7_Primary_Liquid_Flow_Calibrator_CSS-06-3234_V1.pdf

CALIBRATION STANDARD SPECIFICATION

PROCUREMENT PACKAGE

PISTON PROVER LIQUID

FLOW CALIBRATOR

DEPARTMENT OF THE NAVY

METROLOGY AND CALIBRATION PROGRAM

CSS 06-3234

OCTOBER 2024

CALIBRATION STANDARD SPECIFICATION

PROCUREMENT PACKAGE

PISTON PROVER LIQUID

FLOW CALIBRATOR

Physical/Mechanical Standards (MS 33) Measurement Science Department

Naval Surface Warfare Center, Corona Division P.O. Box 5000

Corona, CA 91718-5000

DEPARTMENT OF THE NAVY

METROLOGY AND CALIBRATION PROGRAM

PISTON PROVER LIQUID FLOW CALIBRATOR CALIBRATION STANDARD SPECIFICATION CSS 06-3234 i

Table of Contents

1.0 SCOPE

1.1 General

1.2 Usage

1.3 Classification

1.3.1 Class

1.3.2 Configuration

2.0 APPLICABLE DOCUMENTS

2.1 Reference documents

2.2 Order of precedence

3.0 REQUIREMENTS

3.1 Equipment components

3.1.1 Equipment Configuration

3.1.2 Test Stand

3.1.3 Control Console

3.1.3.1 Software

3.1.4 Flowmeter Inputs

3.1.5 Calibration Standard:

3.1.6 Finish

3.1.7 Interchangeability

3.2 Design and construction

3.2.1 Operator adjustments and controls

3.2.1.1 Operator adjustments

3.2.1.2 Operator controls

3.2.2 Connectors, electric

3.2.3 Wiring, internal

3.2.4 Warranty

3.3 Electrical power sources and connections

3.3.1 Electrical power source

3.3.1.1 Battery restrictions

3.3.1.2 Lithium batteries

3.3.2 Electrical power connections

3.3.2.1 Input power cable

3.3.2.2 Input power switches

3.3.2.3 Test Stand

3.3.2.4 Control Console

ii

3.4 Physical characteristics

3.4.1 Dimensions

3.4.2 Fluid Compatibility

3.4.3 Weight

3.5 Marking and identification

3.5.1 Marking

3.5.2 Panel markings and processes

3.6 Environmental requirements

3.6.1 Warm-up

3.6.2 Temperature and humidity

3.6.2.1 Temperature operating

3.6.2.2 Humidity operating

3.7 Performance requirements

3.7.1 Flow Range

3.7.2 Viscosity

3.7.3 Pressure

3.7.3.1 Input pressure

3.7.3.2 Fluid pressure

3.7.4 Measurement uncertainty

3.7.5 Flow rate repeatability

3.7.6 Data display formats

3.7.7 Data printing and graphing

3.7.8 Data storage and export

3.7.9 Cable assemblies

3.8 Maintainability

3.8.1 Fault isolation

3.8.2 Repair

3.9 Calibration

3.9.1 Calibration certificate

3.9.2 Calibration methodology

3.9.3 Calibration interval

3.9.4 Calibration procedure

3.9.5 Alignment

3.10 Technical manuals

3.10.1 Style and format, technical manuals

3.10.2 Content, technical manuals

3.10.2.1 Safety, technical manual section

3.10.2.2 General, technical manual section

iii

3.10.2.3 Use and installation, technical manual section

3.10.2.4 Maintenance and servicing, technical manual section

3.10.2.4.1 Cleaning maintenance

3.10.2.4.2 Part replacement information

3.10.3 Symbols

3.11 Workmanship

3.12 Installation

3.13 Training

4.0 VERIFICATION

4.1 General

4.2 Technical Manual Review

4.3 Conformance inspections

4.3.1 Production inspection, Group A

4.3.1.1 Group A inspection and test

4.3.1.1.1 Preoperational inspection

4.3.1.1.2 Level A performance tests

4.3.2 Failure criteria

4.3.3 Test conditions

4.3.4 Accuracy of test instruments

PISTON PROVER PRIMARY LIQUID FLOW CALIBRATOR CALIBRATION STANDARD SPECIFICATION CSS 06-3234

1.0 SCOPE

