REPAIR DESC DU009.pdf

REVISION: A Date: 9/1/2015

USCG WPB-110

SPECIFICATION FOR THE REPAIR OF BILGE PUMP

ASSEMBLIES

R-529-552

ORGINATED BY Wayne B.Nickel DATE 10/15/2009 .

ORIGINATOR’S COMMAND: SURFACES FORCES LOGISTICS CENTER (SFLC)

DEPARTMENT / DIVISION: PATROL BOAT PRODUCT LINE (PBPL)

UPDATED BY: Wayne B.Nickel (Rev. A) DATE 9/1/2015 .

INTERNAL REVIEW Daniel Meyers (SFLC ENG SES) DATE: 10/30/15 .

SFLC QA REVIEW: Dale Jacobs, SFLC Quality Assurance DATE: 10/16/2015.

PLSSR REVIEW: DATE: .

1.0 SCOPE

1.1 General: The Contractor shall provide all equipment, labor, and materials for the receipt, disassembly, inspection, condition/test reports, overhaul, reassembly, testing, preservation, packaging, packing, marking, bar-coding and delivery of bilge pump and motor assemblies used on 110’ WPB Coast Guard vessels. The intent is to return the bilge pumps to a serviceable “A” condition.

NOTE

Serviceable “A” condition is defined as a reconditioned bilge pump assembly meeting all required design specifications and design dimensions in accordance with ITT Goulds Pump requirements and being capable of functioning and performing in the same manner as an identical new bilge pump assemblies although it may not have the appearance of a new bilge pump assemblies.

1.2 Government-furnished property (GFP):

ITEM DESCRIPTION NSN EST.

ANNUAL

QTY

Pump Unit, Centrifugal 4320-01-206-4721 10ea Shipping Crate, Reusable N/A 1ea

1.2.1 Descriptive Data: Bronze centrifugal pump unit complete with motor. Monel fitted, 120 GPM, 1750 RPM pump, with close coupled, Open Drip Proof (ODP) marine duty, 5 HP, 460VAC, 3 phase, 60HZ electric motor.

a. All references to the pump herein shall include both pump and motor. The cost estimate and overhaul shall include the pump and motor.

1.2.2 GFP Storage: All GFP must be stored indoors in a locked location at the Contractor’s facility.

a. New shipping crates fabricated per this specification shall be safe guarded and stored in the same manner as other GFP.

1.2.3 GFP Return: All GFP (if any) shall be returned to the Coast Guard Surface Forces Logistics Center before contract close out. The address is:

U.S. Coast Guard Surface Forces Logistics Center 2401 Hawkins Point Rd, Bldg. 88

Baltimore, MD 21226

2.0 REFERENCES

2.1 The below-listed documents form a part of this specification to the extent specified herein.

Approval/publication dates or revision dates/numbers are also identified, to ensure that same document versions are used at time of specification writing and during contract execution.

2.2 All Coast Guard drawings, technical publications, and standard specifications will be provided to Contractors by the Coast Guard at an appropriate time, or upon request, free of charge. Other Government documents may be accessed – free of charge – as follows:

a. MIL/DOD/CID Specifications: http://www.assistdocs.com/search/search_basic.cfm

b. Commandant Instruction Manuals: http://www.uscg.mil/directives/default.asp

c. Public Laws, Code of Federal Regulations, U.S Codes, and other Federal Government laws: www.gpoaccess.gov

2.2.1 The Government is aware of the following internet web links where Contractors may procure commercial specifications:

a. American Welding Society (AWS): http://www.awspubs.com/index.php

b. ANSI, ASTM, IEEEE, NFPA, ASME, SAE Standards: http://www.techstreet.com/

c. NFPA: http://www.nfpa.org

d. SSPC Standards and pictorial guides: http://shopping.netsuite.com/sspcmarketplace

2.3 Coast Guard Drawings

a. None

2.4 Coast Guard Publications

a. Coast Guard SFLC Specification D-000-0100, Rev. G, Change 1, Bar Coding for SFLC Stocked Material.

b. TP-2936, Technical Publication Drainage and Ballasting System – Bilge Pump.

2.5 Other Government Documents

a. FED-STD-595C – Dated 7/31/2008 - Colors Used In Government Procurement. (Incorporates Change 1)

b. MIL-PRF-81309F, Dated 5/16/2005 – Corrosion Preventative Compounds, Water Displacing, Ultra-Thin Film

2.6 Commercial Documents

a. ASTM A 276 / A276M-15 – Dated 2015, Standard Specification for Stainless Steel Bars and Shapes

b. NCSL Z540.3-2006 – Dated 1/1/2006, Calibration Laboratories and Measuring Equipment.

c. SSPC-SP 10 – Dated Jan 2007, Near White Blast Cleaning

d. ASQ Q9001-2008, Dated 1/1/2008, Quality Management Systems – Requirements

2.7 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, unless otherwise specified herein.

