Over Haul Description 2950-01-620-0381_RD.pdf

OVERHAUL DESCRIPTION

FOR OFFICIAL USE ONLY

ITEM NAME REPLACMENT KIT,HP T TURBOCHARGER

STOCK NUMBER

PART NUMBER

USED ON

2950-01-620-0381 SHELF LIFE CD

584-HPTURBO-RPLM

418 FT WMSL

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 DESCRIPTION

ITEM NAME: TURBOCHARGER, HIGH PRESSURE

STOCK NUMBER: 2950-01-620-0381

PART NUMBER: 584-HPTURBO-RPLM

USED ON: 418 FT WMSL

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:

INSPECTION AND OVERHAUL DISCRIPTION

1. SCOPE: U.S. Coast Guard SFLC requires complete overhaul services for the following item(s): TURBO, HIGH PSI 584-HPTURBO-RPLM 2950-01-620-0381

Application: 418 FT WMSL Original Equipment

Manufacturer (OEM): MTU America Inc.

1.1 All references to items herein shall be inclusive to the part number.

Estimate and overhaul shall include the entire assembly.

1.2 Descriptive Data: HP Turbocharger

1.3 Receiving and Inspection report- The Contractor shall notify the Coast

Guard Contract Administrator within 10 days of receipt of the item. The

Receiving and Inspection report shall document the part number of the delivered item and that it conforms to the part cited. The report shall document any missing components or, otherwise, questionable condition that may hinder the overhaul process. The report shall also document the condition of the shipping container.

1.4 The overhaul requirements described herein are considered minimum and arenot intended to replace any procedures, controls, examinations or tests normally employed by the contractor to assure the quality of the product. Overhaul is intended to return the item to a condition equal to that of an identical new unit.

2. Applicable Documents:

a. COMDTINST M10360.3C, Coating & Color Manual, Appendix B, Cutters and

Boatsinterior Painting System.

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

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

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

e. Packaging and Labeling SP-PP&M Rev D dtd 06/06/11

f. ASTM-D-3951, dated 2004, Standard Practice for Commercial Packaging

g. MTU Spare parts catalog EA535000/02DE

h. MTU Engine Service manual M020078/11E

i. MTU Exhaust Turbocharger ZR210, M040059/10E

j. MTU Exhaust Turbocharger ZR170, M040055/10E

k. International Organization for Standardization (ISO), ISO 9001:2008

l. MTU Publication No. M070007

m. Society for Protective Coatings (SSPC) Hand Tool Cleaning SSP-SP2 (SSI-

St3) Nov-04

n. Society for Protective Coatings (SSPC) Power Tool Cleaning SSPC-SP3 (SSI-

St3) Nov-04

o. Society for Protective Coatings (SSPC) White Metal Blast SSPC-5 (SSI-Sa3)

Jan-07

p. Society for Protective Coatings (SSPC) Commercial Blast SSPC-SP6 (SSI-

Sa2)Jan 07

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 Inc parts. Overhaul services shall cover the entire assembly.

3.1 Preliminary Disassembly and Inspection Report-Preliminary disassembly andinspection shall be conducted in accordance with OEM procedures, specifications, references and standard practices to determine estimated cost of overhaul including material, labor, testing, and packing, preservation, packaging and marking costs. A detailed condition report and cost estimate shall be submitted to the Coast Guard Contracting

Officer within 30 days of receipt 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, additionally it is the expectation that the overhauled turbocharger will be returned to the

Coast Guard as part of an HP Turbo Replacement Kit, NIIN: 2950-01-620-

0381, PN: 584-HPTURBO-RPLM. 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.

3.2 Cost Estimate- A detailed cost estimate shall be submitted to the Coast

Guards 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:

1) The part number, NSN and serial number of the component

2) The contract number for the component

3) A listing of individual parts by part number, cost and quantity4) A listing of labor hours and labor rate to perform the overhaul, testing, and PPP&M

a. It is assumed that the Turbochargers will arrive in a re-usable container.In the event the container is deemed unusable the contractor shall state so as part of the inspection report and provide photo documentation. 5) The cost of an identical new component

3.3Beyond 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.

