WI 2_Bubbler Blower System_Procurement Specification.doc

USCG SFLC – Bubbler Blower System

SPEC NUMBER: P-551-XXXX

REVISION: 0

REVISION No. 0 . CHANGE NO. - .

PROCUREMENT SPECIFICATION

BUBBLER BLOWER SYSTEM

140 WTGB CLASS

P-551-XXXX

ORGINATED BY: J. Calvert/G. Kasunik

DATE: 04/16/2012

ORIGINATOR’S COMMAND: Surface Forces Logistics Center (SFLC)

DEPARTMENT / DIVISION: Auxiliary Machinery Section (AMS)

INTERNAL REVIEWER: Andrew P. Dize DATE 04/23/2012

PRODUCT LINE APPROVAL:

DATE

Table of Contents

Title

Page

1.0 SCOPE

2.0 APPLICABLE DOCUMENTS

2.1 Document Availability

2.2 Government Documents

2.2.1 Specifications, Military

2.2.2 Standards, Military

2.3 Other Government Documents

2.3.1 Code of Federal Regulations (CFR)

2.3.2 USCG Surface Forces Logistics Center (SFLC) Drawings

2.3.3 USCG Surface Forces Logistics Center (SFLC) Documents

2.3.4 U.S. Navy Resilient Mount Handbook

2.4 Commercial Documents

2.5 Order of Precedence

3.0 REQUIREMENTS

3.1 Performance and General Requirements

3.1.1 Bubbler Blower

3.1.2 Diesel Drive

3.1.3 Cleanliness

3.2 Specific Requirements

3.2.1 Bubbler Blower Skid

3.2.2 Diesel Engine

3.2.3 Diesel Engine Cooling System

3.2.4 Spark Arrester/Silencer

3.2.5 Blower

3.2.6 Speed Increaser/Coupling

3.2.7 Clutch

3.2.8 Piping

3.2.9 Fittings

3.2.10 Instrumentation

3.2.11 Hoses

3.2.12 Filtration

3.2.13 Bubbler Control System Valve

3.2.14 Guards

3.2.15 Electrical Control Equipment

3.2.16 Operation

3.2.17 Alarms and Indicators

3.2.18 Diesel Engine Electrical System

3.2.19 Air Pressure Switches

3.2.20 Cabling/Wiring

3.2.21 Identification and Labeling

3.3 Noise and Vibration

3.4 Training

Table of Contents (cont)

Page

3.5 Field Services

3.6 Departure from Specifications

3.7 Design Improvements

3.8 Technical Documentation

3.8.1 Technical Publications

3.8.2 Drawings

3.9 Integrated Logistics Support

3.9.1 Engineering Data for Provisioning (EDFP)

3.9.2 Recommended Spare Parts Lists

3.9.3 OEM Maintenance Requirements

3.10 Tests, Inspections, and Reports

3.10.1 First Article Testing (FAT)

3.10.2 Factory Testing (FT)

3.10.3 Shipboard Test Plan

3.11 Workmanship

3.12 Notifications and Inspections

4.0 QUALITY ASSURANCE

4.1 General

4.2 Records

4.3 Calibration System

4.4 Responsibility for Inspection

4.5 Responsibility for Compliance

4.6 Quality Assurance Plan

4.7 Tests and Inspections

4.8 Failure Responsibility

4.8.1 Corrective Action Remedies

4.9 Test and Inspection Reports

4.10 Packaging Inspection

5.0 PRESERVATION, PACKING AND MARKING

6.0 NOTES

6.1 Potential Sources

6.2 Government & Commercial Document Sources

6.2.1 Government Documents

6.2.2 Commercial Documents

Attachment 1 – Provisioning Technical Documentation (PTD)

Attachment 2 - Engineering Data for Provisioning (EDFP)

1.0 SCOPE

This Specification covers the procurement of a Bubbler Blower System for each 140 WTGB Class Cutters (9 total units). The purpose of the bubbler blower system is to provide compressed air to support ice breaking operations. This specification DOES NOT include installation of the equipment, but DOES include limited on-site technical support to the Installation Activity to ensure that the equipment is installed and functions correctly. Hardware and component items (per ship set) to be provided are as follows:

· One (1) Blower Skid Package complete with diesel engine drive, speed increaser, clutch, and blower, and five (5) butterfly valves with motorized operators. The bubbler blower skid shall be provided with isolation mounts. One (1) Main Bubbler System PLC Control Panel (master) for system operation and monitoring from Engineering Control Center. One (1) Remote Bubbler Control Panel (slave) for system operation and monitoring from Pilot House. One (1) Local Blower and Diesel Drive System Display Panel.

· The Vendor shall supply Provisioning Technical Data (PTD), Attachment 1, with their proposal response that includes certified technical manuals and drawings describing the bubbler blower package, control system, and motor controller to provide the United States Coast Guard (USCG) with sufficient information to produce Cutter specific installation drawings.

· The Vendor shall supply Engineering Data for Provisioning (EDFP), Attachment 2, on the system and components concurrent with the delivery of the equipment to allow the USCG to produce maintenance procedure cards (MPCs) and other logistical support documentation. Engineering data shall also include the PLC code for operation of the system.

· The Vendor shall provide on-site technical support for training, system testing, commissioning, and certification.

· The Vendor shall provide maintenance parts lists and a recommended onboard repair parts (OBRP) list for all components.

2.0 APPLICABLE DOCUMENTS

2.1 Document Availability - To obtain the referenced documents, see Section 6.2.

2.2 Government Documents - The following specification 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 therein.

2.2.1 Specifications, Military

a. MIL-DTL-24643C, Cables, Electrical, Low Smoke Halogen-Free, For Shipboard Use General Specification, 2009.