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

3.0 REQUIREMENTS

3.1 Arrival Inspection – Contractor shall conduct an arrival inspection and report determining the pump unit conforms to the description in section 1.2.1.

3.1.1 The assembly delivered for overhaul service is intended to be a complete Goulds Pump Inc. pump model: 3655M 2X2-1/2X9 equipped with a 5 H. P. “Open Drip Proof, Marine Duty” Baldor motor.

3.1.2 The Contractor shall notify the Contracting Officer (KO) of any missing components, incorrect items or, otherwise questionable conditions that may hinder the overhaul process or the make and/or model delivered for overhaul services do not conform to the intended make and/or model cited above.

3.2 Bilge Pump Repair: The Contractor shall carefully remove the bilge pump from the GFP crate, clean and remove all paint and primer to facilitate a thorough inspection to determine all the necessary repairs to return the bilge pump to a serviceable “A” condition. A Condition Found Report (CFR) shall be submitted to the KO within five (5) business days of receipt of GFP. The CFR shall include all inspection findings, test results as specified below, including a breakdown of estimated cost of labor and materials for any repair work including repair or replacement of the shipping crate. The CFR shall also include a breakdown of estimated cost of labor and materials for any repair work that is beyond the scope of work in this specification. No further work shall proceed until authorized by the KO in writing.

3.2.1 The CFR shall contain the following information as a minimum:

a. Contractor name, address and telephone number.

b. Contract number and delivery order number as applicable.

c. Name of the person conducting the inspection and estimate.

d. Bilge pump(s) serial number(s).

e. Condition of shipping crate and any cost of repair or replacement.

f. A list of parts and materials recommended for replacement with individual pricing.

g. Cost of overhaul labor rate and hours.

h. Comments if any pertaining to unusual observations during inspection and disassembly.

3.3 Replacement Parts – All replacement parts used for this specification shall be new Original Equipment Manufacturer (OEM) parts unless otherwise specified in this specification.

Reclaimed, recycled or aftermarket parts are not acceptable and shall not be used unless authorized by the KO in writing, in advance. The overhaul facility or any sub-contractors shall not manufacture parts to be used on overhauled assemblies. 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.

3.3.1 Zerk Fittings: All zerk fittings shall be replaced with new stainless steel zerk fittings with red plastic caps.

3.3.2 Decal: A decal or permanent type label shall be affixed to the side of the pump unit informing the user of the manufactures recommended amount and type of grease to be used.

3.3.3 Pipe Plugs: All pipe plugs shall be replaced with new stainless steel (Series 316) plugs.

Plugs shall be installed using Teflon tape or equal thread sealer.

3.3.4 Gland Studs: Steel gland studs, nuts and washers shall be replaced with new stainless steel

(Series 316) gland studs, nuts and washers.

3.3.5 Label Plates: Contractor shall remove label plates prior to abrasive blasting and replace them at the conclusion of painting. A new label plate shall be used if the original plate is missing, not legible or in poor condition. The label plate shall contain pump unit make, model and serial number as well as all pump unit performance information as a minimum requirement.

3.3.6 Bypass Copper Flush Line: Contractor shall replace the copper or steel bypass flush line. A flexible stainless steel braided flush hose with two 90 deg. stainless steel ¼” NPT elbows shall be used. The replacement parts shall be approved by the OEM, be of sufficient length to prevent stretching or kinking and meet pressure and operational requirements.

3.4 Special Instructions – All pump units delivered for overhaul having packing glands shall be converted to mechanical seal assemblies as part of the overhaul. Contractor shall include conversion work and parts in the 3.2 overhaul estimate if found necessary.

3.4.1 Dimensional Requirements: Due to space requirements the overall dimensions of the pump and motor units shall not exceed a length of 24” x width of 12” and height of 13”.

3.5 Pump Unit Disposition – The Coast Guard will evaluate if bilge pumps(s) will be repaired or scrapped due to the extent of necessary repairs and determine disposition. Disposition options are as follows:

3.5.1 Contractor shall reassemble, package, pack, mark “F” condition and bar code any pump unit not suitable for overhaul and return to the address in section 1.2.3.

