1407103-2059933119Range Pipe Fabrication Specifications.pdf

Specifications Page 1 of 5

BAM Range Phase II Range Pipe Fabrication Specifications

Project Description

The Bush Combat Development Complex (BCDC or OWNER) is soliciting competitive bids for the fabrication of components associated with the Ballistic Aero-Optics and Materials (BAM) Range Phase II expansion project located on the Texas A&M RELLIS Campus in Bryan, Texas.

This bid package includes fabrication of the primary range pipe assemblies required to extend the existing BAM Range. The project will increase the overall range length and support future hypersonic, aero-optics, and materials research capabilities.

The intent of this package is to procure long-lead fabricated steel components to support the Phase II construction schedule as provided within the Schedule Requirements below.

Scope of Work

The successful bidder (“Shop Fabricator”) shall provide all labor, materials, equipment, tooling, quality control, inspections, documentation, and transportation preparation necessary to fabricate the following components:

Base Bid - Range Pipe Assemblies

• Thirty-six (36) range pipe sections

• Associated bulkheads

• Associated flanges

• Associated ports and nozzle openings

• Saddles and attachment points required for fabrication and transport

• Leveling plates

• Teflon bearing plates

• Monorail beams

• Permanent lifting lugs and transport attachments

• Other appurtenances shown on the fabrication drawings

Schedule Requirements

• Anticipated award and issuance of purchase order: August 1, 2026

• Required Fabrication Completion: by July 2027

• Required Delivery: August 2027

Note: Final delivery timeframe is subject to change based on the BAM Range Phase II expansion project.

Specifications Page 2 of 5

APPENDIX A – TECHNICAL REQUIREMENTS

Design Conditions

• FLUID CONTAINED: AIR

• DESIGN PRESSURE: +15 PSIG TO -15 PSIG

• DESIGN TEMPERATURE: +110° F TO +20° F (DURING OPERATION)

• WIND LOAD: NONE (COMPONENTS ARE ENCLOSED BY OTHER STRUCTURES)

• SEISMIC LOAD: ASCE/SEI 7-16 SEISMIC DESIGN CATEGORY “A”

Measurements and Inspections

Dimensions requiring inspection documentation are identified with a Ⓘ symbol. Shop fabricator(s) may use either their in-house forms or metrology subcontractor form for documentation / submittal.

Large items requiring inspection shall be shaded (out of the sun) and at temperature equilibrium when performing measurements. The inspection records shall document the ambient temperature.

Reference temperature & pressure are the NIST NTP values of +68 F (+20 C) and 14.696 PSI (1 ATM). The NTP values apply for any corrections / offsets necessary to the measurement values recorded.

General Requirements

1. Unless written approval is obtained from Owner or the Owner's designee, no deviations are permitted from the drawings included and the referenced documents. This written approval shall be obtained prior to the implementation of any deviations.

2. Unless noted otherwise, all dimensions are finished dimensions in inches. Any additional material required for machining or trimming allowances, or as needed to accommodate weld shrinkage, shall be defined by the Shop Fabricator or for work performed at site, by the site installer.

3. The weld filler metal classification strength shall be 70 KSI. Unless defined otherwise, all welds, including member splices, shall be full penetration made from two sides, with the root pass back-gouged to sound metal before welding the second side. Except where defined, the use of permanent backing strips is prohibited. Weld symbols shall be interpreted per AWS A2.4.

4. Unless noted otherwise, bolt holes in flanges and similar fittings shall straddle an axis parallel to the range pipe longitudinal axis. Alternately, bolt holes for the cylinder end flanges shall straddle the cylinder vertical and horizontal cardinal centerlines.

5. All cut surfaces except for holes, which remain unwelded in the final condition, shall be sawn, sheared, machine burned, laser cut, or water-jet cut. All holes shall be drilled, punched, laser cut, water-jet cut, or machined, as appropriate. Alternately, non- fastener holes may be machine burned.

6. Debur and break all sharp corners.

7. Unless noted otherwise, tolerances and machined surface roughness shall conform to:

Specifications Page 3 of 5

A. The tolerances for cylinders and heads in the completed construction shall conform to paragraphs UG-80 and UG-81 of ASME section VIII division 1. The requirements for internal and external pressure service shall apply.

B. Except for the inside diameter of cylinders and the inside dimensions of heads, length tolerances shall be:

• up to 3 ft: ±1/16”

• over 3 ft to 10 ft: ±1/8”

• over 10 ft: ±3/16”

C. Tolerance on angles: ± 1/2º

D. However, in lieu of the tolerances in items 7.b and 7.c, tolerances affecting the site installation shall be by mutual written agreement of the Shop Fabricator and the site installer. These agreed to tolerances require the written approval of Owner or the Owner's designee.

