MTU_S60 Heat Exchanger_ovhl_SOW.docx

UNITED STATES COAST GUARD

SURFACE FORCES LOGISTICS CENTER

Repair Description

MTU Series 60 Engine 29 Plate Heat Exchanger

Michael McHale

04/27/22

OVERHAUL/ REPAIR DESCRIPTION

This document sets forth the requirements for the overhaul services, receipt, storage, inspection, repair, testing, preservation, packaging, and marking of MTU Series 60 Engine 29 Plate Heat Exchanger, P/N 23535343. 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/ REPAIR REQUIREMENTS:

INSPECTION AND OVERHAUL DESCRIPTION

1. SCOPE: U.S. Coast Guard SFLC requires complete overhaul/ repair services for the following item(s):

Application: 45’ Response Boat Medium (RBM) Original Equipment Manufacturer (OEM): MTU America Inc.

1.1 All references to items herein shall be inclusive to the part number. Estimate and overhaul/ repair shall include the entire assembly.

1.2 Descriptive Data: VARIOUS

1.3 Contractor shall notify the Coast Guard Contract Administrator of any missing components or, otherwise, questionable condition that may hinder the overhaul/ repair process.

1.4 The overhaul requirements described herein are considered minimum and are not intended to replace any procedures, controls, examinations or tests normally employed by the contractor to assure the quality of the product. Overhaul/ repair is intended to return the item to a condition equal to that of an identical new unit.

2. Applicable Documents:

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

b. COMDTINST M10360.3C, Coating & Color Manual, Appendix B, Cutters and Boats interior Painting System.

c. Federal Standard, FED-STD-595 Colors Used In Government Procurement.

d. ASTM A-276-06 Standard specification for stainless steel bars and shapes, 2006 edition.

e. U.S. COAST GUARD SPECIFICATION D-000-0100 REV G. (dated 06/2006) bar coding For U.S.C.G. ELC Material.

f. Packaging and Labeling MIL-STD-2073

g. ASTM-D-3951 Standard Practice for Commercial Packaging

h. MTU Engine Service manual MS25056/00E

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

k. American Society for Testing and Materials (ASTM) D3951-98, dated 2004, Standard Practice for Commercial Packaging

2.1 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. Requirements: The contractor shall provide all labor and materials to perform overhaul services on the MTU America parts. Overhaul services shall cover the entire assembly.

3.1 Preliminary disassembly and inspection shall be conducted in accordance with OEM procedures, specifications, references and standard practices to determine estimated cost of overhaul including material, labor, testing, packing, preservation, and packaging.. A detailed estimate shall be submitted to the Coast Guard Contracting Officer for approval prior to the start of overhaul work. Estimate shall include overhaul, testing, packaging, preservation, and marking. Overhaul is intended to restore the item to a condition that is equal to that of a new item. Contractor shall immediately notify the Coast Guard Contracting Officer if an item delivered for overhaul services does not conform to the intended item cited in section 1.0 above, or is questionable for any reason.

Cost Estimate- A detailed cost estimate shall be submitted to the Coast Guard’s Contracting Officer for review and approval prior to the start of any repair or order of material. The Contractor shall also provide the replacement cost of an identical new item for comparison to the overhaul cost. The detailed cost estimate shall contain the following as a minimum:

a. The part number, NSN and serial number of the component

b. The contract number for the component

c. A listing of individual parts by part number, cost and quantity

d. A listing of labor hours and labor rate to perform the overhaul, testing, and PPP&M

e. The cost of an identical new component

Beyond Economical Repair (BER) - the Coast Guard Contracting Officer will determine the disposition of any component delivered for overhaul that is BER. If a component is BER, the government reserves the right to purchase an identical new component from the contractor.

3.2 Replacement Parts: All replacement parts used in the overhaul shall be new original OEM parts. Reclaimed, recycled or aftermarket parts are not acceptable and shall not be used. Parts not normally manufactured by the OEM, such as seals and cooler plates, shall be equal to the quality of such parts originally installed by the OEM, but are not required to be supplied by the OEM.

3.2.1 Decal: A decal or permanent type label shall be affixed to the side of the unit informing the user of the date of overhaul and location.

3.2.2 Pipe Plugs: All pipe plugs shall be replaced with new grade 316 stainless steel pipe plugs. The stainless steel grade shall conform to ASTM A 276 or equal standard. Plugs shall be installed using Teflon tape or equal thread sealer unless any sealer is specifically prohibited.

3.2.3 Label Plates (if applicable): Remove any label plates and replace at the conclusion of painting. New label plates shall be used if the original plate is not legible or in poor condition. Label plate shall contain unit make, model and serial numbers as well as all performance information as a minimum requirement if applicable. Label plates for Coolers. The Contractor shall attach an anodized aluminum test data plate to each cooler using epoxy resin cement. Ensure that each plate is engraved with ¼-inch high letters, stating the following:

a. Hydrostatic test pressure.

b. Test date.

c. Testing facility.

3.3 Disposition: The Coast Guard shall determine the disposition of any item delivered for repair that is found to be not suitable for repair for whatever reason.

3.4 Painting (if applicable): an item shall be painted with primer and finish coats. Primer coat shall be any rust preventive metal primer suitable for use with the finish coat. Finish coat shall be Silicone Alkyd Enamel Type III Class 1. Color shall be “Machinery Gray” in accordance with Federal Standard 595 color number 16376. Total paint thickness shall be a minimum of 4 to 6 mils dry film thickness, not to exceed 12 mils dry thickness.

