J -- CGC BEAR EMERGENCY RUDDER REPAIR

This is a combined synopsis/solicitation for commercial items prepared in accordance with the format in FAR Subpart 12.6, as supplemented with additional information included in this notice. This announcement constitutes the only solicitation; quotations are being requested and a separate written solicitation will not be issued. The solicitation is issued as a Request for Quotations. The solicitation document and incorporated provisions and clauses are those in effect through Federal Acquisition Circular 01-24 effective 06/18/04. The requirement is being solicited as a 100% Small Business Set-aside using Simplified Acquisition Procedures per FAR Subpart 13. The NAICS Code 336611 with a Small Business Size Standard of 1000 employees. Solicitation number HSCG80-04-Q-3FAW28 applies. A Firm Fixed Price Purchase Order is anticipated. Place of Performance: USCGC BEAR (WMEC 901), Coast Guard Base San Juan PR. Date of Performance: 29 September 2004. USCGC BEAR (WMEC 901) 270-FOOT MEDIUM ENDURANCE CUTTER SPECIFICATIONS FOR EMERGENCY RUDDER REPAIRS (September 23, 2004/Rev-0) Sketches are not applicable. There are no revisions to the specification. List of Applicable References 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. Electronic copies of the 2004 Edition of MLCA Standard Specifications are available on the Internet and may be accessed at the following Internet Uniform Resource Locator (URL) address: http://www.uscg.mil/mlclant/vdiv/specs/default.htm. Order of precedence. In the event of conflicts between text of this specification and the applicable references specified herein, order of precedence shall be in accordance with MLCA Standard Specification 0000_STD, paragraph 3.2 (Order of precedence), unless otherwise specified by the Contracting Officer (KO). The Contractor shall immediately notify the KO in writing of any perceived conflicts contained herein. Nothing in these documents, however, supersedes applicable laws and regulations, unless a specific exemption has been obtained. FEDERAL AND MILITARY SPECIFICATIONS AND STANDARDS MIL-PRF-16173, Jan 1993, Corrosion Preventive Compound, Solvent Cutback, Cold Application MIL-STD-1687, Sep 1994, Thermal Spray Process for Naval Ship Machinery Application OTHER GOVERNMENT DOCUMENTS, DRAWINGS, AND PUBLICATIONS DOCUMENTS Coast Guard Maintenance and Logistics Command Atlantic (MLCA), Standard Specification 0000_STD, 2004 Edition, General Requirements Coast Guard Maintenance and Logistics Command Atlantic (MLCA), Standard Specification 0740_STD, 2004 Edition, Welding and Allied Processes DRAWINGS Coast Guard Drawing 901 WMEC 243-008, Rev A, Hub & Rudder Removal Pad eye A & D Coast Guard Drawing 901 WMEC 562-001, Rev D, Rudder Coast Guard Drawing 905 WMEC 562-004, Rev A, Rudder Stock and Steering Gear A & D PUBLICATIONS Coast Guard Technical Publication (TP) 2718, Chapter 561, Dec 1992, Technical Manual - Operation and Service Instruction for Steering System WMEC 270 Class Ship Drawings are available by email. Contact Mia Robinson at +1 (555) 000-0000 List of Government-furnished Property The following is a list of property, which the Government will furnish. This list supersedes any other material obligations indicated or implied by referenced drawings. WORK ITEM MTI ITEM DESCRIPTION NSN/PN QTY ESTIMATED COST($/Unit) 1 Yes **Rudder Assembly NSN: 2040-01-486-0550 1 ea. 125,000 **Upper Bearing NSN: 3110-01-121-8032 1 ea. 4,323 Rudder Stock Sleeve NSN: 2040-01-F91-0187 1 ea. 6,342 John Crane Seal kit NSN: 5330-01-459-2150 1 ea. 5,058 **Thordon Lower Bearing (SXL 20.7" X 17.5" X 14) PN: F546150102 1 ea. 1,923 *Government-loaned property, which shall be returned to the vessel upon completion of the availability. **New or refurbished equipment that the Government may provide for installation in place of existing equipment. ***Government-furnished property, which is to be supplied by either the vessel, Electronic Systems Support Unit (ESU) or local Electronic Support Detachment (ESD). List of Critical Inspection Items: The following is a list of work items which contain Critical Inspection reports which the Contractor must complete within the first 25% of the availability contract period (see Std Spec 0000_STD, paragraph 3.6.2 (Inspection report particulars)): This section is not applicable to this package. General Requirements: 1. SCOPE 1.1 Scope. This item describes the general requirements to be followed by the Contractor while conducting this availability. 