Posting RD.pdf

OVERHAUL DESCRIPTION

FOR OFFICIAL USE ONLY

ITEM NAME MOTOR,ALTERNATING CURRENT

STOCK NUMBER 6105-01-598-4411

PART NUMBER 808008-3

USED ON CGC WMSL 418 ' NSC - STERN BOAT - CENTERLINE WINCH

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 Specification Reliance Motors 0.75 HP AC Motor with attached Stearns Motor Brake

1.0 SCOPE

1.1. This document sets forth the requirements for the receipt, disassembly, inspections, condition/test reports, overhaul/repair, reassembly, testing, preservation, packaging, packing, and marking of the Brake Actuator AC Motor used on 418 ft WMSL U.S. U.S. Coast Guard Cutters.

1.2. Government Furnished Property (GFP)

1.2.1. Reliance Motors, 1 AC Motor with attached Stearns Motor Brake SM-50-

20MB

BALDOR - RELIANCE MOTOR, AC, BRAKE ACTUATOR

PN: A2-413-0022

NSN: 01-598-4411

DIMENSIONS: 14.80" L X 6.85" W X 8.56" H

WEIGHT: 20LBS (APROX.)

SPEC NUMBER: 808008-003-1

SPECS:

0.75HP, 440VAC/3PHASE/60HZ, FRAME:FB56C, SERVICE FACTOR:1.00, DUTY CYCLE: 30

MINUTE, CLASS F INSULATION, TOTALLY ENCLOSED NON-VENTED, FOOTLESS F-3

MOUNTING.

INDIVIDUALLY PACKAGED IN ACCORDANCE WITH MIL-STD-2073-I E METHOD 10, USING

WEATHER-RESISTANT PAPERBOARD FOLDING WITH WATERPROOF BARRIER MATERIALS AND

CUSHIONED, AS NEEDED IN BUBBLE-WRAP, BAGGED AND PACKED IN AN APPROPRIATELY

SIZED ASTM-D5118 DOUBLE-WALL FIBERBOARD BOX. BAG CLOSURE SHALL BE EFFECTED BY

HEAT-SEALING, ADHESIVES, OR TAPING. OTHER TYPE BAG CLOSURES SUCH AS PRESSURE-

FIT, ZIPPER, AND OTHERS, ARE ACCEPTABLE.

MARKING IAW MIL-STD-129R.

END USE: USCGC WMSL 418' NSC - STERN BOAT LAUNCH SYSTEM CENTERLINE WINCH

1.3. Receiving Inspection Report

The Contractor shall submit a "Receiving Inspection Report" to the U.S. Coast Guard Contracting Officer (KO), and Contracting Officers Representative (COR) within 3 days of receiving a motor. The report will document that the make, part number, model and size delivered for overhaul conform to the motor cited. This report will also include digital photographic documentation of the crate and its contents.

2.01 APPLICABLE DOCUMENTS

2.1. General - The documents listed in this section are specified in sections 3, 4, or 5 of this specification. This section does not include documents cited in other sections of this specification or recommended for additional information or as examples. While every effort has been made to ensure the completeness of this list, document users are cautioned that they must meet all specified requirements of documents cited in sections 3, 4, or 5 of this specification, whether or not they are listed.

2.2. Government Documents - The following specifications and standards form a part of this specification to the extent specified herein. Unless otherwise specified, the documents listed here by number and date shall be those in the current Department of Defense Single Stock Point of Specification and Standards (DODSSP) and supplements thereto.

2.2.1. Federal Standard, FED-STD-595C, dated 01/16/2008, Colors Used in Government Procurement

2.2.2. MIL-D-3464E dated 04/1987, Desiccants, Activated, Bagged, Packaging Use and Static Dehumidification.

2.2.3. MIL-PRF-81309F, dated 05/16/2005, type 2, class 1 or 2, Corrosion preventive compounds, water displacing, ultra-thin film.

2.2.4. United States U.S. Coast Guard USCG-SFLC Specification D-000-0100 Rev G Dated 06/2006, Bar Coding for USCG Surface Forces Logistics Center Material.

2.3. Commercial Documents - The following documents form a part of this specification to the extent specified herein. The documents shall be the version listed by number and date from the referenced industry organization.

2.3.1. Steel Structure Painting Council, SSPC-SP 3, Power Tool Cleaning

2.3.2. Institute of Electrical and Electronics Engineers, IEEE Std 112-2004 Standard Test Procedure for Polyphase Induction Motors and Generators.

2.3.3. Institute of Electrical and Electronics Engineers, IEEE 43-2000 (R 2006) Recommended Practice for Testing Insulation Resistance of Rotating Machinery

2.3.4. National Electrical Manufacturers Association NEMA, MG1-2006 Rev 1- 2007, section 1, part 7

2.3.5. National Conference of Standards Laboratories (NCSL) Z540-3-2006, dated 2006, Requirement for the Calibration of Measuring and Test Equipment.

2.3.6. American Society for Quality (ASQ) Q90001-2008, dated 2008, Quality Management Systems-Requirements

2.3.7. Specification Packaging and Labeling SP-PP&M Rev D dated 6/6/11

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

SHELF LIFE CD 0

Overhaul Specification Reliance Motors 0.75 HP AC Motor with attached Stearns Motor Brake

1.0 SCOPE

1.1. This document sets forth the requirements for the receipt, disassembly, inspections, condition/test reports, overhaul/repair, reassembly, testing, preservation, packaging, packing, and marking of the Brake Actuator AC Motor used on 418 ft WMSL U.S. U.S. Coast Guard Cutters.