3.5.2 Contractor shall dispose of unit on site. QA personnel will witness items being destroyed and disposed.

3.5.3 Contractor shall replace bilge pump unit with new unit meeting all requirements of this specification.

3.6 Preservation (Coating) – Each pump unit shall be prepared and painted as described below.

3.6.1 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 the blasting operation.

3.6.2 Coating: The 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, 2-3 mils dry film thickness. Allow appropriate drying time per primer manufacturer requirements.

Finish coat shall be Silicone Alkyd Enamel Type II Class 1. Color of finish coat shall be machinery gray in accordance with Federal Standard 595C color number 26307, 3-6 mils dry film thickness. Total Paint thickness shall result in a 5-mil minimum dry film and a maximum 9-mil dry film at time of inspection.

Note:

A coating thickness gauge shall be used to determine coating thickness. A calibration certificate shall be provided to the Coast Guard Representative upon request. The calibration shall be traceable to the National Institute of Standards and Technology (NIST).

3.7 Drive Motor – The drive motor supplied on the pump shall be reconditioned to like new condition as part of the pump overhaul services. The drive motor is rated at 5 HP, 460 VAC, Three Phase, 1750 RPM, 60 HZ. 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 manufacturer's tolerances shall be repaired or replaced as determined by the Contractor.

Note:

Plastic tie wraps holding rodent screen if applicable, shall be replaced with stainless steel wire neatly applied and shall have sharp ends rolled over to prevent injury.

3.7.1 Motor windings shall be baked to thoroughly dry any moisture that may be present within the windings. Check resistance of any contaminants between the windings and ground by megohmeter or equal test. Depending on the condition of winding insulation, windings shall be re-dipped in a qualified insulation material or otherwise, manufacturer’s recommended insulation material, as determined by the Contractor’s inspections and/or conducted testing. The re-dipped windings shall be baked until thoroughly dry.

3.7.2 Motor Certification: Contractor shall provide written certification that the motor was reconditioned to the same standards as new.

a. A detailed list of all replaced parts shall be included in final inspection report for the motor assembly.

b. Contractor shall provide name, address and telephone number of motor overhaul facility, if applicable.

3.8 Testing Requirements – After completion of overhaul, Contractor shall conduct the following described tests. All testing shall be accomplished using Contractor supplied calibrated test equipment. Any failed pump unit shall be repaired and re-tested as necessary until a successful test is achieved. All tests in this section will be witnessed by Coast Guard Quality Assurance Representative(s) (QAR) during QA inspection at contractor’s facility.

3.8.1 Rotational Test: To ensure the pump turns freely and without binding, the pump rotor assembly shall be rotated 10-20 times by hand. The QAR will inspect for smoothness of rotation and check for signs of binding. Contractor shall investigate any questionable test results and correct as necessary.

3.8.2 Operational Test: The pump unit set up shall be in accordance with the installation and operation procedures of the technical publication and run for a minimum of 15 minutes. The pump shall meet the flow curve to a tolerance of +/- 5% of a new pump. During the tests the bearings and seals shall be monitored. Any leakage, binding, excessive heat or unusual noise such as squealing coming from the pump during this test shall be corrected and retested after corrective work is complete.

3.8.3 Hydrostatic Test: Contractor shall conduct a hydrostatic test using clean fresh water or OEM specified test fluid. Test shall be conducted to certify the integrity of the pump case and seal areas. Testing will be witnessed by a Coast Guard Quality Assurance Representative. Test shall be conducted at 50 PSIG for a fifteen (15) minute time period. Test shall be discontinued at any sign of leakage for repairs and re-tested until satisfactory results are obtained.

3.9 Final Inspection and Test Report – A detailed final inspection and test report shall be submitted to KO for approval prior to scheduling SFLC Quality Assurance personnel. A copy of the inspection and test report shall be turned over to the Coast Guard Quality Assurance Representative upon arrival for final inspecting and testing. A copy shall also be packed with the inspected and tested pump assembly. The inspection and test report shall contain the following information as a minimum:

a. Contractor name, address and telephone number.

b. Contract number and delivery order number as applicable.

c. Pump unit model & serial number.

d. Date of test

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

f. Name of person conducting the inspecting and testing.

g. Test equipment used, nomenclature, serial number, and calibration date.

3.10 Assembly – The overhauled pump and motor unit shall be delivered to the Coast Guard completely assembled and ready for installation. The Contractor shall preserve, package, pack, mark and bar-code each pump and motor unit in accordance with section 5.0 of this specification.

