressure differential across each of the hydraulic motors on the first davit modified; this shall be witnessed by the government QAR. This information shall be placed in a note or table on the hydraulic diagram for diagnostic reference.

L. The contractor shall provide an accumulator unit, a hand pump, a hand-pump reservoir, quick-disconnect fittings for the hand pump, hydraulic test port(s), and associated gages and manual cut-out valves – for installation by the Installing Activity on the side of the davit pedestal, in accordance with the contractor’s drawings.

i. The accumulator circuit shall normally self-charge from the pressurized main. The accumulator shall have sufficient capacity to launch the boat from the cradle, when HPU pressure is not available. Accumulator gages shall be calibrated and tagged.

ii. The accumulator shall meet 46 CFR requirements. The accumulator shall have a nitrogen precharge, and standardized fittings for precharge test and fill. Manual operation cut-out valves shall be provided for charging and operation of the system. An accumulator relief valve shall be provided, with tagged calibration date.

a. Note: An accumulator recharge kit is not required, as other accumulator test kits on the cutter.

iii. The hand pump reservoir shall be the original reservoir, or a replacement, based on condition and cost. Provision shall be made for clean-out and for bleeding of air.

iv. A portable hand pump shall provide the capability to recharge the accumulator, using fluid from the hand-pump reservoir. Quick-disconnect fittings shall provide for quick installation or removal of the hand pump suction and discharge; the fittings shall be installed to ensure pump suction alignment/discharge. The pump shall be intended for inside storage. Caps shall be provided for all nitrogen charging ports, and quick disconnect valves.

v. The test port(s) shall provide the capability to vent air from the accumulator circuit, and to verify the accumulator pressure.

vi. An engraved “Emergency Use - Valve Alignment Chart” shall be provided to identify the Normal valve positions, Manual Charging valve positions, and Accumulator Discharge valve positions. Text accompanying the chart shall explain emergency use and recharging procedures. The chart and instructions shall be in appendix to the publication, and shall be provided as an engraved aluminum plate with backfill paint, which shall be clear-coated.

M. A hydraulic diagram meeting SAE J-1780 shall be provided. The diagram shall identify all major components, including all filter elements, and show the locations of all test, vent and sampling connections. The diagram shall show all piping system design pressures. The diagram shall also identify all valve set pressures, the target contamination limits, and the as-installed differential pressures on hydraulic motors.

3.4.7. Rigging Systems

A. The wire rope shall be renewed; the wire shall meet the API Standard 9A. The wire rope assembly, with attached fitting, shall be pull tested to not less than 40% of Rated Breaking Strength of the rope; A pull test certificate shall be provided. The wire rope shall be pressure lubricated with Dynagard Blue™, or Dynagard E™ marine grade lubricant.

B. Sheaves shall be inspected for wear. Blocks shall be inspected for corrosion. Components with slight wear should have a projected service life of at least 8 years. Blocks and sheaves which fail inspection shall be renewed. Blocks and sheaves shall be cleaned, and painted with the polysiloxane coating system, except that the running surface of sheaves shall be double coated with modified inorganic zinc primer. All bearings, sleeves, circlips, grease nipples and seals shall be renewed.

C. Sheave and shackle pins shall be inspected for wear, and examined by NDT methods. If renewed, the pin material shall be of adequate strength, with stainless type materials preferred where appropriate.

D. The SOLAS hook shall be installed.

3.4.8. Mechanical Components.

A. Pins and retainers: All structural pins shall be cleaned, measured for wear, and examined by NDT methods. If renewed, the pin material shall be of adequate strength, with stainless type materials preferred where appropriate.

B. All bearings, sleeves, circlips, grease nipples and seals shall be renewed.

3.5. Coatings and Plates:

3.5.1. Identification labels and warning plates: Remove or mask all identification plates and warning labels. Renew any missing, illegible or damaged plates and labels

3.5.2. The davit shall be prepared and painted in accordance with SFLC Standard Specification 6310. The coating system shall be an approved polysiloxane multi-coat system over enriched inorganic zinc primer base [6310 Appendix A, Deck Machinery, Options I or II]. The coatings shall be listed in 6310 Appendix C.

A. The color coats on the davit and control stand shall be SPAR (Fed Standard 595 #10371).

B. 300 series stainless steel surfaces need not be painted.

C. Winches, gearboxes, hydraulic motors, brake enclosures, sheaves, accumulators, valve bodies and other replaceable parts shall be separately painted and then reassembled on the davit. Where these assemblies or parts are provided as spare parts, they shall be painted by the Contractor so that they do not require coating when installed.

D. The wear tread of sheaves, the ring gear bearing, and other wear component areas, as appropriate, shall be double coated with enriched inorganic zinc based primer, without a top color coating.

E. Emergency Stop devices shall be color coded RED (Fed Std 595 #11105).

F. The Contractor shall maintain records of coating thickness testing as part of the Contractors QA program. The QAR reserves the right to request additional thickness testing on individual davit assemblies, particularly in way of areas susceptible to corrosion.

3.5.3. The davit body may be fitted on each side with a manufacturer’s decal and/or emblem not to exceed lettering of 2-1/2 inch height, or a total of 100 sq inches. Advertisement decals, emblems or ratings shall not be placed on the sides of the davit boom.