E. Machined surface roughness: 125µ inches

Geometric tolerances shall be interpreted per ASME Y14.5.

8. The Shop Fabricator shall design and supply lifting lugs or other permanent lifting attachments, such that all range ducts and range vessels can be safely loaded for transportation, unloaded, and installed. Such lugs and attachments shall accommodate a 100% impact factor. To facilitate the site installation, the Shop Fabricator shall define the final weight and center-of-gravity location of all ducts and vessels.

9. The Shop Fabricator shall prepare, check, and submit detail shop drawings and detailed installation drawings, respectively. Such documents require the written approval of Owner or the Owner's designee prior to starting their fabrication or installation work.

In addition, the following documents shall be submitted for review and approval:

A. Mill test reports or certificates of compliance for all materials

B. Weld procedure specifications, procedure qualification records when such are required, and welder performance qualification records

C. Non-destructive examination reports and final inspection reports

D. As-built construction drawings

10. All codes and standards shall be the latest edition at the time of contract award.

11. Regarding the referenced codes and standards, where differences exist between these referenced documents and the drawings and specifications, the drawings and specifications take precedence.

Pressure Retaining Components

Pressure retaining components are the cylindrical shells, heads, ports and nozzles, covers and doors for the ports and nozzles, bolted flanges, and the cover/door/flange bolting. All rings, Specifications Page 4 of 5 stiffeners, and pad plates on these components shall be considered pressure retaining. All welds on these components, including those for attachments, shall be treated as pressure retaining.

1. All shop fabrication and site installation work shall conform to ASME section VIII Division

1. ASME code stamping is not required.

2. Materials, unless noted otherwise:

• PLATES: ASTM A36 (5/8” THICK OR LESS) OR ASTM A516 GRADE 70

• BARS: ASTM A36 (5/8” THICK OR LESS) OR CUT FROM THE SPECIFIED PLATE

• SHAPES: ASTM A36 (5/8” THICK OR LESS) OR BUILT FROM THE SPECIFIED PLATE

• PIPES: ASTM A53 GRADE B (TYPE E OR S) OR ASTM A106 GRADE B

• FORGINGS: ASTM A105

• BOLTING: ASTM A193 GRADE B7 STUDS WITH ASTM A194 GRADE 2H HEAVY HEX NUTS

3. All welding, including the use of certified welders and qualified procedures, shall be in accordance with ASME Section IX.

4. In addition to a full visual examination, the minimum weld examination shall be as follows:

A. All butt welds shall be ³spot radiographed per the procedures and acceptance criteria of ASME Section VIII Division 1.

B. In addition, 33% of the aggregate weld length shall be either magnetic particle (MT) or liquid penetrant (PT) examined, per the procedures and acceptance criteria of ASME Section VIII Division 1. No more than a 12" length shall be examined at a single location.

5. Prior to shipment, where duct or vessel sections are field welded together, the Shop Fabricator shall trial fit such sections, to ensure the field weld can be properly made within the tolerances defined by ASME Section VIII Division 1. Alternately, other approaches may be used to ensure proper fit up at these field welds, if mutually agreed upon in writing by the Shop Fabricator and the site installer.

Non-pressure Retaining Components

For other than pressure retaining components:

1. All shop fabrication and site installation work shall conform to ANSI/AISC 360, “Specification for structural steel buildings”.

2. Materials, unless noted otherwise:

• PLATES: ASTM A36, ASTM A572 GRADE 50, OR ASTM A516 GRADE 70

• BARS: ASTM A36 OR ASTM A572 GRADE 50

• SHAPES: ASTM A36, ASTM A572 GRADE 50, OR ASTM A992

• STRUCTURAL BOLTING: ASTM F3125 GRADE A325 BOLTS WITH ASTM A194 GRADE 2H

HEAVY HEX NUTS

Specifications Page 5 of 5

3. All welding, including the use of certified welders and qualified procedures, shall be in accordance with either AWS D1.1 or ASME section IX.

4. In addition to a full visual examination, at least 15% of the aggregate weld length shall be either magnetic particle (mt) or liquid penetrant (pt) examined, per the procedures and acceptance criteria of either AWS D1.1 or ASME section VIII Division 1. No more than a 12" length shall be examined at a single location.

Surface Coating

Surface preparation and surface coatings shall be per the facility paint specification.

Pressure Testing

Since the range ducts and range vessels will initially be used only from full vacuum to 1.2 PSIG, internal pressure testing is not part of the initial construction work. However, prior to their use at an internal pressure exceeding 1.2 PSIG, pressure testing may be warranted using air as the test medium. Such a test shall be conducted under the direction of a registered professional engineer with experience conducting such tests, who shall define all safety protocols, pretest inspections and examinations, and other requirements of the test. Note that neither the range ducts, the range vessels, nor their foundations have been designed to support the water weight of a hydrotest.