2.2.2 Standards, Military

a. MIL-STD-167-1A, Mechanical Vibrations of Shipboard Equipment (Type I –Environmental and Type II – Internally Excited), 2-Nov-2005.

2.3 Other 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.

2.3.1 Code of Federal Regulations (CFR)

a. Code of Federal Regulations (CFR), Title 40, Part 94 (Control Of Emissions From Marine Compression-Ignition Engines (2011)

b. Code of Federal Regulations (CFR), Title 46, Chapter I, Subchapter F, Part 56, Piping Systems and Appurtenances (2011)

2.3.2 USCG Surface Forces Logistics Center (SFLC) Drawings

Dwg. No.

Rev.

a. 101-WTGB-551-005 A

Mods Incidental to Centrifugal

Blower Installation (Draft)

2.3.3 USCG Surface Forces Logistics Center (SFLC) Documents

a. D-084-0481 REVA, Preservation, Packaging, and Marking

b. D-086-0508, 2008, Technical Documentation Specifications

c. USCG Planned Maintenance System Development Process Guide, CGTO PG-85-00-230-S

d. Coast Guard Commandant Instruction (COMDTINST) M9085.1 (Series), Naval Engineering Computer Aided Design Standards.

e. Coast Guard Commandant Instruction (COMDTINST) M10360.3 (Series), Coatings and Color Manual.

f. Attachment 1 – Provisioning Technical Documentation (PTD)

g. Attachment 2 - Engineering Data for Provisioning (EDFP)

2.3.4 U.S. Navy Resilient Mount Handbook (0910-LP-000-5250)

2.4 Commercial Documents - The following documents form a part of this specification to the extent specified here. The documents shall be the version listed by number and date from the referenced industry organization. Commercial documents may be listed in the Department of Defense Index of specifications and Standards (DODISS).

2.4.1 American Gear Manufacturing Association (AGMA)

a. AGMA 6001-D97 (1997) - Design and Selection of Components for Enclosed Gear Drives.

b. AGMA 6010-F97 (2003) – Standard for Spur, Helical, Herringbone and Bevel Enclosed Drives

c. AGMA 6023-A88 (2000) - Design Manual for Enclosed Epicyclical Gear Drives

d. AGMA 9005-E02 (2002) – Industrial Gear Lubrication

2.4.2 Society of Automotive Engineers (SAE)

a. SAE J1228, Small Craft - Marine Propulsion Engine and Systems - Power Measurements and Declarations, 1991.

b. SAE J1942/1, Qualified Hoses for Marine Applications, 2010.

c. SAE J1939, Serial Control and Communication Heavy Duty Vehicle Network, 2011.

2.4.3 American Bureau of Shipping, Guide for Building and Classing Naval Vessels (NVR), 2010

2.4.4 American National Standards Institute (ANSI) / National Conference of Standards Laboratories (NSCL)

a. ANSI/ISO/IEC 17025:2005, General Requirements for the Competence of Testing and Calibration Laboratories.

b. ANSI/NCSL Z540-3-2006, Requirements for the Calibration of Measuring and Test Equipment.

2.4.5 American Society of Testing and Materials (ASTM)

a. ASTM F 1836M-09, Standard Specification for Stuffing Tubes, Nylon, and Packing Assemblies (Metric).

b. ASTM F 1837M-97 (2007), Standard Specification for Heat-Shrink Cable Entry Seals (Metric).

c. ASTM D3951-10, Standard Practice for Commercial Packaging

2.4.6 American Welding Society (AWS)

a. AWS D1.1/D1.1M: 2010, Structural Welding Code - Steel.

b. AWS D1.6/D1.6M: 2007, Structural Welding Code - Stainless Steel

c. AWS D1.2/D1.2M: 2008, Structural Welding Code - Aluminum.

2.4.7 Institute of Electrical and Electronics Engineers (IEEE)

a. IEEE 45.2 - 2011, Recommended Practice for Electrical Installations on Shipboard – Controls and Automation.

2.4.8 International Electrotechnical Commission (IEC)

a. IEC Standard 61131-3, System hardware and Software Technical Requirements, Programmable Controllers, 2nd edition, 2003.

2.4.9 International Organization for Standardization (ISO)

a. ISO 1940-1:2003, Mechanical vibration – Balance quality requirements for rotors in a constant (rigid) state – Part 1: Specification and verification of balance tolerances, 2003.

2.4.10 American Society for Quality Control (ASQC)

a. ANSI/ASQC Q9001-2008 – Quality Management Systems - Model for Quality Assurance in Design, Development, Production, Installation, and Servicing Requirements

2.4.11 National Electrical Manufacturers Association (NEMA)

a. NEMA MG 1-2009, Rev, 1-2010, Motors and Generators.

b. NEMA 250-2008, Enclosures for Electrical Equipment (1000 Volts Maximum)

2.4.12 Society of Naval Architects & Marine Engineers (SNAME)

a. T&R Bulletin 3-47, Guide for Sea Trials

b. T&R Bulletin 3-39, Guide for Shop and Installation Tests

2.5 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. The Vendor is required to notify the Contracting Officer (KO) in writing for a resolution of any ambiguity or conflict found in these specifications.

3.0 REQUIREMENTS

The Vendor shall provide all labor and material to provide new bubbler blower systems for installation on the USCG 140 WTGB Class. The US Coast Guard will install the new bubbler blower systems on the 140 WTGB Class Cutters. Any materials and components sub-contracted for the bubbler blower system shall be the responsibility of the Vendor. The USCG drawings referenced herein are provided for information only on the proposed installation for the new bubbler blower system.

