SOW 4320-01-413-9056.docx

1. Scope: This description covers the requirements for contractor inspection, estimate and overhaul of the following cited pump and motor unit.

NSN: 4320 01-413-9056

Item Name: Pump Unit, Centrifugal

P/N: 16-40121-XA11XX-6931

Application: 225 "A" WLB Fire Fighting System Original Equipment Manufacture (OEM): Grundfoss 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, 650 GPM, Total Head 347.0 FEET, 3500.0 RPM, 100 HP motor, 460.0 VOLTS.

1.3 The assembly delivered for overhaul services is intended to be a complete Paco Pump Co. P/N: 16-40121-XA11XX-6931. 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 are not intended to replace any procedures, controls, examinations or tests normally employed by the contractor to assure the quality of the product. Overhaul is intended to return the pump unit to a condition equal to that of an identical new pump unit.

2. Applicable Documents:

a. ANSI/NCSL Z540-3 (dated 2006) Calibration laboratories and Measuring and Test Equipment- General Requirements.

b. SFLC Standard Specification 6310, Requirements for Preservation of Ship Structures c.SAE AMS-STD-595, Colors Used In Government Procurement

d. ISO-IEC-16388-2007, Code 39 Symbology (Bar Coding)

3. Requirements: The contractor shall provide all labor and materials to perform overhaul services on the PACO 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 determine estimated 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: 40121-XA11XX-6931 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 be new 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 indentified 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: All zirc fittings shall 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 of the pump informing the user of the manufactures recommended amount and type of grease to be used.

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 of painting. New label plates shall be used if the original plate is not legible or in poor condition. Label plate shall contain pump make, model and serial numbers as well as all pump performance information as a minimum requirement.

3.3 Special Instructions: Any pump unit 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 overhaul estimate if found necessary.

3.4 Disposition: The Coast Guard shall determine the disposition of any pump unit 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 shall conduct 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 be reconditioned to a like new condition as part of the pump overhaul services. The drive motor is rated at 100 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 manufacturer's 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 that may 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 certification that 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 with fluid 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 of the 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 calibrated and 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 for the performance of all inspection requirements specified herein. The Contractor shall provide space, personnel and test equipment for the conduct of all inspection requirements. All inspection and testing shall be performed at the Contractors facility prior to the Coast Guards acceptance of the contracted items. The Coast Guard reserves the right to verify or have performed any of the inspections set forth herein where such inspections are deemed necessary to assure that supplies and services conform to prescribed requirements. The Coast Guard intents to have QA perform inspection on all pump units.

3.11 Notifications & Inspections: The contractor is responsible for notifying the Contracting Officer no less than ten (10) calendar days prior to the contractor being ready for any Quality Assurance (Q.A.) inspections or testing required herein.

4. Quality Assurance:

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

4.2 Inspections & Tests: The inspections & tests required herein are the minimum necessary and are not intended to replace any controls, examinations, or tests normally employed by the contractor to assure the quality of the product. The following are required:

4.3 Calibration System: The Contractor shall be required to maintain a test equipment calibration program in compliance with ANSI/NCSL Z540-3. The program shall be documented and traceable to the National Institute of Standards (NIST). The calibration system records shall be maintained for inspection for the duration of any contract referencing this specification

4.4 Test & Inspection Reports: A copy of any standard contractor test or inspection report shall be turned over to the Coast Guard Q.A. Inspector upon his arrival at the contractor's plant.

4.5 Warranty. Contractor's standard new pump warranty applies.

5. Preservation Packaging and Marking:

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

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

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

c) Each zirc fitting must be capped with red zirc caps.

d) Each pump shall be bagged in an 8 mil minimum thickness translucent polyurethane bag with at lease four (4) 4 ounce desiccant packs in the bag. Bag opening shall be sealed closed with a plastic tie wrap.

5.2 Packaging: Each overhauled and preserved pump or pump unit shall be individually packaged in its own framed in wooden crate. The crate shall be assembled with stainless steel wood screws. Pump shall be bolted to the inside of the crate and shall be constructed in such a manner as to prevent the pump from shifting within. Crate shall be capable of protecting the pump from damage during multiple shipments by commercial carrier.

5.3 Marking: Shipping container shall be stenciled with black enamel paint with the information as laid out below. Stencil shall be applied directly on the container and be 1/2 inch minimum height black characters on a white painted background. NOTE: ALL PREVIOUS MARKINGS AND / OR QUALITY ASSURANCE DECALS SHALL BE COMPLETELY REMOVED FROM A REUSABLE SHIPPING CONTAINER PRIOR TO THE APPLICATION OF ANY NEW MARKINGS. The following information shall be included in the markings:

NSN: 4320-01-413-9056

Item Name: Pump Unit, Centrifugal

P/N: 16-40121-XA11XX-6931

SERIAL#: (FROM DATA PLATE ON PUMP ASSEMBLY)

Shipping Weight: As determined Government Contract No.: As determined Coast Guard SFLC, Material Condition A, 1 ea."

5.4 BAR CODING: The stock number shall also be bar coded in accordance with reference document 2.d.

Acceptance: Acceptance will be made at destination by a government representative. Acceptance will be contingent upon representative's verification of no damage in transit, correctness and completeness of order and contractors conformance to preservation, packing and marking requirements.

6. Notes:

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