3040-01-415-7761_RD.pdf

PDF 48 KB Posted Mar 7, 2016

Attached to: CYLINDER ASSEMBLY, ACTUATING, LINEAR Federal contract opportunity
Solicitation number: HSCG40-16-Q-49071
Issued by: Department of Homeland Security US Coast Guard

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OVERHAUL DESCRIPTION

FOR OFFICIAL USE ONLY

ITEM NAME CYLINDER ASSEMBLY,ACTUATING,LINEAR

STOCK NUMBER 3040-01-415-7761

PART NUMBER 39249

USED ON 225A BUOY CRANE

Items as received by the contractor must be complete and of the proper cited part number. Discrepancies shall be reported to the Coast Guard Contracting Officer.

OVERHAUL REQUIREMENTS:

1.0. SCOPE

1.1. This specification provides the requirements for the receipt, inspection & condition/test reports, overhaul, testing, preservation, packaging, packing and marking of hydraulic cylinders currently used on U. S. Coast Guard Vessels nationwide.

1.2. Classification : This sets forth the requirements for the following equipment:

1.2.1. Stock No.: 3040-01-415-7761

Name: CYLINDER, HYDRAULIC Part Number: 39249 Manufacturer: Allied Systems Co.

1.3. Government Furnished Property (GFP) : The listed items are managed by the U.S. Coast Guard Surface Forces Logistics Center at Baltimore, MD.

1.3.1. General Description: Included shall be all items shown on drawing 39249. Double acting cylinder, Bore 9", Rod diameter: 6 1/4", retracted length: 305" nominal, extended length: 545" nominal, Stroke length: 240" nominal, pressure rating: 5000 PSI Max, Working pressure: 2500 PSI, Load valve pressure: 850 PSI.

1.3.2. The Contractor shall immediately notify the Coast Guard Contracting Officer if the make, model, or part number received for overhaul does not conform to the hydraulic cylinder specified on the delivery order.

2.0. APPLICABLE DOCUMENTS

2.1. General : The documents listed in this section are specified in sections 3.0, 4.0, or 5.0 of this specification. This section does not include documents cited in other sections of this specification or recommended for additional information or as examples. While every effort has been made to ensure the completeness of this list, document users are cautioned that they must meet all specified requirements cited in sections 3.0, 4.0, or 5.0 of this specification, whether or not they are listed.

2.2. Government Documents : The following specifications, standards, publications, and handbooks form a part of this overhaul description 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 Single Stock Point of Specifications and Standards, (DODSSP), and supplements thereto, cited in the solicitation or contract.

2.2.1. Military Specifications

a. DODD 4140.01-M-1, Dated 7 Sep 2007; Compliance for Defense Packaging:

Phytosanitary Requirements for Wood Packaging Material (WPM).

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

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

2.3.1. Coast Guard Specifications.

a. USCG-SFLC Specification D-000-0100 Rev G, 02/2006; Bar Coding for USCG Surface Forces Logistics Center procured material.

2.3.2. Coast Guard Technical Publications

a. TP 3557 Sec. A, Crane, Buoy, Model TB90-60

2.3.3. Federal Standards

a. FED-STD-595C, Colors Used in Government Procurement

2.4. Commercial 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 of Specifications and Standards (DODSSP) and supplements thereto.

2.4.1. American National Standards Institute (ANSI)/ National Conference of Standards Laboratories (NCSL)ANSI/NCSL Z540.3-2006, 03 Aug 2006, Requirements for the Calibration of Measuring and Test Equipment, dated 01/2006

2.4.2. Society for Protective Coatings SSPC-SP 10/NACE No. 2, Near White Blast Cleaning, dated 09/2000

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

2.5. Document Availability : To obtain the referenced documents see section

6.1 of this specification.

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

3.0. REQUIREMENTS

3.1. General : Inspections, overhaul and testing of each hydraulic cylinder shall be accomplished in accordance with the Original Equipment Manufacturer (OEM) procedures, specifications, references and standard practices. The Contractor shall complete these requirements in accordance with the attached Delivery Schedule.