3.1 Performance and General Requirements

3.1.1 Bubbler Blower

a. Ambient air temperature for the Bubbler Blower shall range from 40°F to 120°F.

b. Inlet air temperature to the Bubbler Blower shall range from -35°F to 95°F.

c. The Bubbler Blower shall be rated based on 13.9 psia and 40°F at the blower inlet flange.

d. The Bubbler Blower shall operate at continuous speed not to exceed 4150 rpm.

e. The following four operating conditions, with blower inlet air conditions as specified herein, shall be on the non-throttled blower performance curve:

BLOWER PERFORMANCE REQUIREMENTS

(Inlet Conditions 13.9 PSIA @ 40 F)

Operating Condition

Inlet Flow

(cfm) Static Discharge Pressure (psig)

3.1.2 Diesel Drive

a. The diesel drive for the blower shall comply with standards for engine emissions set forth in 40 CFR Protection of the Environment for engine installation after 1 January 2014.

b. Diesel engine shall be rated at 1800 rpm, continuous duty, 100 percent load factor, under SAE J1228 conditions.

c. Rated power of the diesel engine shall be based on continuous blower operation with inlet air to the blower at -35°F.

d. For vibration and noise limitations see Section 3.3.

3.1.3 Cleanliness

a. After completion of testing and in preparation for preservation and shipping, all inlet air, exhaust and all fluid connection points shall be sealed and protected from entry of dirt and moisture.

3.2 Specific Requirements

3.2.1 Bubbler Blower Skid

a. After satisfactory first article and factory tests, the Bubbler Blower Skid components; diesel, speed increaser, and blower shall be broken-down and shipped individually to allow for installation into the Cutter. Requirements for re-assembly and alignment shall be provided.

b. The Bubbler Blower Skid base shall be provided as a fabricated steel foundation in no more than 2 sections to allow for installation into the Cutter. The skid shall include integrated lifting points and machined mounting pads with horizontal jacking screws for alignment.

c. The Bubbler Blower Skid shall be designed for mounting Vendor provided isolation mounts on a shipboard foundation. The isolation mounts shall be in accordance with the U.S. Navy Resilient Mount Handbook (0910-LP-000-5250).

d. Dimensions of the fully assembled Bubbler Blower Skid shall not exceed an envelope overall length (OAL) of 155 inches, an overall width (OAW) of 48 inches and an overall height (OAH) of 60 inches as shown on Drawing no. 101-WTGB-551-005.

e. The wet weight of the fully assembled Bubbler Blower Skid shall not exceed 11,000 lbs.

f. The blower, diesel and speed increaser shall be sized to meet all operating condition requirements of the system while maintaining the blower/diesel within an optimum operating speed range for both the blower and the diesel.

g. An overspeed protection system shall be integrated into the Bubbler Blower Control System to prohibit operation of the blower beyond design speed.

h. A blower surge protection system shall be integrated to prohibit operation of the blower under surge conditions.

i. Lube oil cooling for the speed increaser (if required), shall be integrated with the diesel engine cooling system so that only a single seawater inlet/outlet connection is required at the Blower Skid interface.

3.2.2 Diesel Engine

a. The diesel engine shall be rated at 1800 rpm under SAE J1228 conditions and shall provide sufficient power to drive the blower at -35°F inlet air to the blower.

b. The engine shall run ISO Standard 8217 Grade DMA /aka Marine Gas Oil (MGO). The engine shall also be capable of running on MIL-DTL 16884 Fuel, Naval Distillate (NATO F-76). Note: the fuel flash point will be a minimum of 60 degrees C. The engine shall also be capable of running on up to B5 (5%) bio-diesel

c. Turbocharger(s) shall be designed to contain within the housing any parts of the rotating members that may be fragmented due to loosening, shattering, or overspeeding. The requirement shall be demonstrated by actual destructive testing or certification by engineering analysis performed by the turbocharger manufacturer.

d. The engine shall use compartment air for combustion, and shall be fitted with a heavy duty air cleaner system. Filter elements shall be replaceable.

e. Engine shall be factory equipped with air filter, alternator, starter, SAE #1 flywheel, and mounts.

f. The diesel shall be furnished with a 24 VDC, two-wire, ungrounded starter and alternator system.

g. The blower diesel engine shall allow for emergency stop operable by a pull cable which will shut off combustion air or fuel to the engine. The device shall require manual reset before the engine can be restarted. The emergency shutdown shall be independent of the normal stop mechanism

h. The diesel shall be furnished with a 3000 W, 450 VAC, single phase in-line external water jacket heater complete with integrated thermostat.

i. Sacrificial, replaceable zincs shall be furnished at critical locations in the raw water cooling system to protect components exposed to sea water.

3.2.3 Diesel Engine Cooling System

a.

The engine shall be fitted with a circulating fluid type coolant system, which shall in turn be cooled by a salt water heat exchanger. The heat exchanger shall be designed with a thermostatic by-pass control of the coolant fluid. Failure of the thermostatic unit shall not restrict either fluid. The system shall be designed to operate with 95 degree F salt or brackish water, which shall flow unobstructed. Coolant flow calculations shall include a factor for internal degradation of the heat exchanger.

b.

The engine shall be fitted with an attached pump designed for sea water service, which is self-priming and sized for at least the required seawater flow. Required sea water flow rates shall be identified on the equipment arrangement drawings. Seawater piping shall be provided by others as part of the installation process.

c.

The sea water cooler shall be mounted with take down joints in all lines to permit easy removal for cleaning. Isolation cut-out valves shall be provided in all lines to permit the removal of the cooler.

