6029B076-TECH.pdf

1. Scope:

STATEMENT OF SPECIFICATIONS

W130 TEST BENCH SYSTEM with OPTIONS

1.1. The following sets forth the minimum requirements for the procurement of a custom turn-key valve testing system. This system shall be for testing air/nitrogen and water valves. The system is to be installed at Naval Station Norfolk Bldg. W130. The testing system shall be complete with the equipment and accessories described herein. The system shall contain all principle components for the requirements listed in section.

2. Applicable Documents:

2.1. General: The documents listed in this section are specified in sections 3 and 4 of this specification. This section does not include documents cited in other sections of this specification or recommended for additional information or as examples. While every effort has been made to ensure completeness of this list, document users are cautioned that they must meet all specified requirement documents cited in section 3 and 4 of this specification, whether or not they are listed.

2.2. Government Documents:

2.2.1. Other Government documents, drawings and publications form a part of this document to the extent specified herein. Unless otherwise specified, the issues are those cited in the solicitation.

2.3. Non-Government Publications: The following documents form a part of this document form a part of this document to the extent specified herein.

2.3.1. American Petroleum Institute (API):

2.3.1.1. API-598: API STD 598 Valve Inspection and Testing

2.4. Order of precedence: In the event of a conflict between text of this document and the references cited herein, the text of this document takes precedence. Nothing in this document, however, supersedes applicable laws and regulations unless a specific exemption has been obtained.

3. Requirements:

3.1. Design: The items offered shall be new and a current commercially available model. A current model is defined as the manufacturer's currently produced model, which, on the date this solicitation is issued, has been designed, engineered, sold, or is being offered for sale through advertisements or manufacturer's published catalogue or brochures. Products such as a prototype unit, pre-production model, or experimental unit do not qualify as meeting the requirements specified herein. The test system shall include all components, parts, and features necessary to meet the performance requirements specified herein. All parts subject to wear, breakage or distortion shall be accessible for adjustment, replacement, and repair.

3.2. Materials: Unless_specified herein, materials shall be in accordance with the manufacture's materials specifications for test bench assemblies. The material shall be capable of meeting all operational and environmental requirements specified herein. Asbestos, Cadmium, and radioactive material shall not be used in this item. Radioactive material is defined by CFR, Title 10, parts 30 and 40, and other radioactive material in which the specific activity is greater than 0.002 microcopies per gram or the activity per item equals or exceeds 0.01 microcuries. Recovered materials shall be used to the maximum extent practical (see 4.4.1).

3 .3. Design/Build System (PS-15M Test Bench) shall be designed to allow an air/nitrogen or water test to be performed on the valves (size and pressure) listed in table 1 with optional Accumulator. All testing shall be accomplished on the same clamping system. Test Bench to include: 2-Way water connection system to easily switch from the closed water system to direct-use of external water. NPT connection for exit drain of water basin. HP-air hose to connect to storage bottle of air compressor. Connection ( 1) for reference gauges or gauges with different precisions (standard). Digital leak counter. Automated documentation of seat leakage test with water for control and block valves. Adapters for butt-welded valves. Valve Doc Documentations System with disabled camera. Additional 3 reference connections for a total of 4. Test gauges in psi. All external threaded connections will be in NPT. The internal pipe threads will be in G (BSPP). Piping & Bolting, stainless steel, for PS-M with air pressure PS-M-200-1 tests up to 2900 or 4350 psi. HP-air hose to connect to storage bottle of air compressor.