1.2. Government Furnished Property (GFP)

1.2.1. Reliance Motors, 1 AC Motor with attached Stearns Motor Brake SM-50-

20MB

BALDOR - RELIANCE MOTOR, AC, BRAKE ACTUATOR

PN: A2-413-0022

NSN: 01-598-4411

DIMENSIONS: 14.80" L X 6.85" W X 8.56" H

WEIGHT: 20LBS (APROX.)

SPEC NUMBER: 808008-003-1

SPECS:

0.75HP, 440VAC/3PHASE/60HZ, FRAME:FB56C, SERVICE FACTOR:1.00, DUTY CYCLE: 30

MINUTE, CLASS F INSULATION, TOTALLY ENCLOSED NON-VENTED, FOOTLESS F-3

MOUNTING.

INDIVIDUALLY PACKAGED IN ACCORDANCE WITH MIL-STD-2073-I E METHOD 10, USING

WEATHER-RESISTANT PAPERBOARD FOLDING WITH WATERPROOF BARRIER MATERIALS AND

CUSHIONED, AS NEEDED IN BUBBLE-WRAP, BAGGED AND PACKED IN AN APPROPRIATELY

SIZED ASTM-D5118 DOUBLE-WALL FIBERBOARD BOX. BAG CLOSURE SHALL BE EFFECTED BY

HEAT-SEALING, ADHESIVES, OR TAPING. OTHER TYPE BAG CLOSURES SUCH AS PRESSURE-

FIT, ZIPPER, AND OTHERS, ARE ACCEPTABLE.

MARKING IAW MIL-STD-129R.

END USE: USCGC WMSL 418' NSC - STERN BOAT LAUNCH SYSTEM CENTERLINE WINCH

1.3. Receiving Inspection Report

The Contractor shall submit a "Receiving Inspection Report" to the U.S. Coast Guard Contracting Officer (KO), and Contracting Officers Representative (COR) within 3 days of receiving a motor. The report will document that the make, part number, model and size delivered for overhaul conform to the motor cited. This report will also include digital photographic documentation of the crate and its contents.

2.01 APPLICABLE DOCUMENTS

2.1. General - The documents listed in this section are specified in sections 3, 4, or 5 of this specification. This section does not include documents cited in other sections of this specification or recommended for additional information or as examples. While every effort has been made to ensure the completeness of this list, document users are cautioned that they must meet all specified requirements of documents cited in sections 3, 4, or 5 of this specification, whether or not they are listed.

2.2. Government Documents - The following specifications and standards form a part of this specification to the extent specified herein. Unless otherwise specified, the documents listed here by number and date shall be those in the current Department of Defense Single Stock Point of Specification and Standards (DODSSP) and supplements thereto.

2.2.1. Federal Standard, FED-STD-595C, dated 01/16/2008, Colors Used in Government Procurement

2.2.2. MIL-D-3464E dated 04/1987, Desiccants, Activated, Bagged, Packaging Use and Static Dehumidification.

2.2.3. MIL-PRF-81309F, dated 05/16/2005, type 2, class 1 or 2, Corrosion preventive compounds, water displacing, ultra-thin film.

2.2.4. United States U.S. Coast Guard USCG-SFLC Specification D-000-0100 Rev G Dated 06/2006, Bar Coding for USCG Surface Forces Logistics Center Material.

2.3. Commercial Documents - The following documents form a part of this specification to the extent specified herein. The documents shall be the version listed by number and date from the referenced industry organization.

2.3.1. Steel Structure Painting Council, SSPC-SP 3, Power Tool Cleaning

2.3.2. Institute of Electrical and Electronics Engineers, IEEE Std 112-2004 Standard Test Procedure for Polyphase Induction Motors and Generators.

2.3.3. Institute of Electrical and Electronics Engineers, IEEE 43-2000 (R 2006) Recommended Practice for Testing Insulation Resistance of Rotating Machinery

2.3.4. National Electrical Manufacturers Association NEMA, MG1-2006 Rev 1- 2007, section 1, part 7

2.3.5. National Conference of Standards Laboratories (NCSL) Z540-3-2006, dated 2006, Requirement for the Calibration of Measuring and Test Equipment.

2.3.6. American Society for Quality (ASQ) Q90001-2008, dated 2008, Quality Management Systems-Requirements

2.3.7. Specification Packaging and Labeling SP-PP&M Rev D dated 6/6/11

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

2.4. 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 shall take precedence. Nothing in this specification, however, supersedes applicable laws and regulations unless a specific exemption has been obtained.

3.0 REQUIREMENTS

3.1. General - Inspections, repair/overhaul and testing of the motor and motor brake shall be accomplished in accordance with the Original Equipment Manufacturer (OEM) procedures, specifications, references and standard practices. The government does not provide these OEM procedures, specifications or references as part of this solicitation and it is SOLELY the Contractor's responsibility to obtain these documents, adhere to them and make these documents available to the government upon request anytime during repair or after repairs have been completed. The Contractor shall conform to all requirements throughout this specification during performance of this contract. 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.

3.1.1. The overhaul requirements described herein are considered the minimum necessary and are not intended to replace any procedures, controls, examinations, or tests normally employed by the Contractor to assure the quality of the product. The overhaul of the motor is intended to return the motor's performance and appearance to a like new condition.

3.2. Overhaul - The Contractor shall provide all labor and materials to perform the overhaul services as described below for the motor.