1.1 General. This document specifies the minimum requirements for a Piston Prover Liquid Flow Calibrator to be installed at the Portsmouth Naval Shipyard, Portsmouth, New Hampshire. This equipment may be of a commercial design or modified commercial design. The Piston Prover Liquid Flow Calibrator is intended to be used by civilian Navy personnel in shore-based NAVSEA METCAL calibration laboratories for support of a wide variety of liquid flowmeters used as transfer standards or as flow rate measurement devices in test and measurement equipment.

1.2 Usage. Equipment covered by this Calibration Standard Specification (CSS) is intended for use in calibrating flowmeters in controlled environments.

Flowmeters requiring calibration include but are not limited to: turbine flowmeters, variable area flowmeters, positive displacement flowmeters, and Coriolis type flowmeters. The requirements of this CSS are tailored to the intended use of the equipment. Specific requirements of MIL-PRF-28800F, as identified in this CSS, are invoked according to the class of equipment.

1.3 Classification.

1.3.1 Class. The Piston Prover Liquid Flow Calibrator shall be classified as Class 3 equipment and shall conform to Class 3 requirements in accordance with MIL- PRF-28800F, and as specified in this specification. Class 3 equipment is designed for operational environments where conditions are routinely encountered in a diverse, controlled climate.

1.3.2 Configuration. The Piston Prover Liquid Flow Calibrator shall at a minimum cover the range of 0.4 to 400 gpm. The minimum throat length for testing of flowmeters for this configuration shall be 50 inches to allow testing of two 1-1/2 inch flowmeters at one time.

1.3.2.1 The system will be installed at the Portsmouth Naval Shipyard, Portsmouth, New Hampshire. The manufacturer shall be responsible for shipping of the Piston Prover Liquid Flow Calibrator to the installation site. The Navy will be responsible for locating the calibrator in the test area. The manufacturer will be responsible for final standup, installation, and calibration of the Piston Prover Liquid Flow Calibrator as part of the procurement contract.

2.0 APPLICABLE DOCUMENTS

2.1 Reference documents. The following documents form a part of this specification to the extent specified herein. Unless otherwise indicated, the issues of these documents shall be those in effect on the date of this solicitation.

DEPARTMENT OF DEFENSE SPECIFICATIONS

MIL-PRF-28800F - Test Equipment for use with Electrical and Electronic Equipment, General Specification for

MIL-PRF-38793 Manuals, Technical: Calibration Procedures Preparation of.

(Copies of DoD specifications are available online at http://assist.daps.dla.mil/quicksearch/ or from the Standardization Document Order Desk, 700 Robbins Avenue, Building 4D, Philadelphia, PA 19111-5094.)

NATIONAL INSTITUTE OF STANDARDS AND TECHNOLOGY

NIST Technical Note 1297 - Guidelines for Evaluating and Expressing the Uncertainty of NIST Measurement Results

Copies of NIST Technical Notes are available online at http://physics.nist.gov/Pubs/guidelines/TN1297/tn1297s or from the National Institute of Standards and Technology, Gaithersburg, MD 20899-0001

2.2 Order of precedence. In the event of conflict between the text of this CSS and the references cited herein, the text of this specification shall take precedence.

Nothing in this CSS, however, supersedes applicable laws and regulations unless a specific exemption has been obtained.