VALVE WATER AIR

1/2" - 2" 5584 psi 4350 psi (300 bar)

(385 bar) 2-1/2" - 3" 2964 psi 2970 psi (205 bar)

(204 bar) 4" 1773 psi 1660 psi (115 bar)

(122 bar) 5" 1225 psi (84 1160 psi (80 bar) bar) 6" 858 psi (59 790 psi (55 bar) bar) 8" 530 psi (36 430 psi (30 bar) bar) 10" 395 psi (27 290 psi (20 bar) bar)

TABLE 1

3 .3 .1. Test Control Panel: The control station is constructed of sheet metal with 2 front plates in brushed stainless steel. It contains all main devices to control the clamping system and to execute pressure tests. All mounted gauges are made of stainless steel with laminated safety glass and are of high quality. The test gauges shall be calibrated according to EN 1024-3. lB and come with test certificates, showing calibration details.

3.3.2. Clamping System: The clamping system shall be designed to conform to the clamping requirements specified in API-598. Any clamping or external forces applied during testing must not interfere with the accurate assessment of the valve's inherent sealing performance.

3.3.2.1. Clamp Station: The clamping device consists ofa water sump with a clamping station mounted on top. Below the 3-armed clamping cross there shall be a hydraulic clamping cylinder, which holds the lower test table. Each arm of the clamping cross shall have a sliding clamp. The sliding clamps shall be moved centrally.

3.3.2.2. Clamp Position: Valves shall be clamped and tested in vertical position and filled from the bottom to assure good venting of the valve.

3.3.2.3. Clamp Control: The clamping control shall be located at the Control Station to allow for quick and secure valve positioning and clamping.

3.3.2.4. Safety Interlock system: The Clamping system shall be designed with a safety interlock system that will not release the clamp pressure until the test pressure drain valve is opened and internal test pressure is released.

3.3.3. External Valve Tests: Valves larger than DN 10" (or smaller than 10" but with higher test pressures than specified above) shall have the ability to be tested externally, outside the clamping station, with test pressures up to 5584 psi (385 bar) for testing with water, and up to 2900 psi (200 bar) for testing with air/nitrogen. A suitable high-pressure hose of 16' length shall be included.

3.3.4. Optional equipment built into Test Stand/Required Testing Equipment and materials:

3.3.4.1. Piping & Bolting, stainless steel, for PS-M with air pressure (PS-M-200-1) tests up to 2900 or 4350 psi

3.3.4.2. Accumulator - upgrade for PS-M Test Bench (PS-M-200-14) High pressure pump with accumulator, pneumatic for test pressures up to 5584 psi. HP pump pressurizes the accumulator automatically to 5800 psi.

3.3.5. Seat leakage tests required materials:

3.3.5.1. PS-M Digital Bubble Counter (PS-M-200-3) for seat leakage test.

3.3.5.2. PS-M Digital Drop Counter for seat leakage tests (PS-M-200-Dr) for block and control valves only, not applicable for PRV's/safety valves.

3.3.5.3. PS-M Digital gauges for tests with water (PS-M-200-4) Set pressure tests on safety relief valves with peak value storage function 2 pressure transducers included.

3.3.5.4. PS-M Digital gauges for tests with air/nitrogen (PS-M-200-5). Set pressure tests on safety valves with peak value storage function. 2 pressure transducers included.

3.3.5.5. Seat leakage testing from both sides (PS-M-200-20). Valve to be tested stays in the same clamping position.

3.3.5.6. Safety Valve Plugs & Discs for seat leakage tests with air (PS-M-200-7c). DN 1/2" - 10".

3.3.5. 7. VAL VE-DOC 02 Documentation & Analysis System for VAL VE-DOC Safety & Shut-Off Valves to capture, store, and display valve test data during & after testing, suitable for all test benches includes software for shut-off, control & safety valve tests. Laptop version, printer included any camera on laptop must be disabled.

3.3.5.8. Valve-Doc Table (PS-M-200-Ta) Special Discount: Included with purchase of the above quote Valve Doc & PS-15M.

3.3.5.9. Automatic documentation of seat leakage tests, 2 cards (PS-M-200-AD)

Seat leakage test with air/nitrogen: PRV's, SV's & block & control valves. Requires digital bubble counter (PS-M-200-3) Seat leakage tests with water: Block & control valves only.