SHELF LIFE CD 0

1.0. SCOPE

1.2. Classification : This sets forth the requirements for the following equipment:

1.2.1. Stock No.: 3040-01-415-7761

Name: CYLINDER, HYDRAULIC Part Number: 39249 Manufacturer: Allied Systems Co.

1.3. Government Furnished Property (GFP) : The listed items are managed by the U.S. Coast Guard Surface Forces Logistics Center at Baltimore, MD.

2.0. APPLICABLE DOCUMENTS

2.2.1. Military Specifications

a. DODD 4140.01-M-1, Dated 7 Sep 2007; Compliance for Defense Packaging:

Phytosanitary Requirements for Wood Packaging Material (WPM).

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

2.3.1. Coast Guard Specifications.

a. USCG-SFLC Specification D-000-0100 Rev G, 02/2006; Bar Coding for USCG Surface Forces Logistics Center procured material.

2.3.2. Coast Guard Technical Publications

a. TP 3557 Sec. A, Crane, Buoy, Model TB90-60

2.3.3. Federal Standards

a. FED-STD-595C, Colors Used in Government Procurement

2.4.2. Society for Protective Coatings SSPC-SP 10/NACE No. 2, Near White Blast Cleaning, dated 09/2000

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

2.5. Document Availability : To obtain the referenced documents see section

6.1 of this specification.

3.0. REQUIREMENTS

3.1.1. The overhaul requirements described herein are considered the minimum necessary and are not intended to replace any procedures, controls, examinations, or tests normally employed by the Contractor to assure the quality of the product. The overhaul of the hydraulic cylinders is intended to return the cylinder performance and appearance to a like new condition.

3.2. Storage : The Contractor shall provide a secured inside storage location for all GFP with complete protection from the weather elements.

3.3. Overhaul : The Contractor shall provide all labor and materials to perform the overhaul services as described below for each hydraulic cylinder.

3.3.1. Preliminary disassembly and inspection of the hydraulic cylinder shall be conducted in accordance with OEM procedures, specifications, references and standard practices to determine the condition of all components of the hydraulic cylinder. All external fittings and piping will be removed for inspection and replaced as needed.

3.3.2. A detailed cost estimate shall be submitted with a Condition Found Report (CFR) to the Coast Guard Contracting Officer for review and approval prior to the start of any overhaul or order of material. The Contractor shall also provide the replacement cost of an identical new hydraulic cylinder for comparison to the overhaul cost.

3.3.3. A Condition Found Report (CFR) with a detailed cost estimate shall be submitted to the Coast Guard Contracting Officer for review and approval within ten (10) days after receiving each hydraulic cylinder. No further work shall be accomplished until the approval of the Contracting Officer.

a. The open and inspect Condition Found Report with a detailed cost estimate shall contain the following as a minimum:

1. Date of inspection.

2. Identification of cylinder by serial number, part number, and stock number. If no serial number appears on the hydraulic cylinder, the Contractor shall assign a serial number. The serial number shall be stamped on the hydraulic cylinder.

3. Condition of the shipping crate and any cost of repair.

4. Cost of overhaul labor as applicable.

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

6. A list of defective or worn parts recommended for repair/refurbishment (vice replacement) and the associated cost to accomplish these repairs.

7. List of required replacement parts. Identify any existing non-OEM parts that need replacement.

8. Provide digital photo documentation as per subsection 3.6. of this specification.

9. Cost of new cylinder for comparison to cost of overhaul.

b. Upon acceptance of the cost estimate and authorization to proceed by the Contracting Officer, the Contractor shall overhaul the hydraulic cylinder in accordance with the OEM procedures, specifications, references, standard practices and the references cited in section 2.0 of this specification.

3.3.4. The Coast Guard Contracting Officer will determine the disposition of any hydraulic cylinder delivered for overhaul that is Beyond Economical Repair (BER).

a. If the hydraulic cylinder is BER, the government reserves the right to purchase an identical new hydraulic cylinder from the Contractor.

3.3.5. Each cylinder shall be overhauled to a condition which is equivalent to an identical new hydraulic cylinder, with the operating and performance characteristics restored to the original design and technical specifications.

