Overhaul Description.pdf

OVERHAUL DESCRIPTION

FOR OFFICIAL USE

ONLY

SHELF LIFE CD 0

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: This description covers the requirements for contractor inspection,estimate and overhaul of the following cited pump and motor unit. NSN: 4320-01-032-4611

Item Name: Pump Unit, Centrifugal

P/N: 60063935

PAC Stock Pump No: 60063935

Application: WYTL 65 Fire Pump

Original Equipment Manufacturer (OEM): PCC Flow Technologies LP DBA PACO

Pumps.

1.1 All references to pump herein shall include both pump and motor.

Estimate and overhaul shall include pump and motor.

1.2 Descriptive Data: Pump unit complete with motor, flow rate OF 250 GPM.

Clockwise rotation; total head-250.0 FT.; pumping position-horizontal; 2

1/2"

NPT suction, 2" NPT discharge; drive shaft DIA.-1.375" NOM. MINIMUM of 550

GPM not to exceed 850 GPM, Total Head 314 TH, 3500 RPM, 75 HP motor, 230/460 volts AC. This is used on the WYTL 65 Fire Fighting System.

1.3 The assembly delivered for overhaul services is intended to be a complete

PACO Pump Co. P/N: 60063935. Contractor shall notify the Coast Guard

Contract Administrator of any missing components or, otherwise, questionable condition that may hinder the overhaul process.

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

2. Applicable Documents:

a) ANSI/NCSL Z540.3-2006, Calibration laboratories and Measuring and

TestEquipment General Requirements (1994 edition).

b) The Society for Protective Coatings, SSPC-SP 10, Near White

BlastCleaning, January 2007 edition.

c) SAE-AMS-STD-595 dated 2017.

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

e) Marking IAW MIL-STD-129R except bar coded IAW ISO/IEC-16388-2007 Code 39

Symbology.

f) Overhaul in accordance with OEM Tech Manual for the pump.

g) ASTM D3951-10, Commercial packaging.3. Requirements: The contractor shall provide all labor and materials to perform overhaul services on the PCC

ITEM NAME PUMP,CENTRIFUGAL

STOCK NUMBER 4320-01-032-4611

PART NUMBER 60063935

USED ON WYTL

FOR OFFICIAL USE ONLY

Flow Technologies Centrifugal Pump Unit. Overhaul services shall cover the entire pump unit that includes both the pump and motor.

3.1 Preliminary disassembly and inspection shall be conducted to determineestimated cost of overhaul including material, labor, testing, packing, marking and preservation costs. The shipping container that the pump unit was received in shall be inspected for possible re-use and addressed in the inspection report as to its condition or need for replacement. 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 both pump and motor sections.

Overhaul is intended to restore the pump unit to a condition that is equal to that of a new complete PACO Pump Co. P/N: 60063935 pump unit. Contractor shall immediately notify the Coast Guard Contracting Officer if the make and/or model delivered for overhaul services do not conform to the intended make and/or model cited in section 1.0 above, or is questionable for any reason.

3.2 Replacement Parts: All replacement parts used in the overhaul shall benew original OEM pump unit parts. All parts of the components shall be inspected for reusability and recorded on the inspection report, with the

OEM reference and allowable tolerance. Any non OEM parts used for overhaul shall be identified on cost estimate. 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 Zirc Fittings: If Grease fittings are installed. All zirc fittingsshall be replaced with new stainless steel zirc fittings with plastic caps on each fitting.

3.2.2 Decal: A decal or permanent type label shall be affixed to the side ofthe pump informing the user of the manufactures recommended amount and type of grease to be used if grease fittings are installed.

3.2.3 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.

3.2.4 Label Plates: Remove any label plates and replace at the conclusion ofpainting. 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 Special Instructions: Any pump unit delivered for overhaul having packingglands shall be converted to mechanical seal assemblies as part of the overhaul. Contractor shall include conversion work and parts in the overhaul estimate if found necessary.

3.4 Disposition: The Coast Guard shall determine the disposition of any pumpunit 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.

