Over Haul Description 01-F12-2755.pdf

OVERHAUL DESCRIPTION

FOR OFFICIAL USE ONLY

ITEM NAME CONTROL VALVE

STOCK NUMBER 4820-01-F12-2755

PART NUMBER 27771

USED ON WLR-75 / TB 20-50

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:

OVERHAUL REQUIREMENTS

1. SCOPE

1.1 This description initiates the inspection and overhaul of the item described below for SFLC stock replenishment.

NSN: 4820-01-F12-2755

Name: Valve, Control P/N: 27771 Application: WLR 75 TB 20-50 CRANE Original Equipment Manufacture (OEM): Allied Systems Co.

1.2 The control valve assembly delivered for overhaul services is intended to be a complete Allied Systems flow control valve, P/N: 27771. Contractor shall notify the Coast Guard Contracting Officer of any missing components or, otherwise, questionable condition that may hinder the overhaul process.

1.3 The overhaul requirements described herein are considered basic and are not intended to replace or eliminate any procedures, controls, examinations or tests normally employed by the contractor to assure the quality of the product. Overhaul is intended to restore the valve assembly to a condition equal to that of an identical new valve assembly.

2. Applicable Documents:

a) Technical Manual 3363, Crane, Telescoping Boom Model TB20-50.

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

c) SAE AMS-STD 595 Colors Used In Government Procurement.

d) MIL-PRF-16173E Int. Amendment 1, Corrosion Preventive Compound Solvent Cutback, Cold Application, dated 09/2006.

e) International Standard Organization (ISO) 4406, Hydraulic Fluid -Method of coding level of contamination by solid particles.

f) DOD 4140.01-M-1, Dated 07 Sept. 2007; Compliance for Defense Packaging:

Phytosanitary Requirements for Wood Packaging Material (WPM).

g) The Society for Protective Coatings, SSPC-SP 10, Near White Blast Cleaning, Sept. 2000 edition.

h) ANSI/NCSL Z540-3, Calibration laboratories and Measuring and Test Equipment General Requirements (1994).

i) ANSI/ASQ Q9001- 2008, Quality Management Systems - Requirements.

j) ASTM D3951-05 Rev. D, Commercial Packaging.

k) U.S Coast Guard Specification D-084-0481 Rev B. Equipment Unit Preservation, Packing and Marking.

l) ISO/IEC-16388-2007, Code 39 Symbology

2.1 Specification Order of Precedence: In the event of a conflict between the text of this specification and the references cited herein, the text of this specification takes 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 above Allied Systems valve assembly.

Overhaul services shall cover the valve assembly.

3.1 Preliminary disassembly and inspection shall be conducted to determine estimated cost of overhaul including material, labor, testing, preservation, packing and marking costs. 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 and testing of the entire valve assembly. Overhaul is intended to restore valve assembly to a condition that is equal to that of a new Allied Systems valve assembly.

3.1.1 Estimate shall include, as a mininum, a breakdown of costs for parts, labor, testing and other standard contractor procedures not covered by this description.

3.2 Requirements: The valve assembly shall be overhauled and tested in accordance with Allied Systems standard practices.

3.2.1 Overhaul shall include disassembly and thorough cleaning of all components. All gaskets, seals, bearings and any part normally replaced during overhaul shall be replaced. All other parts worn or damaged beyond manufacturers tolerances shall be repaired or replaced as determined by the contractor. All surfaces intended for paint shall be repainted in accordance with the original equipment paint standards.

3.2.2 Replacement parts used in overhaul shall only be new original Allied System parts. After market, substitute, reclaim or recycled parts are not acceptable and shall not be used.

3.2.3 Zirc Fittings: All zirc fittings shall be replaced with new stainless steel zirc fittings with plastic caps on each fitting.

3.2.4 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.

3.2.5 Label Plates: 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 valve assembly make, model and serial numbers as well as all pump performance information as a minimum requirement.