2. APPLICABLE DOCUMENTS Coast Guard Maintenance and Logistics Command Atlantic (MLCA), Standard Specification 0000_STD, 2004 Edition, General Requirements 3. REQUIREMENTS 3.1 General. The Contractor shall conform to all requirements specified in Std Spec 0000_STD and in this item, as applicable, during the performance of this availability. NOTICE! The requirements of paragraph 3.1 (General) apply not only to all work under the scope of this contract, whether explicitly stated in work items or not, but also to all other work subsequently authorized by changes, modifications, or extensions to the contract. 3.2 Contractor-provided fire extinguishers. The Contractor shall provide portable fire extinguishers. 4. QUALITY ASSURANCE No additional requirements. 5. NOTES This section is not applicable to this specification. Work Item 1: Service Rudder Assembly on Waterborne Cutter 1.1 Scope. This work item describes the requirements for the Contractor to service the designated rudder assembly while the cutter is waterborne. 1.2 Location. Steering Gear Room (3-228-0-E). 2. APPLICABLE DOCUMENTS: MIL-STD-1687, Sep 1994, Thermal Spray Process for Naval Ship Machinery Application MIL-PRF-16173, Jan 1993, Corrosion Preventive Compound, Solvent Cutback, Cold Application Coast Guard Maintenance and Logistics Command Atlantic (MLCA), Standard Specification 0740_STD, 2004 Edition, Welding and Allied Processes Coast Guard Technical Publication (TP) 2718, Chapter 561, Dec 1992, Technical Manual - Operation and Service Instruction for Steering System WMEC 270 Class Ship Coast Guard Drawing 901 WMEC 243-008, Rev A, Hub & Rudder Removal Pad eye A & D Coast Guard Drawing 901 WMEC 562-001, Rev D, Rudder Coast Guard Drawing 905 WMEC 562-004, Rev A, Rudder Stock and Steering Gear A & D 3. REQUIREMENTS: 3.1 Technical representatives. Provide an on-site qualified technical representatives (Tech Rep) for the following: 3.1.1 Thordon Bearing. Provide the services of a qualified Tech Rep familiar with the Thordon bearing, to advise on manufacturer's proprietary information, dimensions, and clearances associated with the system, assist with proper repair methods, and ensure compliance with manufacturer's procedures and standards during disassembly, inspection, and reassembly of the bearing system. The technical representative shall be a Thordon technical representative or its licensee. 3.1.2 John Crane Seal. Provide the services of a qualified Tech Rep to provide proprietary techniques, assist with proper alignment, clearances, and repair methods associated with installation, and ensure compliance with manufacturers' standards during disassembly, inspection, and reassembly of the John Crane type ES stern tube seal assemblies. The Tech Rep must have a resume of demonstrated experience with the John Crane seal assembly system as described above and must be able to provide a list of references upon request to the COR. The technical representative must be present when work is being performed on the seal assembly and sub-assemblies. 3.2 Safety Precautions. Prior to any work, the Contractor shall: 3.2.1 Verify in the presence of the Coast Guard inspector that the trim of the cutter is such that the rudder assembly may be removed without causing flooding through the lower seal. Changes in the loading condition of the vessel will be accomplished by the unit prior to commencement of work. 3.2.2 Determine and implement, with the approval of the Coast Guard Inspector, an appropriate means of securely plugging or capping the rudder stock tube to minimize the risk of flooding after removal of the rudder stock. 3.3 Carrier bearing clearance measurement. Before maintenance work is begun, the Contractor shall measure the rudder carrier bearing clearances of both rudders. Submit CFR. 3.4 Rudder maintenance requirements. The Contractor shall perform the following for each rudder assembly: 3.4.1 Removal. Disconnect and remove the tiller, upper roller bearing, bearing housing, rudder shaft seal assembly, retainer plates and other associated mounting components, shown on Coast Guard Drawings 901 WMEC 243-008, 901 WMEC 562-001, and 905 WMEC 562-004. Scribe a mark on the tiller and rudder stock assembly, to facilitate later reinstallation. 3.4.1.1 Cut out the 18" x 18" x 3/8" removable plate (Item 6), shown on Coast Guard Drawing 901 WMEC 562-001. 3.4.1.2 Scribe a mark to indicate the existing rudder nut position on the rudder stock, to facilitate later reinstallation. Remove the rudder stock nut and locking bars, shown on Coast Guard Drawing 905 WMEC 562-004. Mark the rudder stock and rudder prior to separation. Disconnect and separate rudder from its associated rudder stock and transport them to a suitable repair facility. 