3.0 REQUIREMENTS

3.1 Equipment components. Parts, materials, and process shall be as specified in

3.1.1 Equipment Configuration through 3.1.7 Interchangeability.

3.1.1 Equipment Configuration. The Piston Prover Liquid Flow Calibrator shall consist of a Test Stand and a Control Console. The Test Stand shall consist of all plumbing/piping/valves, interfacing hardware, and other components required to generate and measure the flow rates necessary to meet the performance requirements of this CSS. The Control Console shall consist of a controller, software, monitor, and an interface connecting the controller to the Test Stand. The interface may be incorporated into the controller or may be a separate instrument system. The Control Console monitors the Piston Prover Liquid Flow Calibrator operation, provides data acquisition, and performs calculations using the data received for the system and TI flowmeter being calibrated, and provides measurement results. The Control Console may or may not be integrated into the Test Stand.

3.1.2 Test Stand. The Piston Prover Liquid Flow Calibrator shall be capable of supporting and connecting to standard turbine flowmeters from Cox AN8-6 to Cox AN32 and similar models from Flow Technology, Flow Dynamics, Exact

Flow, and Hoffer. The Test Section of the flow calibrator shall be designed to facilitate quick and easy installation and removal of flowmeters under tests. The led during meter installation/removal or leaks if they occur. The Test Section basin shall have a 10 micron (minimum) filtered pump to facilitate drip pan drain return to the main tank. The system shall include a Drain/Fill system that facilitates fluid drain and fill of the calibrator. The Drain/Fill system shall include all tubing and fittings, a main system 10 micron (minimum) filter, and valves for shut off and isolation. The Test Section shall be designed to calibrate meters horizontally. The Test Section for the Primary Liquid Flow Calibrator basin shall be of sufficient size to accommodate two Cox AN24 flowmeters in tandem, including adequate upstream and downstream straighteners, and adapters.

Based on calculations this distance is 50 inches or larger.

3.1.3 Control Console. The Control Console shall consist of a PC based compatible controller/computer with the latest generation microprocessors, all required operating software, cabling, keyboard, mouse, and all Piston Prover Liquid Flow Calibrator interface connections necessary to operate the system and meet the requirements of this CSS. The PC shall support USB 2.0 or better and include a DVD/CD write capable drive (internal or external) for data transfer. The Control Console shall include a color printer for hardcopy of calibration certificates, data, charts, and graphs. The Control console shall also include a minimum 17 inch color monitor for displaying all necessary control and measurement information.

3.1.3.1 Software. At a minimum the Piston Prover Liquid Flow Calibrator software shall support testing of flowmeters, data reduction, calibration of the system, and leak testing. Complete copies of the executable software shall be provided with the system. The latest edition of Microsoft Excel or equivalent shall be installed on the Piston Prover Flow Calibrator controller.

3.1.4 Flowmeter Inputs. The Piston Prover Liquid Flow Calibrator electronics at a minimum shall have the ability to test two turbine flowmeters or one dual rotor turbine flowmeter at one time. The electronics shall have at a minimum 3 sets of turbine meter inputs including magnetic, modulated carrier, and pulse. The Piston Prover Liquid Flow Calibrator shall be capable of connecting to and calibrating a variety of turbine flow meters including but not limited to Cox, Flow Technology, Exact Flow, and Hoffer meters. The Piston Prover Liquid Flow Calibrator shall be capable, at a minimum, of supporting the following single channel analog inputs: 0-5 VDC, 0-10 VDC, and 4-20 mA.

3.1.4.1 Piston Prover Liquid Flow Calibrator must be capable of supporting visual type flowmeters. When calibrating a visual flowmeter, the system software must allow the operator to input the visual meter indication for the flowmeter being tested.

3.1.5 Calibration Standard: The Piston Prover Liquid Flow Calibrator manufacturer, as part of the procurement, shall provide one Corning Model 5640-4L or equivalent 4000 mL flask Borosilicate (TICB) Glass, calibrated in compliance with NIST Handbook 105-2 or equivalent with a Report of Calibration with a maximum uncertainty of ± 0.50 mL to the receiving activity. The flask will be used to perform the initial calibration of the calibrator during stand up of the system by the manufacturer and future calibrations by the Navy. The manufacturer shall also provide the required fluid draw line (Swagelok fitting with needle valve compatible with the Piston Prover Liquid Flow Calibrator) to conduct the calibration of the system with the flask.