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

3.4 Painting: All outside surfaces intended for paint shall be painted in accordance with COMDTINST M10360.3C, Appendix B, Cutters and Boats Interior Painting System under: Machinery, Interior. NOTE: Contractor shall ensure

SHELF LIFE CD 0

OVERHAUL REQUIREMENTS

1. SCOPE

1.1 This description initiates the inspection and overhaul of the item described below for SFLC stock replenishment.

NSN: 4820-01-F12-2755

Name: Valve, Control P/N: 27771 Application: WLR 75 TB 20-50 CRANE Original Equipment Manufacture (OEM): Allied Systems Co.

1.2 The control valve assembly delivered for overhaul services is intended to be a complete Allied Systems flow control valve, P/N: 27771. Contractor shall notify the Coast Guard Contracting Officer of any missing components or, otherwise, questionable condition that may hinder the overhaul process.

1.3 The overhaul requirements described herein are considered basic and are not intended to replace or eliminate any procedures, controls, examinations or tests normally employed by the contractor to assure the quality of the product. Overhaul is intended to restore the valve assembly to a condition equal to that of an identical new valve assembly.

2. Applicable Documents:

a) Technical Manual 3363, Crane, Telescoping Boom Model TB20-50.

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

c) SAE AMS-STD 595 Colors Used In Government Procurement.

d) MIL-PRF-16173E Int. Amendment 1, Corrosion Preventive Compound Solvent Cutback, Cold Application, dated 09/2006.

e) International Standard Organization (ISO) 4406, Hydraulic Fluid -Method of coding level of contamination by solid particles.

f) DOD 4140.01-M-1, Dated 07 Sept. 2007; Compliance for Defense Packaging:

Phytosanitary Requirements for Wood Packaging Material (WPM).

g) The Society for Protective Coatings, SSPC-SP 10, Near White Blast Cleaning, Sept. 2000 edition.

h) ANSI/NCSL Z540-3, Calibration laboratories and Measuring and Test Equipment General Requirements (1994).

i) ANSI/ASQ Q9001- 2008, Quality Management Systems - Requirements.

j) ASTM D3951-05 Rev. D, Commercial Packaging.

k) U.S Coast Guard Specification D-084-0481 Rev B. Equipment Unit Preservation, Packing and Marking.

l) ISO/IEC-16388-2007, Code 39 Symbology

2.1 Specification Order of Precedence: In the event of a conflict between the text of this specification and the references cited herein, the text of this specification takes 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 above Allied Systems valve assembly.

Overhaul services shall cover the valve assembly.

3.1 Preliminary disassembly and inspection shall be conducted to determine estimated cost of overhaul including material, labor, testing, preservation, packing and marking costs. 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 and testing of the entire valve assembly. Overhaul is intended to restore valve assembly to a condition that is equal to that of a new Allied Systems valve assembly.

3.1.1 Estimate shall include, as a mininum, a breakdown of costs for parts, labor, testing and other standard contractor procedures not covered by this description.

3.2 Requirements: The valve assembly shall be overhauled and tested in accordance with Allied Systems standard practices.

3.2.1 Overhaul shall include disassembly and thorough cleaning of all components. All gaskets, seals, bearings and any part normally replaced during overhaul shall be replaced. All other parts worn or damaged beyond manufacturers tolerances shall be repaired or replaced as determined by the contractor. All surfaces intended for paint shall be repainted in accordance with the original equipment paint standards.

3.2.2 Replacement parts used in overhaul shall only be new original Allied System parts. After market, substitute, reclaim or recycled parts are not acceptable and shall not be used.

3.2.3 Zirc Fittings: All zirc fittings shall be replaced with new stainless steel zirc fittings with plastic caps on each fitting.

3.2.4 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.

3.2.5 Label Plates: 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 valve assembly make, model and serial numbers as well as all pump performance information as a minimum requirement.