3.4.1.3 If heat is necessary to facilitate the removal of the roller bearing inner race from the stock, do the following, prior to applying heat: - Remove all grease from upper bearing surfaces. - Remove rollers and outer race. 3.4.2 Inspections. Clean all removed and disassembled components free of all surface contaminants, and perform the following inspections. Submit CIR for each inspection. 3.4.2.1 Rudder blade. Perform the following, in accordance with Std Spec 0740_STD, Appendix C, for rudder blade: - Visually inspect all welds. - Perform an air test of the rudder blade. 3.4.2.2 Rudder stock. Set each rudder stock in a lathe and accomplish the following: - Visually inspect the entire rudder stock surfaces for wear and corrosion. - Measure the stock runout. - Examine the condition of metal spraying coating. - Measure the outside diameter of each stock journal in way of seal area and bearing sleeve at the top, bottom and midpoint. - Conduct non-destructive inspection of the tapers, keys, and keyways in accordance with Std Spec 0740_STD, Appendix C. NOTICE! The stock diameter in way of - John Crane seal is a nominal size 11.100" + 0.003". 3.4.2.3 Upper bearings. - Clean and visually inspect the removed roller bearings. - Measure the dimensions of the roller bearing and outside diameter of rudder stock. 3.4.2.4 Lower bearings. - Visually inspect both port and starboard Thordon lower bearings for any abnormal or excessive wear. - Measure the inside diameters at top, middle and bottom positions. 3.4.3 Component renewals. 3.4.3.1 Bearing sleeve (liner) renewal. After a Change Request has been authorized and released by the KO, renew the bearing liners with Government-furnished sleeve(s), as shown on Coast Guard Drawing 905 WMEC 562-004. 3.4.3.2 Lower bearing renewal. After a Change Request has been authorized and released by the KO, renew the lower - Thordon bearing, with a Government-furnished, as follows (see 5.2(Thordon bearing particulars)): 3.4.3.2.1 Removal. Remove and dispose of the lower bearing from the bearing housing. 3.4.3.2.2 Measurements. After authorized repairs, if any, take all measurements of the rudder stock and lower housing required, to facilitate the machining of the new Thordon bearing. Submit CFR (see 5.2(Thordon bearing particulars)). 3.4.3.2.3 New bearing installation. Install the new Government-furnished lower bearing into the bearing housing(s), in accordance with bearing manufacturer's recommended procedures, under the supervision of the Tech Rep. 3.4.4 Rudder reinstallation. Upon completion of all inspections and authorized repairs, if any, the Contractor shall reassemble and reinstall each rudder assembly, as shown on Coast Guard Drawings 901 WMEC 562-001 and 905 WMEC 562-004. Fill cavity below the new mechanical seal with grease, as shown on Coast Guard Drawing 905 WMEC 562-004. 3.4.4.1 During the final assembly, clean the bore of the rudder and the stock taper area free from dirt and other foreign matter, including lubricants. 3.4.4.2 Prior to final assembly, furnish and apply sealant and fill the sleeve cavities with grease through the newly installed grease fittings in accordance with Coast Guard Drawing 905 WMEC 562-004. 3.4.4.3 In the presence of the Coast Guard Inspector, check the fit the rudder stock taper and the associated rudder by bluing. Obtain a minimum of 75% uniform fit between the rudder stock taper and rudder. Do not use heat to compensate for a poor fit on the rudder stock taper. If the fit is less than 75 percent, grind the rudder bore with fine emery cloth until the 75 percent contact is achieved. Use Coast Guard Drawing 905 WMEC 562-004 as a guide. 3.4.4.4 Reinstall and snug the rudder stock nut. Submit the final torque value to COR after securing the nut. Fabricate two lock bars using Coast Guard Drawing 905 WMEC 562-004 as guidance; in lieu of tack welding, weld the end and both sides of each lock bar to the rudder. Locking bars shall be perpendicular to each other. 3.4.4.5 Reinstall the two removable plates shown on Coast Guard Drawing 901 WMEC 562-001. 3.4.4.6 Coat the rudder interior surfaces with corrosion preventive compound conforming to MIL-PRF-16173, Class II, Grade 3. 