Statement of Work.doc

1.0 SCOPE - This specification covers the requirements for the inspection, overhaul, calibration, testing, preservation, packaging, and marking of Woodward Type Governors used on 175 WLM Class Buoy Tenders.

1.1 TYPES

1.1.1 Governor, Diesel Engine, Woodward Part No. 8540-619, Caterpillar Part Number 124-3174

1.1.2 Governor, Diesel Engine, Woodward Part No. 8540-569, Caterpillar Part Number 124-3174 2.0

APPLICABLE DOCUMENTS

2.1.

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 Index of Specifications and Standards (DODISS) and supplements thereto.

2.2.

GOVERNMENT DOCUMENTS - The following documents form a part of this specification to the extent specified herein. The documents listed shall be by title and effective date, unless otherwise documented.

2.2.1.

US COAST GUARD SPECIFICATION

a.

D-000-100 REV F (dtd. 10/96) Bar Coding For U.S.C.G. SFLC 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. Commercial documents may also be listed in the Department of Defense Index of Specifications and Standards (DODISS).

2.3.1.

American National Standards Institute (ANSI)/National Conference of Standards Laboratories (NCSL) a.

ANSI/NCSL Z540-1-1994 (dtd 1994) Calibration Laboratories and Measuring and Test Equipment General Requirements.

2.3.2.

ANSI/ASQC Q9003-1994 (dtd 1994) Quality Systems Model for Quality Assurance in Final Inspection & Testing.

2.3.3.

Woodward Governor Company bulletin 25075A.

2.4.

SPECIFICATION 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.

3.0

REQUIREMENTS

3.1.

GENERAL - The overhaul requirements described herein are the minimum necessary and are not intended to replace any procedures, controls, examinations or tests normally employed by the contractor to insure quality of the product.

3.2.

TEST AND/OR INSPECTION PLAN The contractor shall submit an Initial Inspection Plan and a Final Test & Inspection Plan, as well as the current Woodward Test Specification Procedure (TSP) for each governor overhauled under this contract to the Contracting Officer for approval.

a.

Separate plans for initial inspection and final testing & inspection shall be submitted together.

3.2.2.

The plan shall include the specific inspections and tests specified herein, and all other inspections and tests needed to verify conformance to every requirement in this specification.

a.

The initial inspection plan shall include, but not be limited to:

1.

Time and date of inspection.

2.

A chronological listing of the inspections to be performed.

3.

Step-by-step inspection procedures to be performed.

4.

Inspection data sheets to be used to record observed condition/performance data, describing all deficiencies found and the proposed corrective action to be taken.

5.

A complete listing of all equipment to be used, with equipment serial numbers.

6.

Dimensional inspection reports, noting all items that are not within tolerances of a new governor.

7.

Date and signatures of inspection personnel.

b.

The final test plan shall include, but not be limited to:

1.

The current Woodward TSP for each governor under this contract

2.

Time and date of test.

3.

A chronological listing of the tests to be performed.

4.

Step-by-step test procedures for the test configuration and pass/fail criteria.

5.

Test data sheets to be used to record observed performance data, and shall include all deficiencies found and the corrective action taken.

6.

A complete listing of all equipment to be used, with equipment serial numbers.

7.

Dimensional report, and all final clearances, with tolerances.

8.

Date and signatures of test personnel.

9.

Signature of Government witness, if any.

3.3.

INITIAL INSPECTION - Initial disassembly and inspection shall be conducted to evaluate needed overhaul.

3.3.1.

The contractor shall develop and submit an individual, written Initial Inspection Estimate for each governor evaluated.

3.4.

The estimate shall consist of the data as required below. No further work shall be done until the Coast Guard Contracting Officer approves the report.

a.

Inspection Report Items:

1.

Date of inspection

2.

Inspector's name

3.

Identification of units by serial number, part number, and stock number

4.

Condition of shipping crate and cost of any repair

5.

List of each part requiring replacement, by actual part number and parts reference number

6.

The price of each part to be replaced as well as the total cost of all parts to be replaced

7.

Cost of overhaul labor

8.

Comments, if any, pertaining to any unusual observations during inspection and testing.

9.

Configuration changes not included in current asset to be overhauled.

b.

The estimate shall include material, labor, 1.

Testing, preservation, packing and marking costs.

3.5.

FINAL TEST REPORT Final calibration and testing shall be conducted in accordance with the current applicable Woodward TSP for each governor overhauled.

3.5.1.

The contractor shall develop and submit an individual, written, Final Test Report for each governor overhauled.

3.6.

The Final Test Report shall consist of the data as required below and shall be submitted to and approved by the Coast Guard Contracting Officer before the newly overhauled governor is shipped to the Coast Guard.

a.

Final Test Report Items:

1.

Date of test

2.

Tester's name

3.