3.11 Notifications & Inspections – The contractor shall be responsible for notifying the KO no less than ten (10) calendar days prior to the contractor being ready for any Quality Assurance (Q.A.) inspections or testing required herein. Forty Five (45) calendar days shall be allowed should the contract be awarded to a foreign Contractor.

4.0 QUALITY ASSURANCE

4.1 General – Contractor shall adhere to the requirements of Federal Acquisition Regulation (FAR) Part 46 - Quality Assurance.

4.2 Inspections – Contractor shall maintain an inspection system which shall insure that each item offered to the Coast Guard for acceptance or approval conforms to the contract requirements. The inspection system shall be documented, meet the requirements of ASQ- Q9001 and be available for review by the Coast Guard.

4.2.1 Contractor shall submit a Quality Assurance Plan for approval to the Contracting Officer.

4.3 Records – Contractor shall maintain records of all inspections and tests. The records shall indicate the nature and number of performed observations, the number and type of deficiencies found and the corrective action taken.

4.4 Calibration System – Contractor, as well as any subcontractors, shall maintain a test equipment calibration program in compliance with NCSL Z540.3. The program shall be documented and traceable to the National Institute of Standards and Technology (NIST).

4.4.1 The calibration system records shall be maintained for inspection for the duration of any contract referencing this overhaul specification.

4.5 Responsibility for Inspection – Contractor shall be responsible for the performance of all inspection requirements specified herein. Contractor shall provide space, personnel and test equipment for the conduct of all inspection requirements. All inspection and testing shall be performed at the Contractor’s 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. Contractor shall notify the Coast Guard Contracting Officer prior to the scheduled commencement of any inspections required by this overhaul specification.

4.6 Responsibility For Compliance – All items shall meet the provisions of Sections 3 & 5. The inspections set forth in this specification shall become part of the Contractor’s overall inspection system or quality program. The absence of any inspection requirement in this 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.

4.7 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 inspections and documentation will be witnessed or reviewed by an SFLC Quality Assurance Representative IAW section

3.0 of this overhaul specification:

a. Conformance to OEM specifications, tolerances, testing procedures, and overall workmanship requirements in accordance with section 3.0.

b. Preservation requirements and thickness as specified in section 3.6.

c. Testing requirements as described in section 3.8.

d. Overall assembly completeness as required by this specification.

e. Inspection of preservation, packaging, packing, marking, and bar-coding.

4.8 Failure Responsibility – If a fire pump assembly fails to pass any inspection or test, the Contractor shall report the failure and their recommended fix to the Contracting Officer. If approved, the corrective action on the materials or processes shall be taken in accordance with this section.

4.8.1 The Contracting Officer reserves the right to totally reject any failed item without considering any suggested corrective action.

a. The inspection/test shall be discontinued until all corrective action has been taken.

b. After all corrective action has been taken the inspection/test shall be continued or repeated at the option of the Contracting Officer.

c. Acceptance shall be withheld until re-inspection has shown that the corrective action was successful and the item satisfactorily passes all inspections and tests.

d. All corrective actions shall be documented as part of the Contractor’s inspection system, and submitted for approval to the Contracting Officer.

1. Each corrective action report shall include, but not be limited to, the cause of each defect, corrective action suggested, and steps taken to prevent a recurrence of each defect.

4.9 Test & Inspection Reports – A copy of any standard Contractor test or inspection report shall be turned over to the Coast Guard Quality Assurance inspector upon his/her arrival at the Contractor's designated facility.

4.10 Warranty – The Contractor’s standard new A/C Raw Water Cooling Pump assembly warranty applies.

4.11 Packing and Packaging Inspection – The Contracting Officer shall be notified prior to the packing, packaging, marking and bar-coding of the overhauled fire pump assemblies in accordance with section 3.11 of this overhaul specification.

NOTE:

For the safety of vendor and Coast Guard personnel, QA inspections shall be completed indoors away from normal shop work, operating machinery, loud noise, welding (arcing) and grinding operations if possible.

5.0 PRESERVATION, PACKAGING, PACKING, MARKING AND DELIVERY

5.1 Preservation (Storage) – Each overhauled pump unit will be placed in warehouse storage and not for immediate installation. The overhauled pump unit shall be individually preserved and wrapped for protection against moisture and deterioration for a period of two (2) years minimum.

It is critical the Contractor ensures the overhauled pump units undergo the below preservation requirements:

a. Each pump shall be drained and dried of all water and/or test fluid.

b. Contractor shall spray a corrosion preventative, water displacing compound fog into the intake and discharge ports of the pump assembly to prevent corrosion during storage.