3.2.4 Spark Arrester/Silence

a. The diesel exhaust system shall be furnished with a spark arrester/silencer to remove dangerous sparks from exhaust gases and to reduce noise levels.

b. The spark arrestor/silencer shall be sized for back pressure not to exceed 2.0 in of H2O

c. Physical size of the spark arrester/silencer must not exceed allotted space shown on drawing 101-WTGB-551-005.

d. The spark arrestor/silencer shall be sized for exhaust noise level not to exceed the requirements stated in Section 3.3.

e. The spark arrester/silencer shall be of fully welded construction and shall be suitable for a marine environment.

f. Connections for the spark arrester/silencer shall be with standard 125/150 lb ASA drilled flanges.

g. The spark arrester/silencer shall be equipped with a drain plug for servicing.

h. Physical size of the Spark Arrester/Silencer when wrapped with required thickness of insulation must not exceed allotted space shown on drawing 101-WTGB-551-005.

3.2.5 Blower

a. The blower shall be a multistage centrifugal type blower with outboard mounted bearing construction in which the impellers are keyed to a heavy ground stainless steel shaft and supported by oil lubricated anti-friction type bearings. To prevent shifting of the impellers while in operation, the hubs of all impellers shall butt together through one-piece metal spacers. The entire rotating assembly shall be secured with a lock washer and lock nut.

b. Impeller casing shall consist of cast iron intermediate sections held securely between cast iron inlet and outlet heads with steel tie rods. Blower casing shall be rated for a pressure of 25 PSIG. Intermediate sections shall receive air from one impeller and guide it into the next impeller via integral (cast-in) diffuser and guide vanes.

c. The head castings shall have integral flanges matching ASA 125-pound pattern, drilled and tapped for piping connections. The modular housing components shall be sealed by precision-machined rabbet joints and bonded with a sealant that can withstand the blower operating pressure and temperature. A tapped drain hole shall be provided in the bottom of each section and outlet head. Each drain shall be piped to a manifold extending to the edge of the equipment skid where a shut-off valve will be installed. Drain hardware and shut-off valve shall be stainless steel.

d. Impellers shall be of cast or fabricated aluminum construction. Each impeller shall be statically balanced and the rotating assembly shall be dynamically balanced in accordance with ISO 1940. The vibration amplitude of the operating blower shall not exceed 1.25 mils (peak to peak) as measured on the bearing housing in the vertical direction. Vibration readings will be taken with the blower at operating speed. Tip speed of the impellers shall not exceed 465 ft/sec.

e. The blower shaft shall be of sufficient diameter to operate at least 15% below the first critical speed. Shaft shall be fabricated from high strength stainless steel for corrosion resistance in a marine environment.

f. Bearings and air seals shall be mounted in cast iron outboard housings, which shall allow for routine maintenance without having to disconnect inlet or discharge piping. Bearing housing shall be equipped with oil level sight glasses. No contact shall be allowed between the rotating element and the housing, except at the shaft bearings. Non-contact labyrinth seals shall be provided to minimize air leakage.

g. Bearings shall be sized for minimum life of 100,000 hrs in accordance with ABMA L-10 standards.

h. Shaft side bearing shall be replaceable without removal of the blower assembly from the Bubbler Blower Skid frame rails.

i. The bearing opposite shaft side bearing shall be replaceable with a pull length restriction of 12-inches.

j. A balance piston will be integrally shaft mounted on the discharge end of the blower to reduce the thrust load seen by the bearings. Air leakage past the balance piston will be vented to atmosphere or returned to the inlet in an external return line.

k. The blower shall be fitted with a stainless steel baffle ring(s) to increase operating efficiency by helping to turn airflow into the impeller eye to reduce inlet passage losses. Baffle ring(s) shall attach to the casing using stainless steel hardware.

l. The blower shall utilize coatings to prevent corrosion caused by marine environment. The blower casing surfaces shall be sandblasted per SSPC-SP6. Surfaces in contact with the air stream (casing interior, impellers, balance piston) shall be coated with Glyptal 1201 enamel or equivalent. The blower exterior and base shall be prime-coated with Tnemec 66 epoxy or equivalent and factory finish coated with Tnemec 69 epoxy or equivalent.

m. Blower rating shall be based on conditions stated in Section 3.1.1.

3.2.6 Speed Increaser/Coupling

a. Speed increaser shall be a gear type increaser with a ratio designed to maintain the diesel within its optimum operating RPM range.

b. Speed increaser shall be appropriately sized for the power transferred and mounted directly to the engine bell housing (standard SAE housing size). A standard keyed output stub shaft shall be supplied for connection to the blower.

c. Positive lubrication to bearings and gearing shall be provided with an integral lubrication pump accessible for maintenance. The lubrication system shall be furnished with a lubrication filter with replaceable element.

d. Gearing shall be precision ground gear sets in accordance with AGMA standards.

e. Bearings shall be anti-friction type bearings.

f. The blower shall be connected to the speed increaser output shaft with a spacer-type flexible coupling having a minimum service factor of 1.5 over the driver nameplate rating. The couplings shall be aligned in accordance with the manufacturer’s instructions to an offset tolerance not to exceed 2 MILS (0.05mm).

g. A Critical Speed Analysis and Torsional Analysis shall be performed for the first article unit provided to assure proper matching and sizing of components to assure safe and reliable operation. The calculations shall be submitted as part of the Provisioning Technical Documentation (PTD), Attachment 1, with the Vendors proposal.

3.2.7 Clutch

a. A pneumatically operated clutch shall be provided to permit operation of the diesel engine without turning the blower.

b. The clutch assembly shall include all pneumatic operating hardware, including, but not limited to: actuation cylinder, solenoid valve, filter and regulator. This hardware shall be mounted within the boundary of Blower Skid with a 3/8 NPT air supply connection at the interface. Air supply will be compressed air at 90 psig minimum pressure.

c. Operation of the clutch shall be spring set and pneumatically released.

d. Clutch shall be fully enclosed. Clutch enclosure shall be equipped with a removable inspection cover for inspecting clutch wear.

e. Friction pads/surfaces shall not contain any asbestos materials.