3.4.4.7 Install the upper bearing into bearing housing. If the outer race of the upper bearing can not be tightly fitted into the bearing housing, apply bearing manufacturer's recommended tightening compound to secure the upper bearing into the bearing housing to prevent from loosening. Renew the seal and packing material in the bearing housings, as shown on Coast Guard Drawing 905 WMEC 562-004. 3.5 Mechanical seal assembly installation. The Contractor shall accomplish the following for each - John Crane mechanical seal assembly: 3.5.1 Seal reinstallation. 3.5.1.1 Machine the stationary seal faces to remove grooves and wear at 25 RPM with 0.005" per revolution feed rate to achieve a 63 micro inch finish. Polish with a block and 600 grade wet and dry emery paper. 3.5.1.2 Reassemble and reinstall the seal assembly to original configuration, using the Government-furnished seal kits, under the supervision of the seal Tech Rep. 3.5.2 Tiller reinstallation. 3.5.2.1 Reinstall tiller arm in accordance with prescribed marking, ensuring proper orientation. 3.5.2.2 Reinstall feedback rod mechanism, and ensure proper adjustment. 3.5.2.3 Tack weld locking bars to the tiller arm nuts. 3.5.3 Check the rudder alignment with pilot house rudder angle indicator, and adjust as necessary to obtain correct alignment within 1/2 degree port or starboard. 3.6 Bearing clearances. The Contractor shall check the carrier bearing axial clearance (end play) of each shaft to ensure that it does not equal or exceed 0.031" greater than the original installed axial clearance. The design axial clearances for new carrier bearing are minimum 0.0274" and maximum 0.0412". 3.7 Rudder assembly change-out. The Contractor shall be aware that the Government reserves the right to provide a new rudder assembly for installation in place of one removed, at no additional cost to the Government. When the Government exercises this right, the Contractor shall turn over the removed rudder assembly to the PA as a MTI item. 3.8 Rudder air test. The Contractor shall air test the each rudder in accordance with Std Spec 0740_STD, Appendix C. Submit a CFR. 3.9 Touch-up preservation. The Contractor shall prepare and coat all new and disturbed exterior and interior surfaces to match existing adjacent surfaces, in accordance with COMDTINST M10360.3B, Appendix A (Cutter and Boat Exterior Paint Systems) and Appendix B (Cutter and Boat Interior Paint Systems), respectively, to match existing adjacent surfaces. 4. QUALITY ASSURANCE: 4.1 System test. The Contractor shall test the steering and rudder system to ensure the rudders travel smoothly throughout full range of travel and at the required rate of train without chattering or binding. 4.1.1 Dock trial. Conduct a test of the steering gear in accordance with the Section 6-11 (Scheduled Test procedure) through Section 6-15 (Gyro Mode Test) of TP-2718. The rudder shall travel a total of 70 degree arc (35 degrees to port and to starboard) without chattering or binding. Ensure no leaks are present. Provide a written testing report to the COR within 24 hours. 4.1.2 Sea trial. Upon satisfactory completion of dock trials, conduct a sea trial of the steering gear system. The system shall be operated in all possible modes of operation and demonstrate satisfactory operation in accordance with the manufacturers specifications. 5. NOTES 5.1 Government-furnished property. MTI ITEM DESCRIPTION NSN/PN QTY ESTIMATED COST($/UNIT) Yes **Rudder Assembly NSN: 2040-01-486-0550 1 ea. 125,000 **Upper Bearing NSN: 3110-01-121-8032 1 ea. 4,322 Rudder Stock Sleeve NSN: 2040-01-F91-0187 1 ea. 9,932 John Crane Seal kit NSN: 5330-01-459-2150 1 ea. 5,057 **Thordon Lower Bearing (SXL 20.7" X 17.5" X 14) PN: F546150102 1 ea. 6,025 5.2 Thordon bearing particulars. Government-furnished Thordon bearings are reserved and stored at the bearing manufacturer's facilities. Upon request, the bearing manufacturer will machine new bearing to the final dimensions based on the measurements of the existing bearings. The new bearings will then shipped to the Contractor's facility within 2 to 3 days, after being machined, for installation. 5.3 Rudder stock runout. The runout should be no more than 0.005. 5.4 Seal Manufacturer. John Crane was bought by the Wartsila. 5.5 Water Depth. The minimum depth beneath the hull for rudder removal and replacement is approximately 15 feet. Schedule of Supplies and services: BASE - CLIN 0001 - Service Rudder Assembly on Waterbourne Cutter 1 JOB $_____________ OPT A - Composite Labor Rate 50 Hours at $__________ = _____________ BASE B - GFP REPORT NSP 1 EA NSP BASE C - Travel and Per Diem 1 JOB $ _____________ TOTAL PRICE: $____________________