Over Haul Description 4320-01-619-2264_RD.pdf

OVERHAUL DESCRIPTION

FOR OFFICIAL USE ONLY

ITEM NAME SEA WATER PUMP REPLACEMENT KIT

STOCK NUMBER

PART NUMBER

USED ON

4320-01-619-2264 SHELF LIFE CD

584-SWPMP-RPLM

418 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 REQUIREMENTS:

INSPECTION AND OVERHAUL DISCRIPTION 1. SCOPE: U.S. Coast Guard SFLC requires complete overhaul services for the following item(s): Sea Water

Pump Replacement Kit

584-SWPMP-RPLM

4320-01-619-2264

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: SEA WATER PUMP

2. Applicable documents:

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

b. ANSI/NCSL Z540.3-2006 Requirements for the Calibration of Measuring and

Test Equipment.

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

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

e. MIL-PRF-24635E Coating Systems, Weather-Resistant, Exterior Use 09/15/2009

f. MTU Engine Service manual M020078/11E

g. MTU Spare parts catalog EA535000/02DE

h. Packaging and Labeling SP-PP&M Rev D dtd 06/06/11Society for Protective

Coatings (SSPC) Hand Tool Cleaning SSP-SP2 (SSI-St3) Nov-04

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

St3) Nov-04

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

Jan-07

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

Sa2)Jan 07

l. U.S. COAST GUARD SPECIFICATION D-000-0100 REV G. (dated 06/2006) Bar coding For U.S.C.G. ELC Material. 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 the overhaul services. Overhaul services shall cover the entire assembly. 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 is intended to return the item to a condition equal to that of an identical new unit.

3.1 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. 3.1.1 It is assumed that the repairable item will arrive in a re-usable container. In the event the container is deemed unusable the contractor shall provide a recommendation on fixing or replacing the container to the contracting officer as part of the receiving report.

Photo documentation shall be included for any containers that will require repair or replacement. 3.2 Disassembly and inspection: Disassembly and inspection shall be conducted in accordance with OEM procedures, specifications, references and standard practices. A detailed condition found report shall be submitted to the Coast Guard Contracting Officer within 30 days of receipt of the material. Overhaul is intended to restore the item to a condition that is equal to that of a new item, it is the expectation that the overhauled sea water pump, will be returned to the Coast Guard as part of a Sea Water Pump Replacement Kit, NIIN: 4320-01-619-2264, PN: 584-SWPMP-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. The disassembly and inspection report 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 that will required to be repaired/replaced by part number, and quantity

d. For items found to be BER the Contractor shall provide in the report the conditions that render the item BER. 3.3 Beyond economical repair (BER):

the Coast Guard Contracting Officer will determine if any component delivered for overhaul is BER.

a. The Contracting Officer will determine the disposition of any item delivered for repair that is found to be not suitable for repair for whatever reason.

b. The Contractor shall mark the shipping containers for BER items that are being returned to the USCG IAW section 5.4.1 of this SOW with the exception of ?Coast Guard SFLC Material Condition A, Refurbished" shall be

?Coast Guard SFLC Material Condition H, BER". 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

Installation instructions: If the sea water pump requires any special pre-lube or instructions, they shall be red tagged and placed on the sea water pump 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 in accordance with OEM Spec. Label plate shall contain model and serial numbers. 3.7 Surface preservation: All surface coatings shall be removed from the sea water pump 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).

3.7.1 Painting: The entire pump/pump unit shall be painted with primer and finish coats of paint (excluding flange faces). Primer coat shall be a High

Build Epoxy suitable for use with the finish coat. Finish coat shall be in accordance with MIL-PRF-24635 Silicone Alkyd Enamel Type II Class 1. Color shall be ?Machinery Gray? in accordance with Federal Standard 595 color number 16307 or match the OEM color. High Build Epoxy total paint thickness shall be a minimum of 5 to 6 mils Dry Film Thickness (DFT). Finish coat

Silicone Alkyd Enamel Type II Class 1 total paint thickness shall be a minimum of 2 to 3 mils DFT. Total DFT shall be between 7 - 9 mils. 3.8

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). 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. 3.8.1 Any rotating part must rotate freely without any abnormal noise and vibration. 3.8.2 Clearances and tolerances shall be verified as per OEM specifications.