3.2.8 Piping

a. All piping materials, design and fabrication shall comply with CFR Title 46 Chapter I, Subchapter F, Part 56.

b. Piping design and installation shall provide sufficient flexibility to absorb stresses on the piping imposed by the ship’s structural flexing and thermal gradients from minimum compartment ambient temperatures to full operating temperature conditions and to absorb the full range of motion permitted by the bubbler skid isolation mounting. Piping shall not be pre-stressed during installation.

3.2.9 Fittings

a. If required, tubing bends shall be used to the maximum extent possible in lieu of elbow fittings. For fittings 2 inch and smaller, standard radius tees and elbows shall be used. For fittings larger than 2 inch, standard tees and long radius elbows shall be used. Tee fittings shall be of a design which minimizes sharp corners. Short radius fittings shall be minimized to the extent practical.

3.2.10 Instrumentation

a. Gauges shall be provided to monitor engine functions as provided in the Vendor standard instrumentation package. The gauges shall be commercially available, marine grade gauges with direct action, multi-wound bourdon tube elements, with an accuracy of 1 percent.

b. Gauges that are shop-installed on equipment and panels shall be mounted in such a manner that the supply tubing and gauge valve are protected from damage.

c. Thermometers shall be provided to monitor inlet and outlet temperatures of heat exchanger sea water and engine coolant, and exhaust. Thermo wells shall be provided for installation of the thermometers.

3.2.11 Hoses

a. All hoses shall be in accordance with SAE J1942/1.

b. Flexible hose used on the engine for flammable fluid service shall be fire resistant with no need for external sleeving. The hose shall meet the applicable requirements of 5-1-1B of the NVR.

c. Hoses (if provided) shall be tested and test certifications shall be furnished with each hose. Each installed hose shall have affixed a weather resistant tag engraved or embossed in ¼” high letters with the part number, “S/N BBS-XXX” (where XXX is a sequential number), "Tested 150% WP" and Test Date [DD/MM/YY]. The hose tags shall identify system design pressure, hose test pressure, hose length, hose model, and both end fitting OEM part numbers. The Vendor shall identify all hoses in the Technical Publication.

3.2.12 Filtration

a. An engine mounted duplex oil filter with replaceable filter elements shall be provided in accordance with the engine manufacturer’s requirements.

b. An engine mounted duplex fuel filter with replaceable filter elements shall be provided in accordance with the engine manufacturer’s requirements.

c. All filters shall be located for ease of servicing. Provision shall be made to control or contain fluid spills which might occur when changing filters.

3.2.13 Bubbler Control System Valves

a. Bubbler system manifold air control valves (four) shall be 8-inch butterfly type, lug/deadend style rated 200 psig. Valve body shall be epoxy coated ductile iron (A536). Elastomer seat in valve body shall be EPDM (ethylene propylene). Disc and shaft shall be MONEL. Bushings shall be PTFE. Valve stem and body shall be configured for electric actuator operation. Valve shall be suitable for marine applications.

b. Bubbler system bypass air control valve (one) shall be 6-inch butterfly type, lug/deadend style rated 200 psig. Valve body shall be epoxy coated ductile iron (A536). Elastomer seat in valve body shall be EPDM (ethylene propylene). Disc and shaft shall be MONEL. Bushings shall be PTFE. Valve stem and body shall be configured for electric actuator operation. Valve shall be suitable for marine applications.

c. Bubbler system air control valves shall be actuated with a 120 VAC, 1 PH, 60 Hz rotary electric actuator mounted directly on the valve. The actuator shall be furnished with a NEMA 4X enclosure suitable for marine applications. The actuator shall be furnished with a mechanical dial position indicator to indicate the open/closed position of the valve.

d. Valves shall be permanently marked to indicate proper connection in the system; directional arrows shall be used, as appropriate.

3.2.14 Guards

a. Guards for personnel protection shall be provided for flywheels, couplings, drive belts and other exposed moving parts in accordance with NVR 2-2-1 sect. 3.12.4. Hot machinery surfaces shall be shielded or insulated so that the external surface shall not exceed 220 °C (428 °F). Asbestos insulating products shall not be used. Fuel and lubricating oil filters, strainers, charge air system, aftercooler, lines or fittings, including gauge lines, shall be located or shielded such that any leaks cannot drip or spray on any components with a surface temperature of 220 °C (428 °F) or greater or into the engine intake.

3.2.15 Electrical Control Equipment

a. Electrical equipment, panels and termination boxes shall be NEMA 4 (NEMA STD 250) enclosures or greater.

b. Electrical equipment furnished to this specification mounted on the bubbler skid shall conform to the requirements of MIL-STD-167-1 for vibration.

c. The electrical control system for the new bubbler blower system shall be PLC based with touchscreen HMI control displays for operator interface. The system hardware and software shall be developed in accordance with IEC standard 61113-3 and include (1) logic flow charts, (2) source code, and (3) original programming software. The control package shall be a standalone system with Modbus protocol capability for future connection to the ships MPMCS system.

d. The local/master HMI control display will be mounted in the main PLC control panel located in the Engineering Control Center. This panel will be located in the space of the existing bubbler control panel (30”H x 24”W x 8”D). The remote/slave HMI control display will be mounted panel at the location of the existing pilot house bubbler control panel (16”H x 16”W x 8”D). The local/master HMI control display and main PLC control panel shall be supplied by 24 VDC power.

e. The PLC control algorithms shall perform the following functions; system operational control with valve status/alarm annunciation, compressor status/alarm annunciation, diesel engine status/alarm annunciation, and data/error logging. Each of these functions shall be accomplished by unique screens on the HMI control displays.