3.5 Testing:

3.5.1 Testing Requirements: After completion of an overhaul, contractor shall conduct the following described tests. Coast Guard reserves the right to provide a Quality Assurance Representative (QAR) to witness or review any testing highlighted in 3.5 testing.. All testing shall be accomplished on contractor supplied calibrated test equipment. If an item fails, it shall be repaired and re-tested as necessary until a successful test is achieved. All repairs shall be in accordance with OEM specifications and procedures and shall be made available to the QAR.

3.5.2 1. Blank off all inlet and outlet connections using a sealed flanges and install the coolant level sensor to the jacket water cooler.

2. Pressure test system for possible leaks using the radiator cap test kit.

a. Attach the tester kit to the adapter provided.

b. Attach the pressure cap to the end of the adapter.

c. Operate the pressure tester pump until the gauge on the tester indicates 5 psi.

(1) Verify the CAP valve is opened.

d. Release the pressure on tester until 5 psi is indicated on gauge.

(1) Verify the pressure indicated on tester pressure gauge remains constant at 5 psi for at least 60 seconds using the stopwatch.

(2) Verify that the CAP valve is closed.

e. Remove the cap from the tester.

3.5.3 Test Report: Test results shall be documented on a report. A copy of the test report shall be packed with the tested item and a copy shall be turned over to the Coast Guard Quality Assurance Representative. Report shall contain the following information as a minimum:

a. Contractor name.

b. Contract number.

c. Item Model & Serial Numbers

d. Date of test.

e. Description of each test conducted and results of each test.

f. Name of the person conducting the testing.

3.6 Calibration: All test equipment and attached gages shall be calibrated and have a current calibration sticker. Calibration shall be traceable to National standards.

3.7 Assembly: Overhauled items shall be delivered to the Coast Guard completely assembled and ready for installation.

3.8 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 the conduct of all inspection requirements. All inspection and testing shall be performed at the Contractors facility prior to the Coast Guard’s acceptance of the contracted items. The Coast Guard reserves the right to 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.

3.9 Notifications & Inspections: The contractor is responsible for notifying the Contracting Officer no less than ten (10) calendar days prior to the contractor being ready for any Quality Assurance (Q.A.) inspections or testing required herein.

4. Quality Assurance:

4.1 General: The Contractor is responsible for the conformance and overall quality of each item offered to the Coast Guard for acceptance or approval

4.2 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 are required:

a. Test requirements described in part 3.5.

b. Paint thickness as specified in 3.4 Inspection of preservation, packaging, packing, marking and bar-coding in accordance with section 5

c. Verify OEM installation of parts in part 3.2

d. Verify label/name plate installation in part 3.2.3

e. Final inspection and test reports as required in section 3.5.4

4.3 Calibration System: The Contractor shall be required to maintain a test equipment calibration program in compliance with ANSI/NCSL Z540-1. 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.

4.4 Test & Inspection Reports: A copy of any standard contractor test or inspection report shall be turned over to the Coast Guard COR (Contracting Officer’s Representative).

4.5 Warranty. Contractor’s standard new unit warranty applies.

4.6 Failure Responsibility – If a component fails to pass any inspection/test the contractor shall report the failure and the recommended fix to the Coast Guard Contract Officer.

5. Preservation Packaging and Marking:

5.1 Preservation: Any overhauled item is intended for warehouse storage for up to two (2) year minimum and not for immediate installation. Therefore, it is critical that the contractor ensures that the overhauled unit undergo the below preservation requirements:

a. Any fluid shall be drained and the unit must be dry.

b. Intake and discharge ports shall have plastic cap inserts or wood covers installed with a desiccant pouch stapled to the inside of each cap or cover.

5.2 Packing: The overhauled and preserved item shall be individually packaged in its own framed in wooden crate, totally enclosed, with a skid mount to facilitate handling by a fork lift. The crate shall be assembled with wood screws. The item shall be bolted to the inside of the crate or wooden blocking shall be incorporated and shall be constructed in such a manner as to prevent the item from shifting within. Crates shall be capable of protecting the item from damage during multiple shipments by commercial carrier.

5.3 Packaging:

All open ports shall be sealed using waterproof caps or covers to prevent the intrusions of moisture and other contaminates. Just before the package is sealed, add the appropriate amount of desiccant shall be placed inside each item as per MIL-D-3464D.

5.4 Marking: Shipping container shall be stenciled with black enamel paint with the information as laid out below. Stencil shall be applied directly on the container and be 1/2 inch minimum height black characters on a white painted contrasting background in the upper left-hand side of the two longest sides (two opposite sides if square) of each box. NOTE: ALL PREVIOUS MARKINGS AND / OR QUALITY ASSURANCE DECALS SHALL BE COMPLETELY REMOVED FROM A REUSABLE SHIPPING CONTAINER PRIOR TO THE APPLICATION OF ANY NEW MARKINGS. The following information shall be included in the markings:

NSN: 4420-01-600-2330

Item Name: COOLER, FLUID INDUSTRIAL (HEAT EXCHANGER) P/N: 23535343 Unit of Issue: 1 EA Shipping Weight: 216LBS Government Contract No. TBD Condition Code: “A”

US Coast Guard SFLC Material

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 contractors conformance to preservation, packing and marking requirements.

6. Notes:

Source of Documents:

Naval Publication and Forms Center 5801 Tabor Ave.

Philadelphia Pa. 19120 215-697-2000 / 2626

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

MTU America Inc.

13400 Outer Drive West Detroit, MI. 48239

WARRANTY:

__x___ A. Standard Manufacturer’s Warranty

GOVERNMENT ACCEPTANCE:

Acceptance will be made at destination by a Government representative. Acceptance will be contingent upon the representative’s verification of no damage in transit, correctness and completeness of order and contractor’s conformance to preservation/packaging, packing, marking requirements.