3.2.1. Preliminary disassembly and inspection of the motor shall be conducted in accordance with motor unit OEM specifications, references and standard practices to determine the total estimated cost to repair including material, labor, testing, Preservation, Packing and Marking (PP&M) costs.

**The Stearns motor brake shall NOT be disassembled as the item is a non-serviceable hermetically sealed unit per the OEM.** Upon KO approval of the complete repair estimate provided by the vendor, which shall include cost of new Stearns brake, the Stearns brake shall be REPLACED with identical new unit of same manufacturer and model. Regardless of its appearance or functionality, the brake unit that is removed from the motor shall be stored onsite and provided to the USCG Quality Assurance Representative at the time of the final acceptance testing (see section 3.3).

A Condition Found Report (CFR) with photos, shall be submitted to the KO, and COR within 10 days of the completion of the Receiving Inspection Report detailing any Contingency Repair parts recommended for replacement above and a total repair cost.

a. It is assumed that the motor with attached brake 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.

3.2.2. The CFR shall be submitted to the KO and COR for review and approval prior to the start of any repair or order of any material. The Contractor shall also provide the replacement cost of an identical new motor and motor brake for comparison to the overhaul cost. At a minimum, mandatory replacement parts shall include Stearns motor brake, all motor bearings, bushings, seals and gaskets. All parts that are worn, have an improper fit and or damaged beyond the OEM tolerances, shall be repaired or replaced as determined by the COR.

a. The detailed cost estimate shall contain the following as a minimum:

1. The part number, NSN (if applicable) and serial number of the motor

2. The contract number and delivery order number for the motor

3. A listing of individual parts by part number, cost and quantity

4. A listing of labor hours and labor rate to perform the overhaul, testing, and PP&M

5. The cost of an identical new motor (see section 3.2.3.a. of this specification)

6. The cost of an identical new motor brake (see section 3.2.3.a. of this specification)

b. Upon acceptance of the cost estimate and authorization to proceed by the KO, the Contractor shall overhaul the motor unit in accordance with the OEM procedures, specifications, references, standard practices and the references cited in section 2.0 of this specification.

3.2.3. The government reserves the right to dispose of the motor and/or motor brake if the motor and/or motor brake is Beyond Economic Repair (BER). The contractor will dispose of the unit at a predetermined cost to the government. The contractor shall provide a scrap credit to the government or a price to discard any motor unit BER.

a. The U.S. Coast Guard KO will determine the disposition of any unit delivered for overhaul that is Beyond Economical Repair (BER) prior to disposal.

b. If the motor and/or motor brake is BER, the government reserves the right to purchase an identical new motor and/or motor brake unit from the Contractor.

3.2.4. All replacement parts used in the motor overhaul shall be new OEM parts. Reclaimed, recycled or aftermarket parts are not acceptable and shall not be used. Commercial parts such as seals and ball/roller type bearings which are not manufactured by the motor manufacturer shall be identified by their marking or through the use of the technical manual for identification purposes. Commercially available items such as these are generally interchangeable between different manufacturers and may be substituted as long as they are equal in all respects.

3.2.5. The motor shall be disassembled and all parts thoroughly cleaned and inspected. Inspection findings shall be included in the CFR submitted to the

2.4. 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 shall take precedence. Nothing in this specification, however, supersedes applicable laws and regulations unless a specific exemption has been obtained.

3.0 REQUIREMENTS

3.1. General - Inspections, repair/overhaul and testing of the motor and motor brake shall be accomplished in accordance with the Original Equipment Manufacturer (OEM) procedures, specifications, references and standard practices. The government does not provide these OEM procedures, specifications or references as part of this solicitation and it is SOLELY the Contractor's responsibility to obtain these documents, adhere to them and make these documents available to the government upon request anytime during repair or after repairs have been completed. The Contractor shall conform to all requirements throughout this specification during performance of this contract. 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.

3.1.1. The overhaul requirements described herein are considered the minimum necessary and are not intended to replace any procedures, controls, examinations, or tests normally employed by the Contractor to assure the quality of the product. The overhaul of the motor is intended to return the motor's performance and appearance to a like new condition.

3.2. Overhaul - The Contractor shall provide all labor and materials to perform the overhaul services as described below for the motor.

3.2.1. Preliminary disassembly and inspection of the motor shall be conducted in accordance with motor unit OEM specifications, references and standard practices to determine the total estimated cost to repair including material, labor, testing, Preservation, Packing and Marking (PP&M) costs.

**The Stearns motor brake shall NOT be disassembled as the item is a non-serviceable hermetically sealed unit per the OEM.** Upon KO approval of the complete repair estimate provided by the vendor, which shall include cost of new Stearns brake, the Stearns brake shall be REPLACED with identical new unit of same manufacturer and model. Regardless of its appearance or functionality, the brake unit that is removed from the motor shall be stored onsite and provided to the USCG Quality Assurance Representative at the time of the final acceptance testing (see section 3.3).

A Condition Found Report (CFR) with photos, shall be submitted to the KO, and COR within 10 days of the completion of the Receiving Inspection Report detailing any Contingency Repair parts recommended for replacement above and a total repair cost.

a. It is assumed that the motor with attached brake 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.