Identification of units by serial number, part number, and stock number

4.

List of each part replaced, by actual part number and parts reference number

5.

The price of each part replaced as well as the total cost of all parts replaced

6.

Cost of overhaul labor

7.

Comments, if any, pertaining to any unusual observations during testing.

8.

Configuration changes performed in current overhaul to bring the newly overhauled governor to the same configuration as a new governor of the same series and model.

b.

The report shall include material, labor, testing, preservation, packing and marking costs.

3.7.

OVERHAUL REQUIREMENTS - Each governor shall be overhauled, calibrated, and tested in accordance with Original Equipment Manufacturers (OEM) current design and technical specifications and TSP. Governor shall be calibrated and tested to meet Woodward TSP 10257MH, to function properly on CAT 3508 Propulsion Diesel Engines with serial number prefixes: 9WN and 3HM.

3.7.1.

All replacement parts used in overhaul shall be genuine Woodward Governor parts.

3.7.2.

Each overhauled governor shall be restored to the performance standards of a new governor.

3.7.3.

Each overhaul shall include disassembly and cleaning of all parts of all contaminants including but not limited to dirt, grease, oil and paint.

a.

All gaskets, seals, o-rings, bearings, and parts worn or damaged beyond manufacturer's tolerances shall be replaced.

b.

Each governor shall be assembled by Woodward Governor factory trained service technicians to insure that all OEM specified clearances, procedures, calibrations and torque values are applied.

c.

The contractor shall submit standard paint and preservation practices which-shall be applied to all governors included herein.

3.7.4.

If not previously accomplished, indicate the special calibration by annotating the Woodward part number on the label plate (WG CO PART NO) with the suffix “GA” after the Woodward part number (Ex: 8540-619 GA).

3.8.

FINAL TEST - Each governor shall be tested at an authorized Woodward Governor test facility. Each governor shall be calibrated to meet the current applicable Woodward TSP.

3.8.1.

A copy of test results shall be sent to the USCG Contracting Officer for approval.

3.9.

NOTIFICATIONS & INSPECTIONS - The contractor shall be responsible for notifying the Contracting Officer at least seven (7) calendar days prior to said contractor being ready for any inspections or testing required herein.

4.0

QUALITY ASSURANCE

4.1.

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 Contractor's plant or at other facilities acceptable to the Coast Guard. The Coast Guard reserves the right to verify or have performed any of the inspections set forth in this specification where such inspections are deemed necessary to assure that supplies and services conform to the prescribed requirements.

4.2.

RESPONSIBILITY FOR COMPLIANCE - All items shall meet the requirements of sections 3 and 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 requirements in this specification shall not relieve the contractor of the responsibility of assuring that all products or services 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.

4.3.

QUALITY SYSTEM - The contractor shall maintain a documented Quality System in accordance with ANSI/ASQC Q9003.

4.4.

INSPECTIONS AND TESTS - The inspections and tests required herein are the minimum required and are not intended to replace any controls, examinations, inspections or tests normally employed by the contractor to assure the quality of the equipment.

4.4.1.

A Coast Guard Quality Assurance (QA) representative will visit the Contractor’s facility to inspect the following:

a. Final Test Report – section 3.6

b. Preservation, Packaging, and Marking – Section 5.0 4.5.

CALIBRATION SYSTEM - The Contractor, as well as any subcontractors, shall be required to maintain a test equipment calibration program in compliance with ANSI/NCSL Z540-1. The program shall be documented and traceable to the National Institute of Standards (NIST).

4.5.1.

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

4.6.

FAILURE RESPONSIBILITY - If a governor fails to pass any inspection or test, the Contractor shall report the failure and their recommendation for corrective action to the Contracting Officer. If approved, the corrective action on the materials or processes shall be taken in accordance with this section.

a.

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

4.6.2.

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

4.6.3.

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

4.6.4.

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

4.6.5.

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

4.6.6.

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.

4.7.

TEST AND INSPECTIONS. The contractor shall demonstrate, in the presence of the USCG Quality Assurance Representative, that each governor overhauled under this contract has been calibrated in accordance with, and meets the parameters of the current applicable Woodward MASTER TSP, as modified by paragraph 3.7.5 of this specification.

4.8.

REPORTS. One copy of any required inspection, test or tolerance check shall be sent to the Contracting Officer, including one copy of the most current MASTER Woodward TSP for each governor covered herein with the final report.

4.8.1.

A copy of any test, inspection, or calibration record, and the current Woodward TSP for the governor to be tested shall also be turned over to the Quality Assurance representative upon his arrival at the contractor's plant.

4.9.

PACKING INSPECTION - The Contracting Officer 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, PACKAGING AND MARKING (PP&M)

5.1.

