Over Haul Description 4320-01-667-3440.pdf

OVERHAUL DESCRIPTION

FOR OFFICIAL USE ONLY

ITEM NAME PUMP,SEAWATER

STOCK NUMBER 4320-01-667-3440

PART NUMBER 480-7095

USED ON WLB-225 PROPULSION DIESEL ENGINE

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. Scope: This description covers the requirements for contractor inspection, estimate and overhaul of the following cited Pump. Overhaul must be done by a Caterpillar-authorized service center.

NSN: 4320-01-667-3440

Item Name: Pump, Seawater P/N: 480-7095 Application: 225' WLB Raw Water Pump Original Equipment Manufacturer (OEM): Caterpillar INC.

1.1 The assembly delivered for overhaul services is intended to be a complete Caterpillar Sea Water Pump, P/N: 480-7095. Contractor shall notify the Coast Guard Contract Administrator of any missing components or, otherwise, questionable condition that may hinder the overhaul process.

1.2 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 pump to a condition equal to that of an identical new pump.

2. Applicable Documents:

a. ANSI/NCSL Z540-1-1994 (dated 1994) Calibration laboratories and Measuring and Test Equipment- General Requirements.

b. The Society for Protective Coatings, SSPC-SP 10, and Near White Blast Cleaning dated 09/2000.

3. Requirements: The contractor shall provide all labor and materials to perform overhaul services on the Caterpillar Centrifugal Pump. Overhaul services shall cover the entire pump.

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 pump. Overhaul is intended to restore the pump to a condition that is equal to that of a new Caterpillar Model 480-7095 Seawater Pump. Contractor shall immediately notify the Coast Guard Contracting Officer if the make and/or model delivered for overhaul services does not conform to the intended make and/or model cited in section 1.0 above, or is questionable for any reason.

3.1.1 During preliminary disassembly, Contractor shall inspect for the presence of a weep hole. Lack of a weep hole indicates a manufacturing defect that shall be corrected during overhaul at no expense to the Government. See paragraph 3.3 below. If the assembly/disassembly procedure for this pump is needed, contact Mr. Mike Weiland at WEILAND_MICHAEL_D@cat.com.

3.2 Replacement Parts: All replacement parts used in the overhaul shall be new original OEM Pump 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.

3.2.1 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 pump make, model and serial numbers as well as all pump performance information as a minimum requirement.

3.3 If a weep hole is not present, the pump shall be modified at no cost to the Goverment per Caterpillar Service Letter PS47023. Any questions regarding the weep hole modification should be directed to Mr. Mike Weiland at the email address in paragraph 3.1.

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

3.5 Paint Removal: Removal of existing paint shall be accomplished by abrasive blast to near white metal in accordance with SSPC SP-10 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. Remove any label plates and replace at the conclusion of painting.

3.5.1Painting: Entire pump 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 as directed by the OEM. Total paint thickness shall be a minimum of 3 mil dry film.

3.6 Testing:

3.6.1 Testing Requirements: After completion of overhaul, contractor shall conduct the following described tests. The Coast Guard reserves the right to have all testing witnessed by a Coast Guard Quality Assurance Representative.

All testing shall be accomplished on contractor supplied calibrated test equipment. Any failed pump shall be repaired and re-tested as necessary until a successful test is achieved.

3.6.2 Operational Test: Operational Test: Each pump shall be placed onto a calibrated test stand and calibrated as per the CAT mfg manual for this part number.

3.6.3 Test Report: Test results shall be documented on a report. A copy of the test report shall be packed with the tested pump 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.

SHELF LIFE CD 0

1. Scope: This description covers the requirements for contractor inspection, estimate and overhaul of the following cited Pump. Overhaul must be done by a Caterpillar-authorized service center.

NSN: 4320-01-667-3440

Item Name: Pump, Seawater P/N: 480-7095 Application: 225' WLB Raw Water Pump Original Equipment Manufacturer (OEM): Caterpillar INC.

1.1 The assembly delivered for overhaul services is intended to be a complete Caterpillar Sea Water Pump, P/N: 480-7095. Contractor shall notify the Coast Guard Contract Administrator of any missing components or, otherwise, questionable condition that may hinder the overhaul process.

1.2 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 pump to a condition equal to that of an identical new pump.

2. Applicable Documents:

a. ANSI/NCSL Z540-1-1994 (dated 1994) Calibration laboratories and Measuring and Test Equipment- General Requirements.

b. The Society for Protective Coatings, SSPC-SP 10, and Near White Blast Cleaning dated 09/2000.

3. Requirements: The contractor shall provide all labor and materials to perform overhaul services on the Caterpillar Centrifugal Pump. Overhaul services shall cover the entire pump.

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 pump. Overhaul is intended to restore the pump to a condition that is equal to that of a new Caterpillar Model 480-7095 Seawater Pump. Contractor shall immediately notify the Coast Guard Contracting Officer if the make and/or model delivered for overhaul services does not conform to the intended make and/or model cited in section 1.0 above, or is questionable for any reason.

