CSS CIP-H3TC02 Test Stand.pdf

SOLICITATION # FA813222Q0053

AFATS Test Stand

TINKER AFB, OK

The Air Force Sustainment Center’s Maintenance Contracting Branch (AFSC/PZIMC) at Tinker Air Force Base, Oklahoma, intends to award a Firm Fixed Price (FFP) Purchase Order for the software upgrade of one (1) AFATS Test Stand. See Section 2 (entitled Supplies/Services and Price) and attached Statement of Work (SOW) for complete details.

This is a combined synopsis/solicitation for commercial items prepared IAW the format in Federal Acquisition Regulation (FAR) Subpart 12.603, as supplemented with additional information included in this notice. This announcement constitutes the only solicitation; quotes are being requested and a written solicitation will not be issued aside from the one posted here.

This solicitation is being issued as a request for quotation (RFQ) IAW FAR Part 13. This solicitation document and incorporated provisions and clauses are those in effect through Federal Acquisition Circular FAC 2022 07, Defense Federal Acquisition Regulation Supplement (DFARS) changes effective 23 Jun 2022, and Air Force Acquisition Regulation Supplement (AFFARS) Acquisition Circular

(AFAC) 2022-0701.

This is a 100% Small Business Set-Aside.

NAICS Code 335314; Size Standard is 750 Employees

*Large Businesses WILL NOT be eligible; Contractors MUST be active in SAM

QUOTE SUBMISSION

INFORMATION

Quotes are due to the point of contact (POC) below by 30 Nov 2022/12:00 pm, Central Daylight Time

Michael Acree, Contracting Specialist (Primary POC) Elizabeth C Fanning, Contracting Officer (Alternate POC) michael.acree.8@us.af.mil elizabeth.fanning@us.af.mil

All quotes must be good for no less than 90 days after the quote submission date above.

SHIPPING INFORMATION

Shipping will be FOB Destination (Tinker AFB, OK 73145) only. Separate charges for shipping/freight will not be allowed. Please work this into your quote’s total price.

Items will be delivered to:

F3YCHE

76 CMXG/MXDEC

Building 3902

TINKER AFB OK 73145

TERMS, CONDITIONS, PROVISIONS, & CLAUSES

SITE VISIT

A site visit will be held on 17 NOV 2022 at 09:30 AM at The Pass and ID Visitor Center Tinker AFB, OK, so that interested contractors may inspect the site where the work is to be performed to satisfy themselves concerning all general and local conditions which could affect cost of contract performance to the extent such information is available. Interested contractors are required to notify Michael Acree Contract Specialist, by email ONLY at michael.acree.8@us.af.mil if they plan to attend. Failure to notify Mr. Michael Acree in a timely manner could result in non-availability of transportation and contractor inability to attend the site visit. All interested contractors are strongly urged to attend.

Payment terms will, by default, be Net 30, which means the Government has 30 days to pay you after you submit your invoice.

You may offer payment discounts for early payment, but this will not be considered in quote evaluation.

Invoices must be submitted in Wide Area Workflow (WAWF) application, which can be found in the Government's Procurement Integrated Enterprise Environment (PIEE; https://piee.eb.mil/). Payment will be made after the invoice is signed in WAWF and after the item is received and accepted by the Government; do not submit invoices until the item has been delivered.

All clauses and provisions can be found on the following websites:

Federal Acquisition Regulation (FAR) – https://www.acquisition.gov/browse/index/far Defense Federal Acquisition Regulation Supplement (DFARS) – https://www.acquisition.gov/dfars Air Force Federal Acquisition Regulation Supplement (AFFARS) – https://www.acquisition.gov/affars

52.212-1 -- Instructions to Offerors – Commercial Items

ADDENDUM as prescribed in FAR 12.301(b)(1) – As prescribed in FAR 12.301(b)(1), the following addendum is provided for this solicitation and hereby amends any language therein:

1. Quotes in response to this solicitation must be submitted no later than 30 Nov 2022 / 12:00 PM CDT. Quotes must be submitted via email to Michael Acree (Cc Elizabeth Fanning).

2. All quotes must be submitted on the Quote Sheet (see last pages of this document), which must be filled out completely.

3. Shipping will be FOB Destination (Tinker AFB, OK 73145) only. Separate charges for shipping/freight will not be allowed.

Please work this charge into your quote’s total price.

Failure to follow all of these instructions will render your company ineligible for award.

52.212-2 -- Evaluation – Commercial Items

ADDENDUM as prescribed in FAR 12.301(c) –

As prescribed in FAR 12.301(c), the following addendum is provided for this solicitation and hereby amends any language therein:

1. The US Government will award a Purchase Order resulting from this solicitation to the responsible Offeror who provides the lowest-priced ACCEPTABLE quote for the items specified in the item description. Quotes will be determined Acceptable upon contractor addressing all details of Attachment 1, Item Description.

2. After closing of this solicitation, the lowest three quotes will be evaluated by Contracting for the following:

mailto:michael.acree.8@us.af.mil

A. Quote Sheet – Sections 1-3 (the last two pages of this document) must be filled out completely. Failure to do so may render the submitted quote ineligible for award.