Requires digital drop counter (PS-M-200-Dr) Will be built into the PS-ISM Test bench.

3.3.6 Adapters for threaded valves:

3.3.6.1 Adapters for threaded valves~ Test system shall be provided with 1 each set of Adaptors for threaded valves ANSI Bl (male & female threading) adapters for testing 1/4", 3/8", 1/2", 3/4", 1-1/4", 1-1/2" (52210)

3.3.6.2 Adapter flanges for valves with butt-welded ends: Test system shall be provided with 2 pieces for DN 2" (50 mm), including drawing to produce other sizes, only for test bench with upper clamping table (53172)

3.3.6.3 Adapters (NPT 2"): for threaded valves ANSI Bl.201.1 male and female (53173)

3.3.7 Adapter flanges for valves with butt-welded ends (PS-M-200-8) 2 pieces for DN 2" (50 mm).

Included drawing to produce other sizes for test bench with upper clamping table.

3.3.8 Booster Unit for PS-15/M Test Benches (TBP5000VAC) Air compression system, complete with purification & air storage system. Provides clean, dry air without moisture. Maximum working pressure: 5000 psi Final pressure setting: 5000 psi (For PS-M Series: final pressure to either 3190 psi/220 bar or 4640 psi/320 bar) Powered by 7.5 HP motor in 3 Phase 60Hz, volt choices: 460 Includes Bauer Verticus VAC0120 in cabinet, P2 Securus purification & ASME certified air storage system with 2 storage cylinders ( 436cf air/each) with vertically configured storage rack, complete with connecting high pressure hose for compressor & air storage system. Automatic condensate drain system. Locally mounted Interstage pressure gauges. P2 Securus purification ( drying and oil removal) system (High pressure hose for booster unit & PS-15/M Test bench is already included with each test bench.

3.3.9 2 each- O-Rings, complete set, for PS-ISM sealing plates: (53518) - 25 / 56 I 86 / 117 / 144 / 175 I 226 I 265 x 8 NBR 70 o. 80 for PS-15 with upper clamping, 2 sets are needed.

3.3.10 O-Sealing chord, dia. 8 mm (10 m length) & instant glue 1 bottle (12312-12612) For O-ring sealing plates for EFCO PS Test Benches to self-assemble to cut & glue O-rings to size.

4 QUALITY ASSURANCE PROVISIONS - Inspection and acceptance of the supplies, performed at destination by Code 983 and shall consist of type and kind; condition; operability, ifreadily determinable; preservation;

packaging.

4.1 PRESERVATION, PACKAGING AND PACKING - The equipment shall be packaged, packed, and preserved for shipment to reach ultimate destination undamaged. Package shall be prominently marked "NOT FOR OUTSIDE STORAGE." Yellow packaging, packing, preservation, and marking are prohibited.

Additional Requirements: Nameplate: A nameplate shall be permanently and securely attached to each machine the information provided on the plate shall be as listed below.

a. Nomenclature

b. Manufacturer's name

c. Manufacturer's model designation

d. Manufacturer's serial number

e. Power input (volts, total amps, phase, frequency)

f. Amp rating of 1 argest motor

g. Short circuit/over-current protection rating

h. Contract Number or Order Number

i. National Stock Number or Plant Equipment Code

j. Date of manufacture

4.2 Operating and Maintenance Manual:

4.2.1 Machines shall be provided with operating and Maintenance Manual (O&M), Electrical Manual, Mechanical Manual & Schematics three (3) each shall be provided with the machine and one (1) each searchable electronic copy (PDF) shall be E-mailed to TPOC.

4.3 Verification Test: After delivery, the Contractor shall test run the machines at the site to ensure conformance with this purchase description.

4.4 Warranty: These machines shall be warranted against any defects in material, parts, and workmanship for 12 months after the date of installation with labor provided by dealer. Additionally, parts are to be warranted for two (2) years.