3.2.2. The CFR shall be submitted to the KO and COR for review and approval prior to the start of any repair or order of any material. The Contractor shall also provide the replacement cost of an identical new motor and motor brake for comparison to the overhaul cost. At a minimum, mandatory replacement parts shall include Stearns motor brake, all motor bearings, bushings, seals and gaskets. All parts that are worn, have an improper fit and or damaged beyond the OEM tolerances, shall be repaired or replaced as determined by the COR.

a. The detailed cost estimate shall contain the following as a minimum:

1. The part number, NSN (if applicable) and serial number of the motor

2. The contract number and delivery order number for the motor

3. A listing of individual parts by part number, cost and quantity

4. A listing of labor hours and labor rate to perform the overhaul, testing, and PP&M

5. The cost of an identical new motor (see section 3.2.3.a. of this specification)

6. The cost of an identical new motor brake (see section 3.2.3.a. of this specification)

b. Upon acceptance of the cost estimate and authorization to proceed by the KO, the Contractor shall overhaul the motor unit in accordance with the OEM procedures, specifications, references, standard practices and the references cited in section 2.0 of this specification.

3.2.3. The government reserves the right to dispose of the motor and/or motor brake if the motor and/or motor brake is Beyond Economic Repair (BER). The contractor will dispose of the unit at a predetermined cost to the government. The contractor shall provide a scrap credit to the government or a price to discard any motor unit BER.

a. The U.S. Coast Guard KO will determine the disposition of any unit delivered for overhaul that is Beyond Economical Repair (BER) prior to disposal.

b. If the motor and/or motor brake is BER, the government reserves the right to purchase an identical new motor and/or motor brake unit from the Contractor.

3.2.4. All replacement parts used in the motor overhaul shall be new OEM parts. Reclaimed, recycled or aftermarket parts are not acceptable and shall not be used. Commercial parts such as seals and ball/roller type bearings which are not manufactured by the motor manufacturer shall be identified by their marking or through the use of the technical manual for identification purposes. Commercially available items such as these are generally interchangeable between different manufacturers and may be substituted as long as they are equal in all respects.

3.2.5. The motor shall be disassembled and all parts thoroughly cleaned and inspected. Inspection findings shall be included in the CFR submitted to the

COR. As a minimum, mandatory motor replacement parts shall include all bearings, bushings, seals and gaskets. All parts that are worn, have an improper fit and or damaged beyond the OEM tolerances shall be repaired or replaced as determined by the COR.

a. The winding resistance shall be inspected in accordance with the Institute of Electrical and Electronics Engineers, IEEE 43-2000 (R 2006) Recommended Practice for Testing Insulation Resistance of Rotating Machinery.

b. Windings that do not meet the standard of IEEE 43-2000 (R 2006) section 12.3, shall be reinsulated in a qualified insulation material recommended by the motor OEM. Reinsulated windings shall be subjected to a follow up resistance test once thoroughly dry. This process shall be repeated until acceptable resistance readings are achieved, (If acceptable insulation resistance cannot be achieved by re-insulating the contractor shall submit CFR and separate cost to rewind the motor).

c. The motor rotating element shall be balanced in accordance with National Electrical Manufactures Association NEMA, MG1-2006 Rev 1-2007, section 1, part 7. The final result of imbalance shall be documented in the CFR.

d. The Contractor shall provide written certification to the KO that the motor was reconditioned to the same standards as a new motor and a copy shall be turned over to the U.S. Coast Guard Quality Assurance Representative (CG- QAR). All test results shall be made available for review by the CG-QAR upon request.

3.2.6. Where any carbon steel zerc fittings or pipe plugs exist, all items shall be replaced with a non-magnetic grade of stainless steel. Pipe plugs shall be installed with a non hardening thread sealer and protective plastic caps shall be installed on each zerc fitting.

3.2.8. Remove or protect from damage/paint all data plates on the motor and brake. Any existing paint shall be removed from the motor in accordance with Steel Structure Painting Council, SSPC-SP3, Power Tool Cleaning, where practicable. An equal method of paint removal is acceptable where power tool cleaning may pose a risk of damage to internal components.

3.2.9. The NEW Stearns brake shall be attached to the overhauled motor and all surfaces shall be cleaned and free of oils/contaminants in preperation for painting.

3.2.10. The entire motor and motor brake unit shall be painted with primer and finish coats of paint. The primer coat shall be any rust preventive metal primer suitable for use with the finish coat. The finish coat shall be Silicone Alkyd Enamel Type III Class I. The color shall be Machinery Gray, color number 16376, in accordance with the Federal Standards, FED-STD-595C, dated 01/16/2008, Colors Used in Government Procurement. Total paint thickness shall be a minimum of 3-6 mil dry film thickness.

3.2.7. Replace or unprotect all motor and brake data plates after completing motor and brake external preservation/painting. A separate label plate made of similar material as the original label plate shall be attached to the motor stating the Contractor's name, contract number and date of overhaul. A decal or permanent type label shall be affixed to the side of the motor informing the user of the manufacturer's recommended amount and type of grease to be used.

3.3. Motor and Motor Brake Unit Final Tests

3.3.1. The following test procedures shall be performed in the presence of a USCG Quality Assurance representative, and the contractor shall notify the KO a minimum of 10 days in advance of these tests to facilitate scheduling of the USCG Quality Assurance Representative.

3.3.2. To ensure the motor turns freely, the motor shaft shall be rotated a minimum of five revolutions by the use of a strap wrench or other non-damaging tool. The Contractor shall investigate any questionable de-energized motor test results and correct as necessary prior to energized testing.

3.3.3. The Contractor shall conduct an energized test of the overhauled motor using IEEE Std 112-2004. The test shall be conducted to certify, document and report all parameters found on the Annex B Typical report of test form found in IEEE Std 112-2004. The Contractor shall investigate and correct any fault, failure or deviation from the OEM performance characteristics for the motor and retest the motor until satisfactory motor performance and function are achieved.