3.6 Painting: Entire pump and motor unit 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 "Fire Red" in accordance with

Federal Standard 595C color number 11105. Total paint thickness shall be a minimum of 3 mil dry film. 3.7 Testing:

3.7.1 Testing Requirements: After completion of overhaul, contractor shallconduct 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 pump unit shall be repaired and re-tested as necessary until a successful test is achieved.

3.7.2 Drive Motor: The drive motor supplied on the pump shall bereconditioned to a like new condition as part of the pump overhaul services. The drive motor is rated at 75 HP, 440 VAC, Three Phase, 60 Hz and

3500 RPM. Motor shall be disassembled and all parts thoroughly cleaned. As a minimum, mandatory replacement parts shall include upper and lower bearings and all gaskets. All other motor parts worn or damaged beyond manufacturers tolerances shall be recorded, repaired or replaced as determined by the contractor.

3.7.3 Motor windings shall be baked to thoroughly dry of any moisture thatmay be present within the windings. Check resistance of any contaminants between the windings and ground by megohmmeter or equal test. Depending on the condition of winding insulation, windings shall be re-dipped in a qualified insulation material or otherwise, manufacturers recommended insulation material, as determined by the contractor's inspections and/or conducted testing. Bake re-dipped windings until thoroughly dry and reassemble motor onto the pump.

3.7.4 Motor Certification: Contractor shall provide written

certificationthat the motor was reconditioned to the same standards as new.

The motor certification shall be accompanied with CRF on motor and overhaul report, parts replaced, and test conducted with results recorded IAW an electrical standard.

3.7.5 Rotational Test: To ensure the pump unit turns freely and without bind,the pump rotor assembly shall be rotated 10-20 times by the use of a strap wrench or other non-damaging tool. The QAR shall inspect for smoothness of rotation and check for signs of binding. Contractor shall investigate any questionable test results and correct as necessary.

3.7.6 Operational Test: Operational Test: The pump unit shall be run withfluid in a test tank for testing. The pump unit shall meet the flow curve to a tolerance of +/- 5% as a brand new pump unit. During the tests the bearings and seals shall be monitored and recorded on test report. The operational test should be 10 minutes at a minimum. Ensure the pump unit has no leaks. Any binding or unusual noise such as squealing coming from the pump unit during this test shall be corrected and retested after corrective work is complete.

3.7.7 Test Report: Test results shall be documented on a report. A copy ofthe test report shall be packed with the tested pump unit 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 Unit 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.

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

3.9 Assembly: Overhauled pump and motor unit shall be delivered to the Coast

Guard completely assembled and ready for installation. Contractor shall preserve, package and mark each pump and motor unit in accordance with part

5 below.

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

3.10 Responsibility for Inspection: The Contractor shall be responsible forthe 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 pump units.

3.11 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. 4. Quality Assurance:

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

4.2 Inspections & Tests: The inspections & tests required herein are theminimum 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 3.7.

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 testequipment 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 orinspection 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 unit warranty applies.

5. Preservation Packaging and Marking:

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

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

b) Intake and discharge ports shall have plastic cap inserts or wood coversinstalled.

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

d) Pump unit internals shall be sprayed with corrosion preventative MIL-PRF-

81309F.

5.2 Packaging: Each overhauled and preserved pump unit shall be individually packaged in its own enclosed ASTM-D6880 Class 2 wooden box. The box shall be assembled with stainless steel wood screws. Pump unit shall be bolted to the inside of the box and shall be constructed in such a manner as to prevent the pump unit from shifting within. Box shall be capable of protecting the pump unit 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, AND REMOVE BOLTS, LIFT

CRATE FROM SKID.

5.3.2 See below for marking layout:

STOCK NUMBER 4320-01-032-4611

ITEM NAME Pump Unit, Centrifugal

PART NUMBER 60063935

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 Bar code IAW ISO/IEC-16388-2007, Code 39 Symbology.

6. 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

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 4320-01-032-4611

ITEM NAME PUMP,CENTRIFUGAL

PART NUMBER 60063935

GOVERNMENT ORDER NUMBER And the words: "Coast Guard

SFLC Material, Condition "A"

B. See Attachments