3.2.16 Operation

The normal system operation shall provide for start/stop of the prime mover and mode selection of the system. The normal operational modes for the bubbler system shall consist of the following:

· All : All four valves open, bypass valve closed

· Bow : Two bow valves open, bypass valve open

· Aft : Two aft valves open, bypass valve open

· Starboard : Starboard fore and starboard aft valves open, bypass valve open

· Port : Port fore and port aft valves open, bypass valve open

· Rotate Port : Starboard fore and port aft valves open, bypass valve open

· Rotate Starboard : Port fore and starboard aft valves, bypass valve open The programming algorithm shall ensure that the bypass valve is open when any combination of two valves is open to guard against compressor surge conditions. The compressor monitor and control panel shall detect surge conditions and notify the main PLC via the Modbus communications link of the fault. The main PLC program shall subsequently issue an emergency stop command to the diesel engine to prevent compressor and system damage. The PLC shall sequentially close all five valves whenever the blower system is stopped for any reason whether normal stop or emergency/fault induced stoppage.

The normal system operation screen shall show the bubbler system valve positions diagrammatically as well as the seven mode touch screen buttons. Valves shall be opened/closed sequentially depending on the mode selected. Normal system alarms shall include but are not limited to: valve failure to open/close on command, low system pressure, high system pressure, and compressor surge condition. Valve position will be monitored by auxiliary contacts on the valve body. Prime mover RPM will be continuously varied to maintain the bubbler system pressure of 9 psig via the Modbus communications link by inputs from the compressor monitor and control panel to the main PLC panel and outputs to the diesel engine control panel through the use of a Modbus to SAE J 1939 protocol converter.

3.2.17 Alarms and Indicators

The compressor status/alarm annunciation function shall be accomplished diagrammatically showing the compressor and shall include but not be limited to the following parameters:

· Compressor discharge pressure status

· Compressor surge condition fault

· Compressor main bearing vibration fault

The diesel engine status/alarm function shall be accomplished diagrammatically showing the engine and shall include but not be limited to the following parameters:

· Prime mover RPM status

· Prime mover lube oil, jacket water, fuel oil, and sea water pressure status

· Prime mover lube oil, jacket water, and sea water exhaust temperature status

· Prime mover high/low lube oil, jacket water, fuel oil, and sea water pressure faults

· Prime mover high/low lube oil, jacket water, and sea water exhaust temperature faults

The main PLC panel shall contain an audible alarm activated on any bubbler system fault. An alarm silence button shall be programmed into the HMI for alarm acknowledgement. The active alarm will continue to flash until alarm is cleared.

The data/error logging function shall include but not be limited to the following bubbler system data/errors and shall include date and time stamping of the event:

· Daily system runtime with mode of operation (from above)

· Compressor system operational minimum and maximum pressures

· Any system alarm or fault condition (from above) 3.2.18 Diesel Engine Electrical System The engine will be started using a dedicated battery bank provided by the USCG. The starter motor for the diesel engine shall meet the diesel manufacturer’s specifications and shall be a 24 VDC motor rated for marine applications. The engine driven alternator shall be chosen to match the starting requirements of the diesel engine. The battery bank must be capable of providing a minimum of 900 cold cranking amperes (CCA) at 24 VDC. The remote starting/stopping of the engine shall be accomplished by using discrete outputs from the main PLC control panel to the diesel engine control panel start and stop relays. Jacket water heating shall be accomplished by the use of an inline 3000 W, 450 VAC, single phase heater. The heater shall be supplied with a control box and thermostat set to come on at 100 F and go off at 120 F.

3.2.14 Air Pressure Switches

a. Air Pressure sensing switches used by the blower control system for proper system regulation shall be supplied and controlled by 24 VDC.

b. Air Pressure switches shall have a minimum range of 0-100 psig and shall be field adjustable.

3.2.15 Cabling / Wiring

a. Cabling and wiring shall be provided in accordance with IEEE 45 and MIL-DTL-24643C. Cables will be selected per the installation drawings Bills-of-Materials.

b. Cable entry into electrical enclosures shall use either nylon stuffing tubes per ASTM F 1836M or heat-shrink cable entry seals per ASTM F 1837M.

3.2.21 Identification and Labeling A label plate shall be permanently affixed to the bubbler blower skid assembly documenting the installed components. The label plate shall be corrosion resistant metal with engraved information showing the following information as a minimum:

a. Manufactures Model No.

b. Maximum Operating Pressure

c. Maximum Flow Rate

d. Operating Temperature Range XX to XXX degrees F

e. Serial Number

f. Year Built

3.3 Noise and Vibration

a. Airborne noise levels of the equipment as installed aboard ship shall not exceed the requirements of ABS Guide for Building and Classing Naval Vessels, Part 6, Chap. 4 Sect. 2 under Airborne Noise Category D. This requires a steady state A-weighted level not to exceed 84 dB with maximum levels at octave band center frequencies as follows:

32 Hz 97 dB

63 Hz 94 dB

125 Hz 91 dB

250 Hz 88 dB

500 Hz 85 dB

1000Hz 82 dB

2000 Hz 79 dB

4000 Hz 76 dB

8000 Hz 73 dB The airborne noise level in one octave band may exceed the decibels by 2 dB.

b. Isolation mounts for the bubbler skid shall be selected with a natural frequency ½ or less than the machinery’s rotational frequency.

c. Isolation mounts for the bubbler skid shall be selected for loading not to exceed 60% to 70% of their load bearing capacity.

d. Lateral and torsional vibration analysis of the entire rotating assembly shall be conducted and provided to assure that there are no excessive vibration induced stresses in the speed increaser and blower. Diesel drive speed shall be considered over the range of 1500 to 1850 rpm, and diesel engine mis-fire shall be considered in the torsional analysis.