3.5.4. Stainless steel builders plates, which shall include at least the manufacturer’s name, address, government contract number, manufacturer’s model number, date of fabrication or overhaul, and a manufacturer’s serial numbers shall be provided on the back (spine) or one side of the davit, and shall be provided on the console. The serial number on the davit and mating console shall be the same. The original serial number of an overhauled davit (if known) shall carry forward. Lettering shall not exceed ¾ inch in height, and shall be back-filled with black enamel, and sealed with clear coat. The builder’s plate shall be drilled and installed with threaded fasteners or rivets.

3.5.5. A stainless steel rating plate shall be provided for field installation on the davit pedestal (by the installing activity). The plate shall identify the Working Load Limit, and the test loads required for dynamic and modified static / brake tests. Text shall not exceed ¾ inch height and shall be back filled with black enamel and sealed with clear coat. The plate shall be drilled for installation with threaded fasteners or rivets. A printed copy of the plate shall be in an appendix to the Technical Publication.

APPLETON MARINE, Inc. Appleton, Wisconsin Model RAD 30-15.5 Davit, Overhaul/Upgrade BMD 710 [Date]

Modified Static / Brake Test Load

150% WLL)

9000 lbs.

3.5.6. A stainless steel Test Data Plate shall be provided for field installation on the davit pedestal (by the installing activity). The plate shall coordinate with the Rating Plate, and shall have blocks for field engraving of test dates and facility. Text shall not exceed ½ inch in height. Text shall be back filled with enamel, and sealed with clear coat. The plate shall be drilled for installation with threaded fasteners or rivets. It is intended that this plate be replaced every four years. A printed copy of this plate shall be in an appendix to the Technical Publication.

Annual Test

Modified Static / Brake

Dynamic Test

Year 2 Annual Test

Year 3 Annual Test

Modified Static / Brake

Dynamic Test

Year 4 Annual Test

3.6. Davit Re-assembly: Upon completion of the overhaul, reassemble all components.

3.6.1. Threaded fasteners shall be assembled with thread lubricant, where applicable. Fasteners shall be torque in accordance with the Technical Publication.

3.6.2. Lubricate all components of the davit in accordance with the Technical Publication.

3.6.3. The hydraulic system shall be purged with air, to minimize gross contaminants. The hydraulic system shall be hydrostatically tested with water to 150% of the design pressure of the piping. Pressure shall be held for not less than 10 minutes.

3.6.4. The hydraulic system shall be flushed in accordance with the methods documented in MIL-STD 419, and ASTM D4174. The flushing fluid shall be a petroleum fluid compatible with MOBIL DTE 10XL. Turbulent fluid flows shall be achieved and maintained. Piping shall be flushed and fluid analyzed until the fluid reaches an ISO 4406 Code 18/16/13 or better. The water content shall no greater than 500 ppm (0.05% by volume). Contamination test reports shall be provided to the Quality Assurance Representative, or to the Contracting Officer.

3.6.5. Discarded Parts: All discarded parts shall be retained for review by the government QAR at the contractor’s plant, prior to disposal. After review, the contractor shall dispose of the parts as directed by the Contracting Officer.

3.7. INTEGRATED LOGISTICS SUPPORT:

3.7.1. Data For Provisioning

A. The Contractor shall provide data for provisioning (DFP) for all components and systems on the davit for which DFP was not previously provided for the RAD 30-15.5 davit, or where there are supportability changes due to modifications or obsolescence. DFP shall be provided in accordance e with SFLC D-583-0351 for review and comment. This shall include Original Equipment Manufacturer (OEM) part numbers, OEM name and address, quantity used, and keying to any provided drawings. Where an item is modified or adjusted by the Contractor (such as special painting), the modification shall be so noted.

B. The Contractor shall provide a price list for all components identified with DFP. The price list shall be valid for one year, subject to economic adjustments.

3.7.2. Recommended Spare Parts

A. The Contractor shall provide a manufacturer’s recommended spare parts list for all new components. Existing component s in use on the BMD 477 configuration davit that are retained in the BMD 710 configuration davit need not be included. . The list shall separately identify:

i. OBRP: On Board Repair Parts - Parts recommended for stowage on the cutter for immediate use in repair actions. The list shall include gaskets and seals as necessary to re-install components, and general disposable or consumable components. The list shall include any normal wear / spare / repair parts which are critical to the operation of the system.

ii. Depot Parts: Parts recommended for shore-side stowage by the Contractor or government. Includes long lead time items and Coast Guard unique parts, assemblies and subassemblies that the Contractor believes are necessary to support fleet repairs for two years. Long lead time parts are defined as any part which will take longer than 45 days by the vendor to ship once they receive the order. Coast Guard unique parts are defined as any part, assembly or subassembly that is only installed on systems provided to the Coast Guard.

B. Overhaul Parts: Parts necessary to overhaul major assemblies need not be included in the OBRP and Depot Parts lists, but shall be identified in the Technical Publication appendices. Where such overhaul parts are commonly gathered and sold as an overhaul “kit”, such kit shall have a part number in the Technical Publication.

C. The Government reserves the right to purchase items from the OEM identified on the recommended spares list, over the life of this contract.

3.7.3. Drawings

A. The Contractor shall provide equipment arrangement and assembly drawings for the BMD 710 configuration davit.

B. The Contractor shall provide a hydraulic diagram of the davit system. The diagram shall meet SAE J1780 requirements, and shall include all relief valve set pressures, filter identifications, and the ISO 4406 Target System Contamination code. The diagram shall also include, for diagnostic purposes, the pressure drop across each major component.

C. Drawings shall be provided as unlocked AutoCAD™ files, 2012 edition. Drawings shall be prepared in accordance with SFLC Specification D-085-482 (Drawing for Aux Machinery).