3.1.6 Finish. Unless otherwise specified the equipment shall be the finish normally provided by the manufacturer.

3.1.7 Interchangeability. A model number shall be designated for the unit provided.

All Liquid Flow Calibrator units with the same model number and replaceable assemblies, subassemblies, and parts comprising the unit shall be interchangeable on a noninterference basis.

3.2 Design and construction. The Piston Prover Liquid Flow Calibrator shall be designed and constructed to permit compliance with all applicable requirements, as defined in this CSS as well as the operation, performance, accuracy, and other requirements in this CSS.

3.2.1 Operator adjustments and controls. Operator adjustments and controls shall be as specified below in 3.2.1.1 Operator adjustments and 3.2.1.2 Operator controls.

3.2.1.1 Operator adjustments. The Piston Prover Liquid Flow Calibrator shall include adjustments or compensating methods for any function or parameter that would exceed the specified tolerance within the calibration interval defined in 3.9.2 Calibration interval. Under all specified service conditions the variation of any adjustment or control shall produce the desired control action to bring the system within tolerance.

3.2.1.2 Operator controls. Operating controls and indicators shall be readily accessible to the operator from the front of the equipment. The readings presented on the controls and indicators shall be available to the operator without conversion or calculation. All operator controls shall be clearly labeled.

3.2.2 Connectors, electric. Provision shall be made to ensure that connectors will be mated only with the appropriate counterparts. All connectors shall be clearly labeled. If the connector label will be exposed to the system fluid medium, the label must be resistant to common fluids used in the system. Where design considerations require close proximity of connectors of similar configuration, the mating connectors shall be suitably coded or marked to minimize risk.

3.2.3 Wiring, internal. Internal wiring practices shall be such that the wiring shall not be damaged during normal maintenance and calibration.

3.2.4 Warranty. The Piston Prover Liquid Flow Calibrator shall have a minimum of a one year warranty after initial installation by the manufacturer.

3.3 Electrical power sources and connections. The electrical power sources and connections shall be as specified below in 3.3.1 Electrical power source and

3.3.2 Electrical power connections.

3.3.1 Electrical power source. The Piston Prover Liquid Flow Calibrator shall operate at 115 VAC single-phase 50 Hz and 60 Hz source.

3.3.1.1 Battery restrictions. For Navy applications, the use of lithium and mercury batteries is restricted and shall not be used in equipment. An exception is made for small lithium batteries used for memory backup as specified below in 3.3.1.2 Lithium batteries. The Equipment shall incorporate safety precautions of UL1950 and a label containing the following caution and information shall be affixed to the outside of the unit, as applicable for either lithium or mercury batteries:

3.3.1.2 Lithium batteries. Commercial UL approved equipment that contains lithium batteries (size double A or button cell type) used for memory backup are approved for use under a general blanket approval waiver. Lithium or re-chargeable batteries larger than the type specified above requires a separate approval. For the purpose of this specification, a lithium (size double A or button cell type) battery as described above is approved.

3.3.2 Electrical power connections. The requirements specified in 3.3.2.1 Input power cable through 3.3.2.4 Control Console shall apply to equipment rated at 10A rms, or less.

3.3.2.1 Input power cable. Unless specified, the input power cable shall be a detachable power cable normally provided by the manufacturer.

3.3.2.2 Input power switches. The operator shall be able to energize the equipment from the front panel. A standby capability may be incorporated to activate and deactivate the equipment. If such a capability is provided, suitable warnings shall be placed in the operating and service manuals and on the equipment to warn the operator of possible shock hazards during servicing, due to partially activated power supplies.

THIS UNIT CONTAINS LITHIUM BATTERIES

Battery Manufacturer:

Battery Part Number:

3.3.2.3 Test Stand. The Piston Prover Liquid Flow Calibrator Test Stand shall be provided with a fuse or circuit breaker to protect the Test Stand in the event of excessive current.