3.4 Training

The Vendor shall provide onboard training of the ship’s personnel for the first bubbler blower system installed. Training may be performed during the support of Field Services. Training shall comprise operation and maintenance of the new equipment. The training shall include but is not limited to:

a. review of maintenance documentation

b. review of start-up and operational procedures

c. safety

d. settings and adjustments

e. checking and replacement of filters

f. sampling and testing fluids

g. system filling

h. interpretation of displayed sensor data

i. emergency procedures

j. troubleshooting

The Vendor shall specify in the quotation all travel associated costs (airfares, car rentals, mileage, lodging, per diems, etc.) for the number of man hours/man days of training.

Training materials shall include the onboard technical documentation provided for the new equipment plus any additional training documents which will be provided by the Vendor and included in the training.

The Vendor shall prepare and sign a statement regarding the completion or waiver of training services. The COR or his representative shall obtain a release signature before departure of the Vendor or his representative. The Vendor shall forward a copy of the signed release document to the Contracting Officer (KO), with a Commissioning Technical Report.

3.5 Field Services

Included in the cost of the equipment shall be the services of a field service engineer/technician to assist during set-up, testing, commissioning, light-off, and adjustment for optimum performance of the equipment and system. Future warranty work will be performed as needed in accordance with the Contract.

Field service support will be performed at the U.S. Coast Guard Yard at Curtis Bay, Baltimore, MD.

The Vendor shall specify in the quotation the number of man hours / man days and travel included to accomplish this support.

a. All travel associated costs (airfares, car rentals, mileage, lodging, per diems, etc.) for the number of man hours/man days of technical services are to be included in the quotation.

b. An additional day rate for any potential future field service support required outside of any required warranty work. The quoted rate shall be good for one year after installation of the first bubbler blower system.

The Vendor shall prepare and sign a statement regarding the completion or waiver of commissioning services. The Contracting Officers Representative (COR) shall obtain a release signature before departure of the Vendor or his representative from the field service site. The Vendor shall forward a copy of the signed release document to the Contracting Officer (KO), with a Commissioning Technical Report.

3.6 Departure from Specification

Departure from the specifications will not be allowed unless there is a direct benefit to the Government.

a. If the Vendor finds it necessary to change or depart from the applicable requirements he must request permission to do so from the Contracting Officer (KO) at the earliest possible time.

b. Requests by the Vendor for changes shall clearly describe the changes proposed, the reason for and the advantages of the changes proposed. Also to be included is a detailed list of additional costs or savings (if any) that would result.

c. If the proposed change involves the substitution of another material or method for one specifically required, the complete Specification(s) covering the requested method or material shall be submitted.

3.7 Design Improvements

Proposals submitted by the Vendor for design improvements in equipment or processes to simplify, better reliability and or maintainability, and performance, etc are encouraged. Such proposals may be submitted at any time during the contract using the specification departure procedures as outlined herein.

3.8 Technical Documentation

Content for technical documentation (technical publications and drawings) to be provided shall be as defined herein and as defined in D-086-0508. The Vendor shall provide data rights documentation that allows publication on the Coast Guard Intranet and distribution to the Fleet. Quantities shall be provided as specified herein. Additional requirements for the content of technical documentation shall be as identified in Engineering Data for Provisioning (EDFP).

3.8.1 Technical Publications

a. The Vendor shall develop and provide a Technical Publication for the installation, operation and maintenance of the new components and system.

b. Draft Deliverable – One (1) paper and one (1) electronic draft copy of the Technical Publication shall be submitted for review and approval. Comments will be returned along with the assignment of a Coast Guard Document number.

c. Final Deliverable – One (1) paper and one (1) electronic copy of the Coast Guard approved Technical Publication shall be provided to the Coast Guard Contracting Officer or his/her representative for each bubbler blower system delivered. Electronic files include any source files used to produce the Technical Publication.

3.8.2 Drawings

a. The Vendor shall develop and provide system/component drawings and diagrams in AutoCADtm version 2009 in accordance with COMDTINST M9085.1 (Series) "Naval Engineering Computer Aided Design Standards." Standard Coast Guard drawing border templates are available via the internet at: http://www.uscg.mil/hq/elcbalt/ or upon request via the Coast Guard Contracting Officer or his/her representative.

b. Draft Deliverable – One (1) paper and one (1) electronic copy of preliminary Drawings shall be submitted for review and approval. Comments will be returned along with the assignment of a Coast Guard Drawing number.

c. Final Deliverables - One (1) paper (per ship set) and one (1) electronic copy of Coast Guard approved Drawings shall be provided to the Coast Guard Contracting Officer or his/her representative for each bubbler blower system delivered. Electronic files include any source files used to produce the Drawings.

3.9 Integrated Logistics Support

The Vendor shall provide the following logistical support and information for the bubbler blower system. Revised documentation in response to the Government’s initial review shall be deliverable prior to any subsequent bubbler blower system deliveries. Modifications made to the equipment provided during the term of the contract must be accompanied by updates of all the following that relate to those changes.

3.9.1 Engineering Data for Provisioning (EDFP) The Vendor shall be provide Engineering Data for Provisioning (EDFP) in accordance with Attachment 2, and shall include a parts list containing all of the installed parts, the original equipment manufacturer (OEM), OEM part or assembly numbers, the OEM’s name and address, the OEM’s cage code, quantity used in each equipment, and shall be keyed to the provided drawings. All spare parts necessary for overhaul of a unit shall be identified in the printed technical documents supplied.