5 Location: Machines shall be installed inside Bldg.W130 1st floor Naval Station Norfolk.

6 Training: The contractor shall provide training to familiarize Norfolk Naval Shipyard personnel with the equipment and to help ensure reliable performance and maximum service life, during normal usage.

6.1 Operator/ Programmer On-Site Training: Training shall be provided at the receiving activity. Training shall include preparation of part programs, and preparation of equipment for safe operation. The trainees shall be provided instructions for all aspects of machining operations. Trainees shall be provided instruction for the care, use and operation of all attachments and accessories. Training shall be provided for three (3) operators/programmers. The training period shall not be less than one (1) consecutive, eight

(8) hour workday. A training manual (which could be an additional operator's manual) shall be provided for each student.

7 Entry requirements: All personnel expected to visit NNSY shall be US citizens. Contractors/sub-contractors including truck drivers shall:

7.1 30 days before arrival: contractor shall provide SECNAV 5512 data on all personnel expected to visit NNSY to the TPOC. This shall include a list of all personnel expected to visit, identifying those that require SECNAV 5512 forms & those with existing valid base passes. All personnel expected to visit NNSY shall be US citizens. All personnel shall provide two forms of identification. Accepted required identity documentation for proof of US citizenship, US Birth Certificate, US Passport, Certificate of Citizenship, Birthright Citizenship, Certificate of Naturalization, Birth Abroad for US citizens. TPOC shall provide SECNAV 5512 forms upon request. The TPOC will endorse the SECNAV 5512 form and forward to the NNSY Pass Office.

7.2 Vehicle Entry: The Contractor shall display the company name on each door of the Contractor's vehicle in a manner and size that is clearly visible. All contractor vehicles shall display a valid state license plate that complies with the State Vehicle Code with Company's name clearly displayed on the sides on vehicle.

Contractor vehicles shall meet all other requirements of the State Vehicle Code, such as safety standards, proof of insurance and state registration. Contractor vehicles shall have insurance and registration in the company's name. Passes will be issued for vehicles to enter the shipyard. A separate pass is required for entering the CIA. There are parking spots available near each building, including in the CIA. Unloading can be accomplished at high bay door loading and unloading zones. However, the loading and unloading zones may not be near the equipment for each building.

7.3 Portable Electronic Device (PED): In accordance with COMSUBLANT/COMSUBPACINST 2075.lC, the use of Portable Electron Devices (PEDs) while in or on Department of Navy Controlled Industrial Areas are prohibited. A portable electronic device (PED) is defined as any non-stationary electronic apparatus with singular or multiple capabilities of, but not limited to recording, storing, and/or transmitting data, voice, video, or photo images e.g.: cell phones, laptops, tablets and wearable devices such as fitness bands and smart watches. Non-camera cell phones are acceptable (feature phones). Where a laptop computer is required for troubleshooting and machine programming purposes, the contractor must inform TPOC no later than two (2) weeks prior to visit to allow time to schedule inspections and vetting from NNSY IT department.

7.4 Safety or Security: Contractor will need CIA access and PPE. "Per FAR 22.102-l(a) entitled "Safety", Contractors are hereby informed that their employees or representatives present on property under Norfolk Naval Shipyard cognizance must follow Federal and State OSHA requirements and Norfolk Naval Shipyard OSHE Program Manual, NA VSHIPYDNORINST P5090.2 requirements or safety requirements for site specific location of the contract."

7.5 Critical time Constraints: The Installation and training shall be performed between the hours of7:20 am and 3:50 pm excluding any federal holidays.

8 TECHNICAL POINTS OF CONTACT:

8.1 Tim Humphrey PH: 757-636-4937 Email: timothy.m.humphrey2.civ@us.navy.mil Patrick Craig PH: 757-536-3295 Email: parick.a.craig2.civ@us.navy.mil Russell Harris PH: 757-636-4908 Email: russell.r.harris.civ@us.navy.mil