3.3.6. All replacement parts used in the overhaul shall be new OEM parts.

Reclaimed, recycled, or aftermarket parts are not acceptable and shall not be used.

3.3.7. Paint removal: Removal of existing paint shall be accomplished by abrasive blast to near white metal in accordance with SSPC SP-10/NACE No.2 (document 2.4.2.) where practicable. Equal means of paint removal is acceptable where grit blast poses a risk of damage to internal components and cannot be properly protected from blasting operation.

3.3.8. Remove any label plates and replace at the conclusion of the painting.

New label plates shall be used if the original plate is missing, not legible or in poor condition. The label plate shall contain hydraulic cylinder;

model and serial number and pertinent characteristic information as a minimum requirement. A separate label plate made of similar material, as the original label plate, shall be attached stating the Contractor?s name, contract number and date of overhaul.

3.3.9. Paint application: All surfaces intended for paint shall be coated with one application of Zinc-Rich Primer-Polysiloxane System, 3.0 to 4.0 mils DFT. The top coat shall be applied with two (2) applications of (polysiloxane) Ameron PSX-700 or equal. The first application with a thin coat, at 1.0 to 2.0 mils DFT. Followed by a second full coat at 5.0 to 6.0 mils DFT. Prior to the application of paint, surface cleaning and preparation shall be accomplished in accordance with the paint manufacturer's instructions. Authorized colors shall be in accordance with FED-STD-595C (document 2.3.4.a), as applicable and as follows:

a. Spar (10371)

3.3.10. Paint Data Sheet: Paint data sheets shall be prepared to certify the paint type and mil thickness used on each cylinder. The paint data sheet shall be packed with the overhauled hydraulic cylinder at time of packaging.

A copy of the paint data sheet shall also be provided to the Coast Guard Quality Assurance Representative.

3.3.11. Reassembly: The hydraulic cylinder shall be reassembled using only

3.2. Storage : The Contractor shall provide a secured inside storage location for all GFP with complete protection from the weather elements.

3.3. Overhaul : The Contractor shall provide all labor and materials to perform the overhaul services as described below for each hydraulic cylinder.

a. The open and inspect Condition Found Report with a detailed cost estimate shall contain the following as a minimum:

1. Date of inspection.

3. Condition of the shipping crate and any cost of repair.

4. Cost of overhaul labor as applicable.

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

6. A list of defective or worn parts recommended for repair/refurbishment (vice replacement) and the associated cost to accomplish these repairs.

7. List of required replacement parts. Identify any existing non-OEM parts that need replacement.

8. Provide digital photo documentation as per subsection 3.6. of this specification.

9. Cost of new cylinder for comparison to cost of overhaul.

3.3.4. The Coast Guard Contracting Officer will determine the disposition of any hydraulic cylinder delivered for overhaul that is Beyond Economical Repair (BER).

a. If the hydraulic cylinder is BER, the government reserves the right to purchase an identical new hydraulic cylinder from the Contractor.

3.3.6. All replacement parts used in the overhaul shall be new OEM parts.

Reclaimed, recycled, or aftermarket parts are not acceptable and shall not be used.

3.3.8. Remove any label plates and replace at the conclusion of the painting.

New label plates shall be used if the original plate is missing, not legible or in poor condition. The label plate shall contain hydraulic cylinder;

a. Spar (10371)

A copy of the paint data sheet shall also be provided to the Coast Guard Quality Assurance Representative.

3.3.11. Reassembly: The hydraulic cylinder shall be reassembled using only new OEM authorized parts. All fasteners shall be torqued to the manufacturer?s requirements or by use of general torque values for the type and size of fastener.

3.4. Testing : After completion of overhaul, the Contractor shall conduct the following tests to ensure proper functionality and seal integrity. These tests shall be in conjunction with any standard contractor quality assurance procedures. All testing shall be conducted on Contractor-supplied test equipment.

3.4.1. The Contractor shall be required to maintain a test equipment calibration program in compliance with ANSI/NCSL Z540.3-2006 (document 2.4.1.). The program shall be documented and traceable to the National Institute of Standards (NIST). The calibration system records shall be maintained for inspection for the duration of any contract referencing this specification.