3.3.3.a The Contractor shall conduct an energized test of the installed motor brake per OEM specifications. The Contractor shall not disassemble or attempt to correct any discrepancies in performance or function of the new motor brake if discrepancies are identified. The contractor shall include results of motor brake test in the CFR and shall identify the results as Pass with explanation of pass criteria or Fail with explanation of failure criteria.

Failure of the new motor brake shall be corrected by contractor installation of another new identical brake, and completion of identical performance test.

NO REPAIRS TO THE STEARNS BRAKE ARE PERMITTED.

3.3.4. The test results shall be documented on a report and provided to the Contracting Officer. A copy of the test report shall be packed with each motor unit and a copy shall be provided to the QAR. The report shall contain the following information as a minimum:

a. Contractor's name

b. Contract number and delivery order number

c. Motor unit model number, part number and serial number

d. Date of test

e. Description of each test conducted and the results of each test

f. Name of the person conducting the testing

3.5. Motor Configuration - The overhauled motor with attached motor brake shall be delivered to the U.S. Coast Guard completely assembled and in a 100%

COR. As a minimum, mandatory motor replacement parts shall include all bearings, bushings, seals and gaskets. All parts that are worn, have an improper fit and or damaged beyond the OEM tolerances shall be repaired or replaced as determined by the COR.

a. The winding resistance shall be inspected in accordance with the Institute of Electrical and Electronics Engineers, IEEE 43-2000 (R 2006) Recommended Practice for Testing Insulation Resistance of Rotating Machinery.

b. Windings that do not meet the standard of IEEE 43-2000 (R 2006) section 12.3, shall be reinsulated in a qualified insulation material recommended by the motor OEM. Reinsulated windings shall be subjected to a follow up resistance test once thoroughly dry. This process shall be repeated until acceptable resistance readings are achieved, (If acceptable insulation resistance cannot be achieved by re-insulating the contractor shall submit CFR and separate cost to rewind the motor).

c. The motor rotating element shall be balanced in accordance with National Electrical Manufactures Association NEMA, MG1-2006 Rev 1-2007, section 1, part 7. The final result of imbalance shall be documented in the CFR.

d. The Contractor shall provide written certification to the KO that the motor was reconditioned to the same standards as a new motor and a copy shall be turned over to the U.S. Coast Guard Quality Assurance Representative (CG- QAR). All test results shall be made available for review by the CG-QAR upon request.

3.2.6. Where any carbon steel zerc fittings or pipe plugs exist, all items shall be replaced with a non-magnetic grade of stainless steel. Pipe plugs shall be installed with a non hardening thread sealer and protective plastic caps shall be installed on each zerc fitting.

3.2.8. Remove or protect from damage/paint all data plates on the motor and brake. Any existing paint shall be removed from the motor in accordance with Steel Structure Painting Council, SSPC-SP3, Power Tool Cleaning, where practicable. An equal method of paint removal is acceptable where power tool cleaning may pose a risk of damage to internal components.

3.2.9. The NEW Stearns brake shall be attached to the overhauled motor and all surfaces shall be cleaned and free of oils/contaminants in preperation for painting.

3.2.10. The entire motor and motor brake unit shall be painted with primer and finish coats of paint. The primer coat shall be any rust preventive metal primer suitable for use with the finish coat. The finish coat shall be Silicone Alkyd Enamel Type III Class I. The color shall be Machinery Gray, color number 16376, in accordance with the Federal Standards, FED-STD-595C, dated 01/16/2008, Colors Used in Government Procurement. Total paint thickness shall be a minimum of 3-6 mil dry film thickness.

3.2.7. Replace or unprotect all motor and brake data plates after completing motor and brake external preservation/painting. A separate label plate made of similar material as the original label plate shall be attached to the motor stating the Contractor's name, contract number and date of overhaul. A decal or permanent type label shall be affixed to the side of the motor informing the user of the manufacturer's recommended amount and type of grease to be used.

3.3. Motor and Motor Brake Unit Final Tests

3.3.1. The following test procedures shall be performed in the presence of a USCG Quality Assurance representative, and the contractor shall notify the KO a minimum of 10 days in advance of these tests to facilitate scheduling of the USCG Quality Assurance Representative.

3.3.2. To ensure the motor turns freely, the motor shaft shall be rotated a minimum of five revolutions by the use of a strap wrench or other non-damaging tool. The Contractor shall investigate any questionable de-energized motor test results and correct as necessary prior to energized testing.

3.3.3. The Contractor shall conduct an energized test of the overhauled motor using IEEE Std 112-2004. The test shall be conducted to certify, document and report all parameters found on the Annex B Typical report of test form found in IEEE Std 112-2004. The Contractor shall investigate and correct any fault, failure or deviation from the OEM performance characteristics for the motor and retest the motor until satisfactory motor performance and function are achieved.

3.3.3.a The Contractor shall conduct an energized test of the installed motor brake per OEM specifications. The Contractor shall not disassemble or attempt to correct any discrepancies in performance or function of the new motor brake if discrepancies are identified. The contractor shall include results of motor brake test in the CFR and shall identify the results as Pass with explanation of pass criteria or Fail with explanation of failure criteria.

Failure of the new motor brake shall be corrected by contractor installation of another new identical brake, and completion of identical performance test.

NO REPAIRS TO THE STEARNS BRAKE ARE PERMITTED.