3.3.2.4 Control Console. The Piston Prover Liquid Flow Calibrator Control Console shall be provided with a fuse or circuit breaker to protect it in the event of excessive current.

3.4 Physical characteristics. The physical characteristics of the Piston Prover Liquid Flow Calibrator shall be as specified in 3.4.1 Dimensions through 3.4.3 Weight.

3.4.1 Dimensions. Maximum dimensions of the Piston Prover Liquid Flow Calibrator test stand including handles and covers, if any, shall not exceed 98 inches in height, 166 inches in width and 32 inches in depth. For installation purposes, the piston prover must fit through a doorway space that is limited to 83 inches in height and 70.5 inches in width. This requirement may force the removal of the calibrator fluid tank and calibrator plumbing by the manufacturer for shipping and delivery purposes.

3.4.2 Fluid Compatibility. The materials used to build the calibrator that are in direct contact with the calibration fluid used in the systems, at a minimum, must be compatible with hydraulic fluid (MIL-PRF-83282), JP-5 jet fuel (MIL-PRF-5624), stoddard fluid (MIL-PRF-7024), mixtures of propylene glycol and water, lubricating oil (MIL-PRF-6081), water, and other fluids typically used in primary liquid flow standards. (Potential exposure to the fluids noted above does not indicate a need for the systems to meet NEC Class 1, Division 1 requirements).

3.4.3 Weight. The dry weight (no fluid) of the Piston Prover Liquid Flow Calibrator including all covers and accessories shall not exceed 2700 pounds.

3.5 Marking and identification. Marking and identification of the Piston Prover Liquid Flow Calibrator shall be as specified below in 3.5.1 Marking through 3.5.2 Panel markings and processes.

3.5.1 Marking. The Piston Prover Liquid Flow Calibrator shall be marked in a manner that does not adversely affect safety or performance. At a minimum the manufacturer, model number, serial number, and flow range of the unit shall be identified.

3.5.2 Panel markings and processes. Panel markings shall enable the operator to identify the functions and use of all items requiring operator intervention.

3.6 Environmental requirements. The Piston Prover Liquid Flow Calibrator environmental performance requirements shall be as specified below in 3.6.1 Warm-up through 3.6.2 Temperature and humidity. It shall conform to the specified performance when subjected to the environmental conditions of this specification.

3.6.1 Warm-up. The Piston Prover Liquid Flow Calibrator shall comply with the specified performance requirements after a 15-minute warm-up period preceded by a maximum 12-hour non-operating temperature stabilization period.

3.6.2 Temperature and humidity. The temperature ranges and humidity limits for operating conditions shall be as specified below in 3.6.2.1 Temperature operating and 3.6.2.2 Humidity operating.

3.6.2.1 Temperature operating. The Piston Prover Liquid Flow Calibrator shall conform to the specified performance and accuracy while being operated at temperatures over the range of 60 °F to 85 °F.

3.6.2.2 Humidity operating. The Piston Prover Liquid Flow Calibrator shall conform to the specified performance and accuracy while being operated a humidity range of 20% RH to 60% RH.

3.7 Performance requirements.

3.7.1 Flow Range. The Piston Prover Liquid Flow Calibrator shall be capable of generating, controlling, and measuring fluid flow in the minimum range of 0.4 to 400 gpm or better, using a single direction measurement stroke operation.

3.7.2 Viscosity. The Piston Prover Liquid Flow Calibrator shall be capable of generating flow of fluids to the Flow Range requirements of 3.7.1 with viscosities from 0.7 to 100 centistokes.

3.7.3 Pressure. Pressure requirements shall be as specified below in 3.7.3.1 Input pressure and 3.7.3.2 Fluid pressure.

3.7.3.1 Input pressure. The Piston Prover Liquid Flow Calibrator shall operate on pressure between 60 to 125 psig (minimum 45 SCFM at 60 psig). Maximum required input pressure shall not exceed 125 psig.

3.7.3.2 Fluid pressure. The Piston Prover Liquid Flow Calibrator shall provide fluid pressure adequate to preclude calibration errors due to two phase (liquid and vapor) conditions when calibrating flowmeters.