3.9.2 Recommended Spare Parts List

The Vendor shall provide with the EDFP/PTD a recommended spare parts list for onboard repair parts (OBRP) and stock system parts. The spare parts list shall list applicable manufacturer’s maintenance tasks for each line item (both preventive and corrective).

a. Onboard Spare Parts – Onboard spare parts are items that unit personnel can replace without additional special tools or technical support.

b. System Stock - System stock shall be the long lead time materials (materials with lead times over 90 days) and manufacturer designated critical items.

3.9.3 OEM Maintenance Requirements The Vendor shall provide OEM maintenance recommendations, in parallel to maintenance recommendations in the Technical Publication, to allow for USCG the development of Maintenance Procedure Cards. Guidance for providing this information can be found in Chapter 5 of the USCG Planned Maintenance System Development Process Guide. The Vendor shall identify at least the following line items:

a. Applicable Maintenance Task Code

b. Maintenance Procedure Title

c. Maintenance Procedure Interval

d. Maintenance Procedure Description

e. Maintenance Procedure Sequenced Tasks

f. Maintenance Procedure

g. Maintenance Procedure Task Type

h. Associated Parts LCN

i. Associated Parts Name

j. Associated Parts Part Number

k. Quantity of Parts per Maintenance Task

l. Associated Parts Unit of Issue

m. Associated Parts Shelf Life

n. Associated Parts Unit Price

o. Special Tools and Equipment Nomenclature

p. Special Tools and Equipment Cage

q. Special Tools and Equipment PN/NSN Task Descriptions

3.10 Tests, Inspections and Reports

The Coast Guard reserves the right to witness any or all of these tests. The Vendor shall retain records of all tests and submit them to the Contracting Officers Representative (COR). The performance of tests and the preparation of reports shall follow the guidance of SNAME T&R Bulletin 3-39, Guide for Shop and Installation Tests.

A report on the following tests shall be submitted which shall include description of test setup and procedure, photographs, logs of times for start and finish and any measurements taken during the test. Testing shall meet the requirements as identified below.

3.10.1 First Article Testing (FAT) The Vendor shall develop a First Article Testing procedure and perform the First Article Testing and inspection on the first Bubbler Blower System constructed and supplied under this Contract. During the FAT, the blower unit shall not require adjustment or biasing of pressure settings, control limits and the system shall not operate in an overload condition. Testing and inspections shall include as a minimum but not be limited to the following:

a. Testing shall be conducted with the skid completely assembled with the blower powered by the diesel engine.

b. Diesel manufacturer’s break-in procedure for the diesel engine shall be accomplished prior to conducting tests with the blower engaged.

c. Bubbler Blower Skid Burn-In: Bubbler Blower Skid shall be operated for a burn-in period and adjustment period of not less than one (1) hour at varying pressures and speeds. Diesel engine oil filters shall be examined for particulate content. Operating temperatures, oil pressure and other instrumentation readings of both the diesel engine and the blower shall be monitored and recorded at 15 minute intervals.

d. Operation at the rated pressure and capacity for eight (8) hours. Operating temperatures, oil pressures, blower bearing temperatures, speed increaser temperatures and other instrumentation readings of both the diesel engine and the blower shall be monitored and recorded at 30 minute intervals. All measurements must fall well within the manufacturer’s normal operating range.

e. Blower discharge flow and pressure shall be measured during the eight (8) hour test to verify proper operation and capacity of the blower and to verify against the blower operating curves.

f. Motorized Butterfly Valves shall be factory tested for proper operation, cycle time and sealing capability. Butterfly valves must also be wired up to the PLC controller to demonstrate that they will work properly from both the master control panel and from the slave control panel.

g. The vibration level shall also be verified at the system design pressure and capacity during the eight (8) hour test and shall be within the limits stated in section 3.2.5.d.

h. Airborne noise levels shall be tested in accordance with ABS Guide for Building and Classing Naval Vessels, Part 6, chapter 4 and section 3.3 of this specification. This shall be conducted during the eight (8) hour test.

i. A surge condition shall be simulated in the controller to test the surge protection feature and to confirm that the system will automatically shut down. This shall be done after the eight (8) hour test.

j. Pneumatic clutch shall be tested to demonstrate proper functioning and to verify holding capacity to maintain clutch in the disengaged position. Clutch shall be cycled through ten cycles to demonstrate proper operation and shall be held in the clutch disengaged position for one hour on the tenth cycle without any drift back to the engaged position.

3.10.2 Factory Testing (FT) Each complete Bubbler Blower System supplied after the first article shall be factory tested and inspected. The testing and inspections shall include but not be limited to the following:

a. Testing shall be conducted with the skid completely assembled with the blower powered by the diesel engine.

b. Diesel manufacturer’s break-in procedure for the diesel engine shall be accomplished prior to conducting tests with the blower engaged.

c. Operation at the rated pressure and capacity for two (2) hours. Operating temperatures, oil pressure and other instrumentation readings of both the diesel engine and the blower shall be monitored and recorded at 15 minute intervals. All measurements must fall well within the manufacturer’s normal operating range. Diesel engine oil filters shall be examined for particulate content.

d. Blower discharge flow and pressure shall be measured during the two (2) hour test to verify proper operation and capacity of the blower and to verify against the blower operating curves

e. The vibration level shall also be verified at the system design pressure and capacity during the two (2) hour test and shall be within the limits stated in section 3.2.5.d

f. Blower discharge flow and pressure shall be measured during the two (2) hour test to verify proper operation and capacity of the blower and to verify against the blower operating curves system design pressure and capacity.

g. Motorized Butterfly Valves shall be factory tested for proper operation, cycle time and sealing capability.

h. A Factory Test Report shall be provided.

3.10.3 Shipboard…