3.3.4. The test results shall be documented on a report and provided to the Contracting Officer. A copy of the test report shall be packed with each motor unit and a copy shall be provided to the QAR. The report shall contain the following information as a minimum:

a. Contractor's name

b. Contract number and delivery order number

c. Motor unit model number, part number and serial number

d. Date of test

e. Description of each test conducted and the results of each test

f. Name of the person conducting the testing

3.5. Motor Configuration - The overhauled motor with attached motor brake shall be delivered to the U.S. Coast Guard completely assembled and in a 100% ready to operate condition and configuration.

3.6. Photo Documentation - The Contractor shall provide digital photo documentation to the Contracting Officer as follows:

a. During initial opening of the motor shipping container after receipt.

b. When significant findings that will affect cost of repair/overhaul or time are discovered.

c. When other significant or unusual findings such as failed parts or damages are discovered.

d. When the motor's insulation is tested to document megohmmeter readings.

e. When the motor's final energized operational tests are performed to document all performance criteria.

f. When the shipping container integrity is questionable.

g. When the motor is prepared for return shipment back to the USCG, to document "as shipped" configuration (to include images of the PP&M - minimum one photo of motor packed in container prior to closure and one of outside of container showing all labeling upon closure/sealing of the shipping container)

h. The photo documentation shall be color digital and shall be sent to the KO and the COR via email.

3.7. Notifications & Inspections - The Contractor shall be responsible for notifying the KO at least ten (10) calendar days prior to said Contractor being ready for final energized motor and brake test.

4.0 QUALITY ASSURANCE

4.1. General - The Contractor shall maintain an inspection system which shall insure that each item offered to the U.S. Coast Guard for acceptance or approval conforms to the contract requirements. The inspection system shall be documented and available for review by the U.S. Coast Guard.

4.2. Records - The Contractor shall maintain records of all inspections and tests. The records, at a minimum, shall indicate the nature and number of observations made, the number and type of deficiencies found, and the corrective action taken.

4.3. Calibration System - The Contractor, as well as any subcontractors, shall be required to maintain a test equipment calibration program in compliance with the National Conference of Standards Laboratories (NCSL) Z540-3-2006, dated 2006, Requirements for the Calibration of Measuring and Test Equipment. The program shall be documented and traceable to the National Institute of Standards (NIST).

4.4. 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 to conduct all required inspections. All inspection and testing shall be performed at the Contractor's place of business or at other facilities acceptable to the U.S.

Coast Guard. The U.S. Coast Guard reserves the right to verify or have performed any of the inspections or tests that are deemed necessary to assure that supplies and services conform to the prescribed requirements. It is the U.S. Coast Guard's intention for the CG-QAR to witness the testing of all motors overhauled by the Contractor.

4.5. Responsibility for Compliance - All items shall meet the provisions of sections 3 & 5 of this specification. The inspections set forth in this specification shall become part of the Contractors overall inspection system or quality program. The absence of any inspection requirements in the specification shall not relieve the Contractor of the responsibility of assuring that all products or supplies submitted to the government for acceptance comply with all requirements of the contract. Sampling for quality conformance does not authorize submission of known defective material (either indicated or actual) nor does it commit the government to acceptance of defective material.

4.6. Quality System - The Contractor shall maintain an inspection system which shall insure that each item offered to the U.S. Coast Guard for acceptance or approval conforms to the contract requirements in accordance with the American Society for Quality (ASQ) Q90001-2008, dated 2008, Quality Management System-Requirements. The inspection system shall be documented and available for review by the U.S. Coast Guard.

4.7. Tests & Inspections - The inspections/tests required here and in the appropriate subsection in section 3.0. of this specification, are the minimum required and are not intended to supplant any controls, examination, inspections or tests normally employed by the Contractor to assure the quality of the item in question.

4.8. Packing Inspection - The KO shall be notified prior to the packaging and marking of the completed units in accordance with section 3.6 of this specification.

5.0 PRESERVATION, PACKING, & MARKING

5.1. Preservation - An overhauled motor is typically intended for long term warehouse storage and not for immediate installation. Therefore, it is critical that the Contractor ensure that the overhauled motor unit undergoes the following preservation requirements in accordance with the Specification Packaging and Labeling SP-PP&M Rev D dated 6/11.

5.1.1. The motor shall be completely dried, clean and free of foreign debris

5.1.2. The motor shall have 80 units of desiccant placed in the shipping bag in accordance with MIL-D-3464E dated 04/1987, Desiccants, Activated, Bagged, Packaging Use and Static Dehumidification.

ready to operate condition and configuration.

3.6. Photo Documentation - The Contractor shall provide digital photo documentation to the Contracting Officer as follows:

a. During initial opening of the motor shipping container after receipt.

b. When significant findings that will affect cost of repair/overhaul or time are discovered.

c. When other significant or unusual findings such as failed parts or damages are discovered.

d. When the motor's insulation is tested to document megohmmeter readings.

e. When the motor's final energized operational tests are performed to document all performance criteria.

f. When the shipping container integrity is questionable.

g. When the motor is prepared for return shipment back to the USCG, to document "as shipped" configuration (to include images of the PP&M - minimum one photo of motor packed in container prior to closure and one of outside of container showing all labeling upon closure/sealing of the shipping container)

h. The photo documentation shall be color digital and shall be sent to the KO and the COR via email.

3.7. Notifications & Inspections - The Contractor shall be responsible for notifying the KO at least ten (10) calendar days prior to said Contractor being ready for final energized motor and brake test.