3.7.4 Measurement uncertainty. The Piston Prover Liquid Flow Calibrator as a complete system, shall be capable of generating, measuring, and displaying liquid flow rates with a total uncertainty, (Coverage factor of 2 IAW NIST Technical Note 1297), not to exceed 0.05 % of indication.

3.7.5 Flow rate repeatability. The Piston Prover Liquid Flow Calibrator as a complete system, shall be capable of measurement repeatability within 0.02 % of indication once a set flow rate is established.

3.7.6 Data display formats. The Piston Prover Liquid Flow Calibrator shall be capable displaying measurement data in a spreadsheet format with user selectable fields. Data shall be either directly measured parameters such as temperature and frequency or data derived from measured parameters using user-selected algorithms such as flow rate, frequency/viscosity, density, K- factor, etc. The Piston Prover Liquid Flow Calibrator manufacturer will be required to develop a custom template Report of Calibration and Certificate of Calibration for the system. The Report of Calibration and Certificate of Calibration will require NAVSEA METCAL approval.

3.7.7 Data printing and graphing. A color printer shall be provided with each system.

The Piston Prover Liquid Flow Calibrator shall be capable of color printing and graphing all data and the Report of Calibration and Certificate of Calibration.

Printing shall be in user selectable fields as described in 3.7.6 Data display formats. All graphs shall have user selectable ranges, units, resolutions, scaling, and headings/titles.

3.7.8 Data storage and export. The Piston Prover Liquid Flow Calibrator shall store flowmeter calibration data in user-selected data fields. Data shall be stored in a format that can be easily retrieved and displayed. All data shall be capable of being easily exported to Microsoft Excel spreadsheets in user selectable fields.

The latest edition of Microsoft Excel or equivalent shall be installed on the Piston Prover Flow Calibrator controller.

3.7.9 Cable assemblies. All necessary flowmeter cable assemblies and amplifiers to connect the Piston Prover Liquid Flow Calibrator to the turbine flowmeters being calibrated shall be provided.

3.8 Maintainability. Maintainability shall be as specified below in 3.8.1 Fault isolation through 3.8.2 Repair.

3.8.1 Fault isolation. The design of the equipment shall permit isolation of faults, and repair down to the component/subassembly item or lowest replaceable unit with the maintenance provisions furnished.

3.8.2 Repair. Maintenance instructions shall be furnished to facilitate the replacement of components/subassemblies and subsequent testing procedures to ensure the performance of the component or the repair action taken. Spare parts information shall be provided for all major components of the system including but not limited to: valves, seals, circuit cards, filters, system encoder, temperature probes and amplifiers, and flowmeter amplifiers.

3.9 Calibration. The Piston Prover Liquid Flow Calibrator shall meet the calibration requirements as specified below in 3.9.1 Calibration certificate through 3.9.5 Alignment. For the purpose of this CSS, calibration refers to the process of comparing a test instrument with a calibration standard to determine the indicated error at specified test points. Alignment refers to the process of characterizing and adjusting a test instrument to cause it to indicate within its specified accuracy limits.

3.9.1 Calibration certificate. The equipment provided under this CSS shall have a current calibration certificate, with a calibration data sheet, traceable to the National Institute of Standards and Technology (NIST).

3.9.2 Calibration methodology. The preferred calibration methodologies for the Piston Prover Liquid Flow Calibrator shall be through both a fluid draw type method and dimensional measurement type method. Fluid draw will involve collection of a sample of fluid to determine the amount of fluid displaced by the number of pulses collected from the linear encoder. Dimensional measurement will involve measurement of the piston cylinder internal diameter using an internal micrometer and verification of the linear encoder to determine the pulse count per unit length. The ability to use either or both methods is necessary due to the current support structure for the systems. The system software shall support both of the above methods.

3.9.3 Calibration interval. The minimum interval between calibrations shall be 12 months. At the end of this interval, a minimum of 85 percent of the system parameters shall remain in tolerance.