3.1.1 During preliminary disassembly, Contractor shall inspect for the presence of a weep hole. Lack of a weep hole indicates a manufacturing defect that shall be corrected during overhaul at no expense to the Government. See paragraph 3.3 below. If the assembly/disassembly procedure for this pump is needed, contact Mr. Mike Weiland at WEILAND_MICHAEL_D@cat.com.

3.2 Replacement Parts: All replacement parts used in the overhaul shall be new original OEM Pump 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.

3.2.1 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 pump make, model and serial numbers as well as all pump performance information as a minimum requirement.

3.3 If a weep hole is not present, the pump shall be modified at no cost to the Goverment per Caterpillar Service Letter PS47023. Any questions regarding the weep hole modification should be directed to Mr. Mike Weiland at the email address in paragraph 3.1.

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

3.5 Paint Removal: Removal of existing paint shall be accomplished by abrasive blast to near white metal in accordance with SSPC SP-10 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. Remove any label plates and replace at the conclusion of painting.

3.5.1Painting: Entire pump 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 as directed by the OEM. Total paint thickness shall be a minimum of 3 mil dry film.

3.6 Testing:

3.6.1 Testing Requirements: After completion of overhaul, contractor shall conduct the following described tests. The Coast Guard reserves the right to have all testing witnessed by a Coast Guard Quality Assurance Representative.

All testing shall be accomplished on contractor supplied calibrated test equipment. Any failed pump shall be repaired and re-tested as necessary until a successful test is achieved.

3.6.2 Operational Test: Operational Test: Each pump shall be placed onto a calibrated test stand and calibrated as per the CAT mfg manual for this part number.

3.6.3 Test Report: Test results shall be documented on a report. A copy of the test report shall be packed with the tested pump 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. Pump 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.

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

NIST.

3.8 Assembly: Overhauled pump 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.

3.9 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 pumps.

3.10 Notifications & Inspections: The contractor is responsible for notifying the Contracting Officer no less than seven (7) 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 3.8.

b) Visual inspection of the paint coat.

c) Inspection of packaging and marking.

4.3 Calibration System: The Contractor shall be required to maintain a test equipment calibration program in compliance with ANSI/NCSL Z540-3. 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 pump warranty applies.

5. Preservation Packaging and Marking:

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

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

b) Intake and discharge ports shall have plastic cap

c) Each pump 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 pump shall be individually packaged in its own framed in wooden crate. The crate shall be assembled with stainless steel wood screws. Pump shall be bolted or secured inside the crate with the two part expanding foam and the crate cover secured to the inside of the crate and shall be constructed in such a manner as to prevent the pump from shifting within. Crate shall be capable of protecting the pump from damage during multiple shipments by commercial carrier.

5.3 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 background. 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: 4320-01-667-3440

Item Name: Pump, Seawater P/N: 480-7095 Shipping Weight: ______ Government Contract No. ________________ Coast Guard SFLC Material, Condition A, 1 EA

5.4 BAR CODING: The stock number shall also be bar coded in addition to the numerical marking.

1. All bar coded labels shall be in accordance with MIL-STD-129R using ISO/IEC-16388-2007 Code 39 Symbology.

2. Only the National Stock Number need be bar coded.

3. The Bar Code Label can be applied separately or as part of the marking required in 5.3.

5.5 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:

c. Pump 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.

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

NIST.

3.8 Assembly: Overhauled pump 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.

3.9 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 pumps.

3.10 Notifications & Inspections: The contractor is responsible for notifying the Contracting Officer no less than seven (7) 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 3.8.

b) Visual inspection of the paint coat.

c) Inspection of packaging and marking.

4.3 Calibration System: The Contractor shall be required to maintain a test equipment calibration program in compliance with ANSI/NCSL Z540-3. 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 pump warranty applies.

5. Preservation Packaging and Marking:

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

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

b) Intake and discharge ports shall have plastic cap

c) Each pump 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 pump shall be individually packaged in its own framed in wooden crate. The crate shall be assembled with stainless steel wood screws. Pump shall be bolted or secured inside the crate with the two part expanding foam and the crate cover secured to the inside of the crate and shall be constructed in such a manner as to prevent the pump from shifting within. Crate shall be capable of protecting the pump from damage during multiple shipments by commercial carrier.

5.3 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 background. 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: 4320-01-667-3440

Item Name: Pump, Seawater P/N: 480-7095 Shipping Weight: ______ Government Contract No. ________________ Coast Guard SFLC Material, Condition A, 1 EA

5.4 BAR CODING: The stock number shall also be bar coded in addition to the numerical marking.

1. All bar coded labels shall be in accordance with MIL-STD-129R using ISO/IEC-16388-2007 Code 39 Symbology.

2. Only the National Stock Number need be bar coded.

3. The Bar Code Label can be applied separately or as part of the marking required in 5.3.

5.5 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:

None

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 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

4320-01-667-3440

PUMP,SEAWATER

480-7095

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"