3.4.2. Leak Test : The contractor shall conduct the following leak test. If any leakage occurs during the test, the hydraulic cylinder shall be repaired and re-tested until a successful test can be achieved. At the completion of testing, the cylinder shall be drained, rod end retracted, and cylinder hydraulic ports sealed with threaded plugs or caps.

a. Operate cylinder using contractor-supplied test equipment through several cycles of fully extended to fully retracted positions in order to test the general operation. No binding or chatter of the rod is acceptable.

b. Perform a static test of both sides of the piston at 150% of working pressure, or 3750 PSI test pressure (+/- 200 PSI), for not less than 5 minute time period for each position. The hydraulic cylinder shall be tested with the rod fully extended, and the rod end of the hydraulic cylinder shall be tested with the rod fully retracted. Any external leakage shall be grounds for rejection.

c. Test for Internal Bypass leakage. The test shall be tested in both directions of rod travel. Test shall begin with the rod retracted and loaded with 2,000 lbs (the load will try to force the rod to retract) the rod will be extended half its length and stopped. Hold position for 5 minutes and inspect for creeping of the rod. The load can then be reversed (the load will try to force the rod to extend). The rod will be retracted half its length and stopped. Hold position for 5 minutes and inspect for creeping of the rod.

Pass/failure criteria for this test will be rod creep greater than one half inch in either direction is a FAILURE.

3.4.3. Test results shall be documented on a report. A copy of the test report shall be packed with the tested hydraulic cylinder and a copy shall be turned over to the Coast Guard Quality Assurance Representative. The report shall contain the following information at a minimum:

a. Contractor name.

b. Contract number.

c. Delivery order number.

d. Cylinder model number.

e. Date of test.

f. Description of each test conducted, acceptable OEM tolerances as applicable, and actual results observed.

g. Name of the person conducting the testing.

h. Name of Coast Guard Quality Assurance Representative.

3.5. Delivery : Each overhauled and tested hydraulic cylinder shall be delivered to the Coast Guard completely assembled and ready for installation.

The Contractor shall preserve, package, and mark each hydraulic cylinder assembly in accordance with section 5.0. of this specification.

3.6. Photo Documentation : The Contractor shall provide digital photo documentation to the Contracting Officer as follows:

a. During initial opening of the hydraulic cylinder after receipt.

b. When hydraulic cylinder is completely disassembly for open and inspection report.

c. When significant findings that will affect cost of overhaul or time are discovered.

d. When other significant or unusual findings such as failed parts or damages are discovered.

e. When the hydraulic cylinder is tested to document configuration.

f. When the hydraulic cylinder is prepared for shipment to document "as shipped" configuration to include images of the PPP&M.

g. The photo documentation shall be color digital and shall be sent to the Contracting Officer and the Contracting Officer's Representative via email.

3.7. Notifications & Inspections : The Contractor shall be responsible for notifying the Contracting Officer at least ten (10) calendar days prior to the contractor being ready for any Quality Assurance (QA) inspections or testing required herein.

4.0. QUALITY ASSURANCE

4.1. Responsibility for Inspection : The Contractor shall be responsible for the performance of all inspection requirements specified herein. The Contractor shall provide space, personnel, and test equipment to conduct all required inspections. All inspection and testing shall be performed at the Contractor's plant or at other facilities acceptable to the Coast Guard. The Coast Guard reserves the right to verify or have performed any of the inspections or tests that are deemed necessary to assure that supplies and services conform to the prescribed requirements.

4.2. Responsibility for compliance : All items shall meet the requirements of this specification. The inspections set forth in this specification shall become part of the Contractor's overall inspection system or quality program.

The absence of any inspection requirements in the specification shall not relieve the Contractor of the responsibility of assuring that all products or supplies submitted to the government for acceptance comply with all requirements of the contract. Sampling for quality conformance does not authorize submission of known defective material (either indicated or actual) nor does it commit the government to acceptance of defective material.

new OEM authorized parts. All fasteners shall be torqued to the manufacturer?s requirements or by use of general torque values for the type and size of fastener.