PRESERVATION All governors and actuators shall be preserved and packaged in accordance with Woodward Governor Company bulletin 25075A, dated 1975 entitled Commercial Preservation Packaging For Storage Of Mechanical-Hydraulic Controls.

5.1.1.

All governors shall be completely assembled and ready for installation.

5.1.2.

All openings shall be sealed with plastic caps.

5.2.

PACKAGING

5.2.1.

Each overhauled and preserved governor shall be sealed in accordance with Woodward Governor Company bulletin 25075A.

5.2.2.

Each overhauled and preserved governor shall be individually packed in its own wooden box, constructed as described below in accordance with MIL-STD-2073 (and pictured in attachment 1).

a.

The lower base shall be skid mounted with a plywood, base with a nailer strip screwed to the front and back of the base to allow the cover to be attached (screwed) to it (see photo Nos. 1 & 3, in attachment 1).

b.

The unit base shall be constructed of plywood and supports (see photo No. 2, in attachment 1). The unit base may require a hole of sufficient diameter to allow passage of the drive shaft of the governor.

c.

The governor shall be attached to the unit base, through the governor base plate, using 4 each lag bolts (minimum).

d.

The top of each governor shall be secured by a notched 4" X 4" brace as shown in Picture No. 9. The 4 X 4 brace shall be secured (screwed) through two opposite sides of the crate. Plastic-enclosed, molded foam may be used in lieu of wooden bracing, providing the foam completely stabilizes the top of the governor so that it will not shift inside the crate during rough handling.

e.

The top and sides of the crate (cover) shall be constructed using plywood and removable as one piece (see photo No. 4, in attachment 1). The inside dimension of the cover shall allow a minimum of two inch clearance around the sides and top of the governor.

f.

The finished crate dimensions shall be sized in accordance with the above specification.

g.

The crates shall be assembled using decking screws (no nails are to be used).

5.3.

MARKING - The marking described herein shall be placed on the longest two sides of each box (on opposite ends).

5.3.1.

Each container shall be marked in legible 1/2" to 3/4" high black waterproof print on a white contrasting background with the following information:

5.3.2.

This marking shall consist of the following information:

For the type identified in paragraph 1.1.1:

STOCK NUMBER

2910-01-430-0125

ITEM NAME

Governor, Diesel Eng.

PART NUMBER

124-3174

ALT. PART NUMBER

8540-619

CONTRACT NUMBER

See Contract

GROSS WEIGHT

As Determined by Contractor

CONDITION CODE

CONDITION A

QUANTITY & UNIT OF ISSUE

1 EA

OVERHAUL DATE

As determined by Contractor

RE-INSPECTION DATE

60 Months from Overhaul Date

COAST GUARD SFLC MATERIAL

For the type identified in paragraph 1.1.2:

STOCK NUMBER

2910-01-430-0125

ITEM NAME

Governor, Diesel Eng.

PART NUMBER

124-3174

ALT. PART NUMBER

8540-569

CONTRACT NUMBER

See Contract

GROSS WEIGHT

As Determined by Contractor

CONDITION CODE

CONDITION A

QUANTITY & UNIT OF ISSUE

1 EA

OVERHAUL DATE

As determined by Contractor

RE-INSPECTION DATE

(Enter the date that is 60 Months from the date of overhaul)

COAST GUARD SFLC MATERIAL

5.3.3 Stenciling on each crate shall be as pictured in photo Nos. 5,6,7, & 8, as seen in attachment 1, except the contractor shall include the appropriate stock number and part number for each applicable governor enclosed.

5.4 BAR CODING - Bar code labels shall be supplied on all CLIN's except for those that require data submissions only.

5.4.1 All bar coded labels shall be in accordance with SFLC specification D-000-0100, REV F.

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

NOTES

6.1.

DOCUMENT SOURCES

6.1.1.

GOVERNMENT DOCUMENTS

a.

Specifications and Standards (DODISS Documents) Standardizations Document Order Desk 700 Robbins Avenue

Building #4, Section D

Philadelphia, PA 19111-5094

215-697-1187 b.

DOD & Navy Publications and Forms (Other Than DODISS)

Naval Publication and Forms Center

5801 Tabor Ave.

Philadelphia, PA 19120

215-697-2000

6.1.2.

OTHER GOVERNMENT DOCUMENTS

a.

USCG Surface Forces Logistics Center

Icebreaker, Buoy and Construction Tender Product Line

2401 Hawkins Point Road, Mail Stop 25

Baltimore, MD. 21226-5000

410-582-4702

6.1.3.

COMMERCIAL DOCUMENTS

a.

Steel Structures Painting Council 40 24th Street

Pittsburgh, PA 15222 b.

American Society for Quality Control (ASQC)

611 E. Wisconsin Ave.

Milwaukee, Wisconsin 53202 c.

American National Standards Institute (ANSI) 1430 Broadway

New York, NY 10018