4.0 QUALITY ASSURANCE

4.1. General - The Contractor shall maintain an inspection system which shall insure that each item offered to the U.S. Coast Guard for acceptance or approval conforms to the contract requirements. The inspection system shall be documented and available for review by the U.S. Coast Guard.

4.2. Records - The Contractor shall maintain records of all inspections and tests. The records, at a minimum, shall indicate the nature and number of observations made, the number and type of deficiencies found, and the corrective action taken.

4.3. Calibration System - The Contractor, as well as any subcontractors, shall be required to maintain a test equipment calibration program in compliance with the National Conference of Standards Laboratories (NCSL) Z540-3-2006, dated 2006, Requirements for the Calibration of Measuring and Test Equipment. The program shall be documented and traceable to the National Institute of Standards (NIST).

4.4. 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 to conduct all required inspections. All inspection and testing shall be performed at the Contractor's place of business or at other facilities acceptable to the U.S.

Coast Guard. The U.S. Coast Guard reserves the right to verify or have performed any of the inspections or tests that are deemed necessary to assure that supplies and services conform to the prescribed requirements. It is the U.S. Coast Guard's intention for the CG-QAR to witness the testing of all motors overhauled by the Contractor.

4.5. Responsibility for Compliance - All items shall meet the provisions of sections 3 & 5 of this specification. The inspections set forth in this specification shall become part of the Contractors overall inspection system or quality program. The absence of any inspection requirements in the specification shall not relieve the Contractor of the responsibility of assuring that all products or supplies submitted to the government for acceptance comply with all requirements of the contract. Sampling for quality conformance does not authorize submission of known defective material (either indicated or actual) nor does it commit the government to acceptance of defective material.

4.6. Quality System - The Contractor shall maintain an inspection system which shall insure that each item offered to the U.S. Coast Guard for acceptance or approval conforms to the contract requirements in accordance with the American Society for Quality (ASQ) Q90001-2008, dated 2008, Quality Management System-Requirements. The inspection system shall be documented and available for review by the U.S. Coast Guard.

4.7. Tests & Inspections - The inspections/tests required here and in the appropriate subsection in section 3.0. of this specification, are the minimum required and are not intended to supplant any controls, examination, inspections or tests normally employed by the Contractor to assure the quality of the item in question.

4.8. Packing Inspection - The KO shall be notified prior to the packaging and marking of the completed units in accordance with section 3.6 of this specification.

5.0 PRESERVATION, PACKING, & MARKING

5.1. Preservation - An overhauled motor is typically intended for long term warehouse storage and not for immediate installation. Therefore, it is critical that the Contractor ensure that the overhauled motor unit undergoes the following preservation requirements in accordance with the Specification Packaging and Labeling SP-PP&M Rev D dated 6/11.

5.1.1. The motor shall be completely dried, clean and free of foreign debris

5.1.2. The motor shall have 80 units of desiccant placed in the shipping bag in accordance with MIL-D-3464E dated 04/1987, Desiccants, Activated, Bagged, Packaging Use and Static Dehumidification.

5.1.3. The motor shaft and all unpainted surfaces shall be sprayed with a thin film of rust inhibitor in accordance with MIL-PRF-81309F, dated 05/16/2005, type 2, class 1 or 2, Corrosion preventive compounds, water displacing, ultra-thin film. Any exposed threads/shaft keyways shall be protected by a cardboard sleeve.

5.1.4. Each motor unit shall be placed into an 4 mil minimum thickness translucent polyethylene bag. The bag opening shall be sealed with an appropriate sized doubled nylon tie wrap. In any areas where fasteners used to secure motor penetrate the polyethylene bag, a 1/8" thick rubber gasket and RTV shall be used to seal the bag from the entrance of moisture. The motor shall have 80 units of desiccant placed in the translucent polyethylene bag in accordance with MIL-D-3464E dated 04/1987, Desiccants, Activated, Bagged, Packaging Use and Static Dehumidification.

5.2. Packing - Each motor with attached motor brake shall be individually packed back into its original shipping container. The motor shall be securely bolted, strapped or braced to a skid base to prevent any shifting of the motor within the crate. The lid or cover shall be attached using corrosion resistant steel #2 Phillips head screws.

**In the event the original shipping container arrived to the contractor damaged or not re-usable, the contractor shall provide CFR and photo documentation to the KO along with cost to provide a new shipping container.

The container shall be framed (either on the inside or outside) using solid wood as framing material minimum dimension 3/4" x 2". The walls, floor and lid of the crate shall be plywood with minimum thickness of 3/8 inches and attached (stapled, nailed or screwed) to the solid wood framing. The container shall be capable of protecting the motor from damage during multiple shipments by commercial carrier in accordance with the American Society for Testing & Materials (ASTM) D3951-98, dated 2004, Standard Practice for Commercial Packaging.

5.3. Marking - Each preserved and packed motor with attached motor brake shall be stenciled in the upper left-hand side of the two longest sides (two opposite sides if square) of each box. The stenciling shall be 1/2 inches minimum height black characters on a white painted background. NOTE: ALL

PREVIOUS MARKINGS AND QUALITY ASSURANCE DECALS SHALL BE REMOVED FROM A

REUSABLE SHIPPING CONTAINER PRIOR TO THE APPLICATION OF ANY NEW MARKINGS.

5.3.1. This marking shall consist of the STOCK NUMBER, ITEM NAME, PART NUMBER, CONTRACT NUMBER, DELIVERY ORDER NUMBER, GROSS WEIGHT (in lbs.), condition code CONDITION 'A', unit of issue with quantity (i.e. 1-EA), and the words U.S. COAST GUARD SFLC MATERIAL.