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

3.4 Painting: All outside surfaces intended for paint shall be painted in accordance with COMDTINST M10360.3C, Appendix B, Cutters and Boats Interior Painting System under: Machinery, Interior. NOTE: Contractor shall ensure that grease fittings and other surfaces not intended for paint are protected.

3.5 Testing:

3.5.1 Testing Requirements: After completion of overhaul, contractor shall conduct the following described tests. All tests shall be witnessed by a Coast Guard Quality Assurance Representative (QAR). All testing shall be accomplished on contractor supplied calibrated test equipment. Any failed valve assembly shall be repaired and re-tested as necessary until a successful test is achieved.

3.5.2 Operational Test: The valve assembly shall be operated to ensure proper operation and that no leakage of hydraulic fluid occurs. Contractor shall provide test certification for each valve assembly upon determination of satisfactory operation.

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 valve assembly 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. Valve 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 valve assembly shall be delivered to the Coast Guard completely assembled and ready for installation. Contractor shall preserve, package and mark each pump in accordance with part 5 below.

3.7.1 Contractor shall supply a waterproof instruction sheet containing the manufactured alignment procedure. The sheet shall be placed with the valve assembly inside a polyurethane bag required in part 5.1.

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 Guards 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. The Coast Guard intents to have QA perform inspection on all valve assembly.

3.9 Inspections & Notification: The contractor shall notify the Coast Guard Contracting Officer, at least ten days prior to the scheduled commencement of any inspections required by this statement of work.

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) Visual inspection of the paint coat.

c) Inspection of packaging and marking.

d) Operational Test

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 Q.A. Inspector upon his arrival at the contractor's plant.

4.5 Warranty: Contractor's standard new valve assembly warranty applies.

5. Preservation Packaging and Marking:

5.1 Preservation: Any overhauled valve assembly is intended for warehouse storage and not for immediate installation. Therefore, it is critical that the contractor ensures that the overhauled valve assembly undergo the below preservation requirements:

a) Valve assembly shall be drained of and dried of all test fluid.

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

c) Each valve assembly shall be bagged in an 8 mil minimum thickness translucent polyurethane bag with at least four (4) 4 ounce desiccant packs in the bag. Bag opening shall be sealed closed with a plastic tie wrap.

5.2 Packaging: Each overhauled and preserved valve assembly shall be individually packaged in its own enclosed wooden box. The box shall be assembled with stainless steel wood screws. Valve assembly shall be bolted to the inside of the box and shall be constructed in such a manner as to prevent the valve assembly from shifting within. Box shall be capable of protecting the valve assembly from damage during multiple shipments by commercial carrier.

5.3 Marking: Each preserved, packed, and packaged item shall be marked in the that grease fittings and other surfaces not intended for paint are protected.

3.5 Testing:

3.5.1 Testing Requirements: After completion of overhaul, contractor shall conduct the following described tests. All tests shall be witnessed by a Coast Guard Quality Assurance Representative (QAR). All testing shall be accomplished on contractor supplied calibrated test equipment. Any failed valve assembly shall be repaired and re-tested as necessary until a successful test is achieved.

3.5.2 Operational Test: The valve assembly shall be operated to ensure proper operation and that no leakage of hydraulic fluid occurs. Contractor shall provide test certification for each valve assembly upon determination of satisfactory operation.

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 valve assembly 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. Valve 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 valve assembly shall be delivered to the Coast Guard completely assembled and ready for installation. Contractor shall preserve, package and mark each pump in accordance with part 5 below.

3.7.1 Contractor shall supply a waterproof instruction sheet containing the manufactured alignment procedure. The sheet shall be placed with the valve assembly inside a polyurethane bag required in part 5.1.

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 Guards 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. The Coast Guard intents to have QA perform inspection on all valve assembly.

3.9 Inspections & Notification: The contractor shall notify the Coast Guard Contracting Officer, at least ten days prior to the scheduled commencement of any inspections required by this statement of work.