3.4 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 ball / roller type bearings, shall be equal to the quality of such parts originally installed by the OEM, but are not required to be supplied by the OEM. 3.5 If the turbo requires any special pre-lube or instructions, they shall be red tagged and placed on the turbo so the installing authority is aware of special instructions. 3.6 Label Plates (if applicable): The Contractor shall protect all label plates that are determined to be legible and in good condition prior to Surface Preparation, and Painting. Any label plates that have been determined to be not legible or in poor condition shall be removed by the contractor. New label plates shall be installed at the conclusion of painting if the original plate was removed or has been damaged during the overhaul process. Label plate shall contain unit make, model and serial numbers as well as all performance information as a minimum requirement if applicable.

3.7 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.

3.8 Surface Preservation: All surface coatings shall be removed from the

Turbocharger intake and mechanically cleaned by hand Tool Cleaning SSP-SP2

(SSI-St3), Power Tool Cleaning SSPC-SP3 (SSI-St3), White Metal Blast SSPC-5

(SSI-Sa3) or Commercial Blast SSPC-SP6 (SSI-Sa2).

3.9.1 Painting: The intake side of the HP Turbocharger 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.

3.10 Testing: Testing Requirements: After completion of an overhaul, contractor shall conduct the following described tests in the presence of a

Coast Guard Quality Assurance Rep (QAR). QAR shall be provided an opportunity to witness or review any operational or static test. 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.

3.10.1 Any rotating part must rotate freely without any abnormal noise and vibration. Clearances and tolerances shall be verified as per OEM specifications. The Contractor shall remove the hot side of the turbo for the QAR to complete the inspection. The QAR shall inspect for smoothness of rotation and check for signs of binding. The passageways shall be clean and free of debris and the proper preservation applied. The contractor shall also make available a machinists' Stethoscope to listen for noises as the shaft assembly is being turned. Contractor shall investigate any questionable test results and correct as necessary.

3.10.2 Test Report: Test results shall be documented on a Certificate of

Conformance. A copy of the Certificate 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.

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

National standards.

3.12 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.

3.13 Notifications & Inspections: The contractor is responsible for notifyingthe 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.

3.14 Assembly: Overhauled items shall be delivered to the Coast Guard completely assembled and ready for installation. Turbochargers shall be returned to the Coast Guard as a complete HP Turbo Kit, NIIN: 2950-01-

6200381, PN: 584-HPTURBO-RPLM. All parts for the HP Turbo replacement kit shall be packaged with the Turbocharger along with a copy of the test results. Contractor shall preserve, package and mark the Turbochargers in accordance with part 5 below.

4. Quality Assurance: The Contractor is responsible for the conformance and overall quality of each item offered to the Coast Guard for acceptance or approval. 4.1 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) Verify installation of OEM parts as described in part 3.4

b) Verify label/name plate installation in part 3.6

c) Paint thickness as specified in 3.9.1

d) Test requirements described in part 3.10

e) Final inspection and test reports as required in section 3.10.2

f) Inspection of preservation, packaging, packing, marking and bar-coding in accordance with section 5

4.3 Calibration System: The Contractor shall be required to maintain a test equipment calibration program in compliance with ISO 9001:2008. 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 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 C.G.

Contracting Officer.

5. Preservation and Marking:

5.1 Preservation:

5.1.1 Any overhauled item is typically intended for long term warehouse storage and not for immediate installation. Therefore, it is critical that the contractor ensures that the overhauled unit undergo the below preservation requirements in accordance with the Specification Packaging and Labeling SP-PP&M Rev D dated 6/11:

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

b) All open ports shall be sealed using waterproof caps or covers to prevent the intrusions of moisture and other contaminates.

c) Passages shall be fogged with a MIL-L-21260B preservative. i.e. RUSTOP

263.c

d) Each item shall be individually packaged in accordance with Method 51 of

MIL-STD-2073-1E w/Change 1 Desiccant of the proper type and quantity shall be enclosed within the heat sealable envelope prior to sealing the bag.

e) Any grease fittings must be capped with red zirc caps.5.2 Packing:

5.2.1 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 corrosion resistant 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:

5.3.1 The Contractor shall supply all the parts to complete an HP

Turbocharger Replacement Kit PN: 584-HPTURBO-RPLM. The kit shall include the following parts:

584-HPTURBO-RPLM HP Turbocharger Replacement Kit

HP Exhaust Turbocharger 5110201515/87 1

Gasket LP Turbo 5800180680 1

O-Ring LP Turbo 700429045000 2

Sealing Ring Turbos 5841420857 2

Sealing Ring Turbos 114C62033/1 2

Turbos Clamps 5111400241 1

Sealing Ring Housing 111D03014/1 5

Exhaust Gasket 5841422080 3

Exhaust Studs 200835010005 2

Exhaust Nut 200980010001 2

Exhaust Washers 000125010524 2

O-Ring RV 37X3mm 700429037002 2

O-Ring RV 30X3.5 mm 700429030000 2

Sealing Ring 007603030101 2

O-Ring 700429022000 8

O-Ring 22X5 mm 700429022000 8

O-Ring 15x5 mm 700429015004 8

Sealing Ring 007603024106 2

Oil Drain Gasket 5841870980 1

Oil Supply Sealing Ring 007603012111 4

O-Ring 170X8 mm 700429170001 1

O-Ring 140 X 8 mm 700429140000 1

Gasket LP Turbo 5840983680 2

O-Ring 130X6 mm 735254130000 4

O-Ring HP 112X6.3 mm 700429112000 24

O-Ring Air S 158X8 mm 700429158000 3

O-Ring 190X8 mm 700429190000 8

O-Ring 168X5.5 mm 700429168002 2

O-Ring 200 X 5 700429200001 1

O-Ring 345 X 6 mm 700429345000 1

O-Ring 45X5 mm 700429045000 2

Gasket LP Turbo 5840984480 1

O-Ring 83X5 mm WJ 700429083000 1

Gasket WJ 5802034980 1

O-Rings 60 X 5 mm 700429060000 24

Sealing Ring 007603016105 32

Gasket 5802035280 8

5.3.2 A copy of the material certifications shall be packaged inside a protective envelope. 5.3.3 The PP&M shall be in accordance with

SP-PP&M-001

5.4

Marking:

5.4.1 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: 2950-01-620-0381

Item Name: TURBO, EXHAUST HP, REPLACEMENT KIT

P/N: 584-HPTURBO-RPLM

S/N: To be determined by the Contractor

Shipping Weight: To be determined by the Contractor

Government Contract No. See Contract Coast Guard SFLC

Material Condition A, Refurbished 1 ea."

"REUSABLE CONTAINER DO NOT DESTROY"

5.4.2 BAR CODING: The stock number shall also be bar coded on two sides in addition to the numerical marking.

5.4.1 All bar coded labels shall be in accordance with SF LC Bar Coding specification number D-000-100 Rev. G.

a. The actual labels shall be Type "V", Grade "C", Style "2", Composition "A".

b. The Bar Code Label can be applied separately or as part of the marking required in 5.4. 6. 6. SHIPPING:

6.1 Pick Up- If the item is to be picked up by the Contractor from a Coast

Guard facility the Contractor will assume responsibility for the item upon being loaded into the Contractors vehicle. Unless otherwise directed the items shall be picked up from:

US Coast Guard Island Alameda

BLDG 42

Alameda, CA 94501

6.2 Delivery- Unless otherwise directed by the KO, the contractor shall return repaired item to:

US Coast Guard

Surface Forces Logistics Center

2401 Hawkins Point RD, BLDG 88

Baltimore, MD 21226

7. Notes:

Source of Documents:

Commercial:

Steel Structures Painting Council

40 24th Street

Pittsburgh, PA 15222

(412) 281-2331

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

Tognum America Inc.

59525 Mackenzie drive

Novi, MI 48377

International Organization for Standardization

1, ch. De la Voie-Creuse

CP 56 - CH-1211 Geneva 20

Switzerland

+41 22 749 01 11

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 o order and contractor's conformance to preservation/packaging, packing, marking requirements.

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

365 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.

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

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 2950-01-620-0381

ITEM NAME REPLACMENT KIT,HP T TURBOCHARGER

PART NUMBER 584-HPTURBO-RPLM

GOVERNMENT ORDER NUMBER And the words: "Coast Guard

SFLC Material, Condition "A"

B. See Attachments