3.9.4 Calibration procedure. The calibration support methodology for the system shall be provided in the system documentation. The information provided must be sufficient to allow development of a Navy calibration procedure in accordance with MIL-PRF-38793.

3.9.5 Alignment. Alignment is the process by which individual Piston Prover Liquid Flow Calibrator sensors and their measurement circuitry and displays are adjusted to ensure that the system parameters are within the requirements for the overall system measurement uncertainty. Alignment shall not require use of external devices other than commercially available calibration/measurement standards. The Piston Prover Liquid Flow Calibrator shall be capable of alignment in place.

3.10 Technical manuals. Two copies of an operation and maintenance manual shall be provided with the calibrator. Technical manuals shall conform to the requirements specified in 3.10.1 Style and format, technical manuals through

3.10.3 Symbols. The technical manuals shall be provided in both printed and electronic format. The electronic copy shall be in a Portable Document Format (PDF) on a CD or DVD.

3.10.1 Style and format, technical manuals. All text shall be legible. A cover page shall include, equipment name and model number. A table of contents shall be provided.

3.10.2 Content, technical manuals. The contents of the technical manuals shall include sections addressing safety, general information, use and installation, maintenance and service. Drawings of the Piston Prover Liquid Flow Calibrator with sufficient detail to identify all controls and connections shall be supplied.

The content of the sections shall conform to the description provided below in

3.10.2.1 Safety, technical manual section through 3.10.2.4.2. Part replacement information.

3.10.2.1 Safety, technical manual section. The manual shall contain warnings, cautions and notes to prevent injury to personnel and damage to equipment. The warnings shall contain safety precautions where hazards such as high voltage, high pressure, and high temperature may be present during installation, operation, or maintenance.

3.10.2.2 General, technical manual section. The manual shall contain the following:

purpose and functions, capabilities, performance characteristics, description (model number, dimensions, and weight), power information, and operational environment requirements.

3.10.2.3 Use and installation, technical manual section. This section shall contain information on the following: operating instructions (illustrations and explanations of the uses and functions of all controls and indicators), initial adjustments and control settings, startup procedures, required clearances, illustrations of equipment connections, and installation precautions.

3.10.2.4 Maintenance and servicing, technical manual section. The level of maintenance philosophy shall be unit operational verification, and component level.

Maintenance instructions shall be furnished to facilitate the replacement of components/subassemblies on the systems. Testing procedures to ensure the performance of the component or the repair action taken shall be provided.

3.10.2.4.1 Cleaning maintenance. Cleaning information covering intervals, types of solvents, and materials used shall be listed in the maintenance and servicing section of the technical manual.

3.10.2.4.2 Part replacement information. Common commercial parts shall be identified by part number and description to facilitate substitutions of parts from other sources.

3.10.3 Symbols. All symbols used in the technical manual shall be standard or common to the trade. Where nonstandard symbols are used, explanations shall be provided.

3.11 Workmanship. The manufacture and assembly of the items covered by this CSS shall be representative of the best commercial practices and shall conform to the requirements of this CSS. All items will remain securely held in place during normal transit. Adequate protection will be afforded for the equipment on all sides to avoid transient damage.

3.12 Installation. The manufacturer will be responsible for final setup of the Piston Prover Liquid Flow Calibrator. The manufacturer will be responsible for shipping of the Piston Prover Liquid Flow Calibrator to the receiving site. Any damage to the shipping container will be reported to the manufacturer when received by the Navy. The Navy shall locate the delivered Piston Prover Liquid Flow Calibrator in the test area where it will be setup and used. The Navy will uncrate the Piston Prover Liquid Flow Calibrator from its shipping container and position it as required. The manufacturer is responsible for all wiring and connections between the Piston Prover Liquid Flow Calibrator, Interface electronics, and Control Console, as well as all connections to power and air pressure sources.