The compound shall meet or exceed the requirements of MIL-PRF-81309F Type II, Class 2, Grades a or b. The intake and discharge ports shall have plastic cap inserts or wood covers installed as soon as fogging is completed.

c. Zerk fittings, if applicable shall be capped with red zerk caps.

d. Each pump unit shall be bagged in two 8 mil minimum thickness translucent polyurethane bags with one 80 unit desiccant pack in the bag. The bag opening shall be sealed closed with a plastic tie wrap. Since the pump is skid mounted, small holes will need to be cut in the bags to allow for bolting the pump down. These holes shall be sealed around each skid stud with silicon sealant and rubber gaskets to ensure the bag is sealed.

5.2 Packaging and Packing – Each overhauled and preserved pump unit shall be individually packaged in its own skid mounted framed-in wooden crate. The crate shall be built in such a manner to allow the entire top of the crate to be lifted off the crate base exposing the entire pump assembly. The crate lid shall be secured with corrosion resistant wood lag screws for easy removal. The pump unit shall be bolted to the to the crate base in such a manner as to prevent the pump unit from shifting within the crate. The crate shall be capable of protecting the pump unit from damage during multiple shipments by commercial carrier and long term warehouse storage and handling.

5.2.1 A two inch red square shall be painted and centered on each lag screw hole. The lag screw heads shall also be painted red. The following wording shall be stenciled with a minimum of 3/4 inch black block letters on a painted white background, centered on the top of the crate:

TO REMOVE LID, REMOVE RED LAG SCREWS AROUND BOTTOM OF CRATE

5.3 Marking – Each shipping container shall be stenciled with the information as laid out below.

Markings shall be placed on each side of the two longest sides of the container so it will be visible to a forklift driver during storage and shipment. Stencil shall be applied directly on the container and a minimum of ½ inch height black block characters on a highly contrasting painted white background using permanent waterproof ink or enamel paint.

NOTE:

All previous markings and/or quality assurance decals shall be completely removed from the reusable shipping container prior to the application of any new markings.

5.3.1 Required marking for (ready for issue) “A” Condition Bilge Pump:

National Stock Number: 4320 01-206-3745 Item Name: PUMP UNIT, CENTRIFUGAL Part Number: 733E015 Contract Number: See Contract Shipping Weight: As Determined by Contractor Statement: COAST GUARD SFLC MATERIAL

CONDITION "A", 1 EA

5.3.2 Required marking for (not ready for issue) “F” Condition Bilge Pump:

National Stock Number: 4320 01-206-3745 Item Name: PUMP UNIT, CENTRIFUGAL Part Number: 733E015 Contract Number: See Contract Shipping Weight: As Determined by Contractor Statement: COAST GUARD SFLC MATERIAL

CONDITION "F", 1 EA

5.4 Bar Coding: A bar coded label, in accordance with SFLC specification D-000-0100 shall also be applied. The Bar Code Label can be applied separately or as part of the marking required in 5.3 of this specification.

a. The actual labels shall be Type "V", Grade "C" Style "2", Composition "a" with or without plastic laminate.

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

5.5 Shipping: The Contractor shall ship or deliver the Bilge pumps(s) to the following government address:

U.S. Coast Guard Surface Forces Logistics Center

2401 Hawkins Point Rd, Bldg. 88 Baltimore, MD 21226

5.5.1 The Contractor may be required to ship the Bilge pump(s) to a designated location worldwide. The KO will provide the Contractor with shipping instructions and details.

5.5.2 Notify the Contracting Officer Representative (COR) and KO about the shipment 7 days in advance. Provide timely shipping information to the COR including the name of the shipping company, date of shipment leaving Contractor’s facility, and expecting arrival date and time at the government facility. No shipment shall be received at the warehouse outside of government normal business hours as determined by the KO.

6.0 NOTES

None

REVISIONS RECORD

This page is used to record specification revisions, which may have occurred subsequent to a Revision A (Rev-A) package. Information listed is intended to provide Contractors and field unit personnel a means to ensure all the current specification revision pages are present when reviewing or utilizing this specification package.

DATE REV# WORK

ITEM#

CHANGES MADE

NOTE: All work item and paragraph numbers listed above for a given revision correspond to same numbers in the previous revision. This revised specification is self-contained with all of the above listed changes incorporated.

NOTE: Revision record is a Coast Guard internal record. The revision will show the weakness of the spec where the change were made, and should not be published.