STOCK NUMBER SEE CONTRACT

ITEM NAME SEE CONTRACT

PART NUMBER SEE CONTRACT

CONTRACT NUMBER SEE CONTRACT

DELIVERY ORDER NUMBER SEE CONTRACT

SHIPPING WEIGHT AS DETERMINED BY CONTRACTOR

CONDITION CODE CONDITION 'A' (Refurbished)

QUANTITY & UNIT OF ISSUE 1 - EACH

U.S. COAST GUARD SFLC MATERIAL

5.4. Bar Coding - The Contractor shall supply bar code labels on all CLIN's except for those that require data submissions only. Bar code labels shall be installed on the two sides of the shipping crate that contain stenciled markings.

5.4.1. All bar code labels shall be in accordance with SFLC specification D- 000-0100 Rev G.

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

b. Each label shall contain encoded data for the Stock Number.

6.0 SHIPPING

6.1. General- Unless otherwise directed by the KO, the contractor shall return repaired motor units to:

U.S. Coast Guard Surface Forces Logistics Center 2401 Hawkins Point RD, Bldg 88 Baltimore, MD 21226

7.0 HAZARDOUS WASTE DISPOSAL

7.1. The Contractor shall be responsible for proper disposal of all hazardous wastes generated by work under this contract, i.e. asbestos gaskets, test fluids. Label and package all hazardous wastes in accordance with all applicable Federal, state, and local laws and regulations. In addition, comply with CFR title 40 part 262, applicable to handling and disposal of hazardous waste.

8.0 NOTES

8.1. Terms and definitions

a. CFR - Condition Found Report

b. BER - Beyond Economical Repair.

c. PP&M - Preservation, Packing, & Marking.

d. KO - Contracting Officer.

e. NA - Not Available.

f. QAR - Quality Assurance Representative

g. COR - U.S. Coast Guard Contracting Officer?s Representative

h. QA - Quality Assurance

8.2. Government & Commercial Document Sources

8.2.1. Government Documents

a. Department of Defense Single Stock Point (DODSSP Documents) 700 Robbins Avenue Building #4, Section D

5.1.3. The motor shaft and all unpainted surfaces shall be sprayed with a thin film of rust inhibitor in accordance with MIL-PRF-81309F, dated 05/16/2005, type 2, class 1 or 2, Corrosion preventive compounds, water displacing, ultra-thin film. Any exposed threads/shaft keyways shall be protected by a cardboard sleeve.

5.1.4. Each motor unit shall be placed into an 4 mil minimum thickness translucent polyethylene bag. The bag opening shall be sealed with an appropriate sized doubled nylon tie wrap. In any areas where fasteners used to secure motor penetrate the polyethylene bag, a 1/8" thick rubber gasket and RTV shall be used to seal the bag from the entrance of moisture. The motor shall have 80 units of desiccant placed in the translucent polyethylene bag in accordance with MIL-D-3464E dated 04/1987, Desiccants, Activated, Bagged, Packaging Use and Static Dehumidification.

5.2. Packing - Each motor with attached motor brake shall be individually packed back into its original shipping container. The motor shall be securely bolted, strapped or braced to a skid base to prevent any shifting of the motor within the crate. The lid or cover shall be attached using corrosion resistant steel #2 Phillips head screws.

**In the event the original shipping container arrived to the contractor damaged or not re-usable, the contractor shall provide CFR and photo documentation to the KO along with cost to provide a new shipping container.

The container shall be framed (either on the inside or outside) using solid wood as framing material minimum dimension 3/4" x 2". The walls, floor and lid of the crate shall be plywood with minimum thickness of 3/8 inches and attached (stapled, nailed or screwed) to the solid wood framing. The container shall be capable of protecting the motor from damage during multiple shipments by commercial carrier in accordance with the American Society for Testing & Materials (ASTM) D3951-98, dated 2004, Standard Practice for Commercial Packaging.

5.3. Marking - Each preserved and packed motor with attached motor brake shall be stenciled in the upper left-hand side of the two longest sides (two opposite sides if square) of each box. The stenciling shall be 1/2 inches minimum height black characters on a white painted background. NOTE: ALL

PREVIOUS MARKINGS AND QUALITY ASSURANCE DECALS SHALL BE REMOVED FROM A

REUSABLE SHIPPING CONTAINER PRIOR TO THE APPLICATION OF ANY NEW MARKINGS.

5.3.1. This marking shall consist of the STOCK NUMBER, ITEM NAME, PART NUMBER, CONTRACT NUMBER, DELIVERY ORDER NUMBER, GROSS WEIGHT (in lbs.), condition code CONDITION 'A', unit of issue with quantity (i.e. 1-EA), and the words U.S. COAST GUARD SFLC MATERIAL.

STOCK NUMBER SEE CONTRACT

ITEM NAME SEE CONTRACT

PART NUMBER SEE CONTRACT

CONTRACT NUMBER SEE CONTRACT

DELIVERY ORDER NUMBER SEE CONTRACT

SHIPPING WEIGHT AS DETERMINED BY CONTRACTOR

CONDITION CODE CONDITION 'A' (Refurbished)

QUANTITY & UNIT OF ISSUE 1 - EACH

U.S. COAST GUARD SFLC MATERIAL

5.4. Bar Coding - The Contractor shall supply bar code labels on all CLIN's except for those that require data submissions only. Bar code labels shall be installed on the two sides of the shipping crate that contain stenciled markings.

5.4.1. All bar code labels shall be in accordance with SFLC…