The Navy will provide the required electrical power, facility air pressure source, and ventilation in the test area. The Piston Prover Liquid Flow Calibrator must meet all CSS performance, functional and design requirements at the delivery site before the system is considered installed.

3.13 Training. After completion of the Piston Prover Liquid Flow Calibrator installation, on-site training shall be provided by the manufacturer. Training shall include instruction on how to operate, maintain, and calibrate the Piston Prover Liquid Flow Calibrator and shall include a) A complete review of all topics in the operating manual b) Instruction on the use of all software functions and menus. c) Calibration of the Piston Prover Liquid Flow Calibrator d) Instruction on required periodic maintenance. Only one training session will be required at the installation site.

4.0 VERIFICATION

4.1 General. The Piston Prover Liquid Flow Calibrator procured shall be capable of satisfying all of the requirements indicated in Section 3 of this CSS and shall be subjected to testing. Verification shall be accomplished by using the test procedures in MIL-PRF-28800 for Class 3 equipment for those tests identified and as modified in the following paragraphs.

4.2 Technical Manual Review. The Piston Prover Liquid Flow Calibrator Technical Manual(s) shall be reviewed and examined for compliance with the requirements specified in paragraph 3.10 Technical manuals of this CSS.

4.3 Conformance inspections. The test methods, procedures, and conditions specified in 4.3.1 Production inspection, Group A through 4.3.4 Accuracy of test instruments are required for conformance inspection.

4.3.1 Production inspection, Group A. The Piston Prover Liquid Flow Calibrator shall be subjected to the Group A inspection and tests of 4.3.1.1 to ensure qualitatively the proper functioning of the equipment, including all operating controls, and conformance with safety requirements.

4.3.1.1 Group A inspection and test. Group A inspection shall consist of the inspections of 4.3.1.1.1 Preoperational inspection through 4.3.1.1.2 Level A performance tests.

4.3.1.1.1 Preoperational inspection. The preoperational inspections shall consist of mechanical and visual examination and test to determine that all materials, workmanship, and safety characteristics comply with the specified requirements. The equipment shall be examined or tested to confirm that all electrical wiring is correct and that no mechanical problems are evident.

4.3.1.1.2 Level A performance tests. The Level A performance tests shall verify conformance of the system to the performance requirements of this CSS. At a minimum the Level A performance tests shall include the following: leak testing under normal operating pressure, calibration of all required system parameters, verification of system flow range capability, flowmeter calibration demonstrations including magnetic, modulated carrier and pulse type inputs, flowmeter test data reviews, and demonstration of the Drain/Fill system functionality.

4.3.2 Failure criteria. For the purposes of this CSS, equipment failure is defined as any departure from the required performance requirements or operation outside of the required accuracies (not correctable by normal use of the operating controls), or deviation from the criteria specified in 3.7 Performance requirements after the test is initiated. The item shall have failed the test when any of the conditions specified in a. through g. below occur:

a. Monitored functional parameters deviate beyond acceptable limits

b. Catastrophic or structural failure

c. Mechanical binding or loose parts, including screws, clamps, bolts, and nuts, that results in component failure or a hazard to personnel safety

d. Malfunction

e. Degradation of performance beyond limits established in the purchase description

f. Any additional deviations from acceptable criteria established before the test

g. Deterioration, corrosion, or change in tolerance limits of any internal or external parts that could in any manner prevent the test item from conforming to operational service or maintenance requirements

4.3.3 Test conditions. Unless otherwise specified the inspections specified herein shall be performed under the conditions of a. through d. Ambient conditions within the specified ranges need not be controlled. For equipment having a specified warm-up or stabilization period after turn-on, formal measurements and observations shall be made only after the specified time period as specified previously in 3.6.1 Warm-up.

a. Temperature: 60 °F to 85 °F

b. Humidity: 20% RH to 60% RH

c. Power: Nominal or alternate power source specified for the equipment

d. Attitude: Normal operating position

4.3.4 Accuracy of test instruments. The test instruments used to control or monitor the test parameters shall be verified to be within their calibration cycle prior to performing tests.