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) Visual inspection of the paint coat.

c) Inspection of packaging and marking.

d) Operational Test

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 Q.A. Inspector upon his arrival at the contractor's plant.

4.5 Warranty: Contractor's standard new valve assembly warranty applies.

5. Preservation Packaging and Marking:

5.1 Preservation: Any overhauled valve assembly is intended for warehouse storage and not for immediate installation. Therefore, it is critical that the contractor ensures that the overhauled valve assembly undergo the below preservation requirements:

a) Valve assembly shall be drained of and dried of all test fluid.

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

c) Each valve assembly shall be bagged in an 8 mil minimum thickness translucent polyurethane bag with at least four (4) 4 ounce desiccant packs in the bag. Bag opening shall be sealed closed with a plastic tie wrap.

5.2 Packaging: Each overhauled and preserved valve assembly shall be individually packaged in its own enclosed wooden box. The box shall be assembled with stainless steel wood screws. Valve assembly shall be bolted to the inside of the box and shall be constructed in such a manner as to prevent the valve assembly from shifting within. Box shall be capable of protecting the valve assembly from damage during multiple shipments by commercial carrier.

5.3 Marking: Each preserved, packed, and packaged item shall be marked in the upper left-hand side of the two longest sides, (two opposite sides if square) of each box, carton, package, etc. The lettering shall be black painted stencil and permanently affixed to each container. The lettering shall be at least 1" high, and be applied on a highly contrasting white painted background.

5.3.1 This marking shall consist of the STOCK NUMBER, ITEM NAME, PART NUMBER, SERIAL NUMBER, CONTRACT NUMBER, SHIPPING WEIGHT (in lbs.), CONDITION CODE, UNIT OF ISSUE with QUANTITY (1EA) and the words COAST GUARD SFLC MATERIAL

CONDITION "A" REUSABLE CONTAINER, DO NOT DESTROY, REMOVE BOLTS, LIFT CRATE

FROM SKID.

5.3.2 See below for marking layout:

STOCK NUMBER 4810-01-F12-2755

ITEM NAME Valve, Control

PART NUMBER 27771

SERIAL NUMBER (As determined) CONTRACT NUMBER (See Contract) SHIPPING WEIGHT (As determined)

CONDITION CODE CONDITION A

QUANTITY & UNIT OF ISSUE 1-EA

OTHER DATA AS DIRECTED COAST GUARD SFLC

MATERIAL, REUSABLE

CONTAINER, DO NOT DESTROY

REMOVE BOLTS, LIFT CRATE

SKID

5.4 Bar Coding: Bar coding shall be supplied on all CLIN's except for those that require data submissions only.

5.4.1 All bar coded labels shall be in accordance with ISO/IEC-16388-2007, Code 39 Symbology

1. The actual labels shall be Type "V", Grade "A", Style "2", Composition "B" with plastic laminate.

2. Each label shall contain encoded data for the Stock Number, part number, and Contract Number.

WARRANTY:

X A. Standard Manufacturer's Warranty

B. Item being repaired as an "onboard repair" or a "system stock" item and will be put into inventory. NOT FOR IMMEDIATE INSTALLATION.

Contractor must guarantee item against defects that lead to failure for

90 days after installation for a period of up to two (2) years after delivery to Coast Guard.

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 and marking requirements.

PACKAGING AND MARKING FOR SHIPMENT:

X A. Each unit shall be packed individually in it's own wooden box which shall be capable of providing adequate protection to the item during multiple shipments. Mark each box in legible black print lettering with the following information:

NATIONAL STOCK NUMBER

ITEM NAME

PART NUMBER

GOVERNMENT ORDER NUMBER

4820-01-F12-2755

CONTROL VALVE

27771

PRESERVATION / PACKAGING:

X A. Each unit shall be individually preserved and wrapped for protection against deterioration for a period of two (2) years minimum.

B. See Attachments

B. See Attachments

And the words: "Coast Guard SFLC Material, Condition "A"