3.8.3 The Contractor shall remove the hot side of the turbo for the QAR to complete the inspection. 3.8.4 The QAR will inspect for smoothness of rotation and check for signs of binding. 3.8.5 The passageways shall be clean and free of debris and the proper preservation applied. 3.8.6 The contractor shall also make available a machinists? Stethoscope to listen for noises as the shaft assembly is being turned. 3.8.7 Contractor shall investigate any questionable test results and correct as necessary. 3.9

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

3.11 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. 3.12 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. 3.13 Assembly: Overhauled items shall be delivered to the Coast Guard completely assembled and ready for installation. Sea water pump shall be returned to the Coast Guard as a complete Sea Water Pump Replacement

Kit, NIIN: 4320-01-619-2264 PN: 584-SWPMP-RPLM. All parts for the Sea Water

Pump Replacement Kit shall be packaged with the Sea water pump along with a copy of the test results. Contractor shall preserve, package and mark the Sea

Water Pump Replacement Kit 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 3.7.1

d. Test requirements described in part 3.8

e. Final inspection and test reports as required in section 3.9

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

4.2 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. 4.3 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. 4.4 Warranty: Contractor?s standard new unit warranty applies.

4.5 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.

Contract Officer.

5. Preservation packaging 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:

a. The pump shall be drained and completely dried of all test fluid and blowndry with compressed air.

b. All open ports shall be sealed using plastic or rubber caps or covers to prevent the intrusions of 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. Wood screws directly into plywood will not be acceptable. The crate shall be assembled with corrosion resistant wood screws. Each item shall be securely fastened to the shipping container using lag bolts, washers and nuts or wooden blocking. The areas where skid mount bolts penetrate the heat sealed bag, a 1/8? thick rubber gasket and RTV shall be used to seal the bag from the entrance of moisture. 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 a Sea Water Pump

Replacement Kit, PN: 584-SWPMP-RPLM. The kit shall include the following parts: 584-SWPMP-RPLM

Sea Water Pump Replacement Kit

Sea Water Pump

5842004101/87

O-Ring 118 x 4

700429118000

Screw M10 x 60

000933010144

Washer 10.5

735151010200

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: 4320-01-619-2264

Item Name: Sea Water Pump Replacement Kit

P/N: 584-SWPMP-RPLM

Shipping Weight: To be determined by the Contractor

Government Contract No. See Contract ?Coast Guard SFLC Material Condition A, Refurbished." ?REUSABLE CONTAINER DO NOT DESTROY? 5.5 Bar coding: The stock number shall also be bar coded on two sides in addition to the numerical marking.

a. All bar coded labels shall be in accordance with SF LC Bar Coding specification number D-000-100 Rev. G. 1) The actual labels shall be Type

?V?, Grade ?C?, Style 2?, Composition ?a?. 2) The Bar Code Label can be applied separately or as part of the marking required in 5.4. 6. Notes:

6.1 Shipping:

a. 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

b. Delivery: Unless otherwise directed by the KO, the contractor shall returnrepaired item to: US Coast Guard

Surface Forces Logistics Center

2401 Hawkins Point RD, BLDG 88

Baltimore, MD 21226 6.1

Source of Documents:

a. 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

MTU America

Inc.

39525 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 4320-01-619-2264

ITEM NAME SEA WATER PUMP REPLACEMENT KIT

PART NUMBER 584-SWPMP-RPLM

GOVERNMENT ORDER NUMBER And the words: "Coast Guard

SFLC Material, Condition "A"

B. See Attachments