B. Shipping – it must be FOB Destination, which mean it’s paid through to Tinker AFB, OK; it must be incorporated into the cost of the items, not quoted as a separate line item. Failure to provide us with FOB Destination shipping will render you ineligible for award.

3. Contracting will notify the successful Offeror they will receive the award via email or phone call.

4. Unsuccessful Offerors will not be notified personally but can find the award information online (SAM.gov) within 24 hours of award. The information posted will be as follows:

a. Contractor/Business Name

b. City and State

c. Purchase Order Number

d. Award amount

No other details or debrief will be provided.

52.212-3 -- Offeror Representations and Certifications -- Commercial Items.

The offeror shall complete only paragraphs (b) of this provision if the Offeror has completed the annual representations and certification electronically via the System for Award Management (SAM) Web site located at http://www.sam.gov/portal (Only complete and return if there are changes to current SAM Registration. If 52.212-3 is not returned the contractor is affirming that the current SAM registration is current, accurate, and complete). If the Offeror has not completed the annual representations and certifications electronically, the Offeror shall complete only paragraphs (c) through (u) of this provision.

The following FAR clauses and provisions are included but not limited to:

52.203-6, Alt 1, Alternate I Restrictions on Subcontractor Sales to the Government 52.204-7, System for Award Management 52.204-10, Reporting Executive Compensation and First-Tier Subcontract Awards 52.204-13, System for Award Management Maintenance 52.204-16, Commercial and Government Entity Code Reporting 52.204-18, Commercial and Government Entity Code Maintenance 52.204-19, Incorporation by Reference of Representations and Certifications 52.204-22, Alternative Line Item Proposal 52.204-24, Representation Regarding Certain Telecommunications and Video Surveillance Services or Equipment 52.204-25, Prohibition on Contracting for Certain Telecommunications and Video Surveillance Services or Equipment 52.204-26, Covered Telecommunications Equipment or Services-Representation 52.209-5, Certification Regarding Responsibility Matters 52.209-7, Information Regarding Responsibility Matters 52.209-11, Representation by Corporations Regarding Delinquent Tax Liability or a Felony Conviction under any Federal Law 52.212-3, Alt 1, Offeror Representations and Certifications- Commercial Items 52.212-4, Contract Terms and Conditions -- Commercial Items 52.212-5, Contract Terms and Conditions Required to Implement Statues or Executive Orders—Commercial Items 52.219-6, Notice of Total Small Business Set-Aside 52.219-8, Utilization of Small Business Concerns 52.219-14, Limitations on Subcontracting 52.219-28, Utilization of Small Business Concerns.

52.223-22, Public Disclosure of Greenhouse Gas Emissions and Reduction Goals-Representation 52.232-39, Unenforceability of Unauthorized Obligations 52.232-40, Providing Accelerated Payments to Small Business Subcontractors 52.246-16, Responsibility for Supplies 52.247-34, FOB Destination 52.252-2, Clauses Incorporated by Reference

*The following FAR clauses within FAR 52.212-5 are included but not limited to:

52.203-6, Restrictions on Subcontractor Sales to the Government (Sep 2006), with Alternate I 52.204-10, Reporting Executive Compensation and First-Tier Subcontract 52.209-6, Protecting the Government's Interest When Subcontracting with Contractors Debarred, Suspended, or Proposed for Debarment 52.219-6, Notice of Total Small Business Set-Aside 52.219-8, Utilization of Small Business Concern 52.219-9, Small Business Subcontracting Plan 52.219-14, Limitations on Subcontracting 52.219-16, Liquidated Damages-Subcontracting Plan 52.219-28, Post Award Small Business Program Representation 52.219-33, Nonmanufacturer Rule 52.222-3, Convict Labor 52.222-19, Child Labor—Cooperation with Authorities and 52.222-21, Prohibition of Segregated Facilities 52.222-26, Equal Opportunity 52.222-35, Equal Opportunity for Veterans 52.222-36, Equal Opportunity for Workers with Disabilities 52.222-37, Employment Reports on Veterans 52.222-40, Notification of Employee Rights Under the National Labor Relations Act 52.222-50, Combating Trafficking in Persons 52.223-18, Encouraging Contractor Policies to Ban Text Messaging While Driving 52.225-1, Buy American-Supplies 52.225-13, Restrictions on Certain Foreign Purchases 52.232-33, Payment by Electronic Funds Transfer-System for Award Management 52.242-5, Payments to Small Business Subcontractors

The following DFARS clauses and provisions are included but not limited to:

252.203-7000, Requirements Relating to Compensation of Former DoD Officials 252.203-7002, Requirement to Inform Employees of Whistleblower Rights 252.203-7005, Representation Relating to Compensation of Former DoD Officials 252.204-7003, Control of Government Personnel Work Product 252.204-7015, Notice of Authorized Disclosure of Information for Litigation Support 252.204-7017, Prohibition on the Acquisition of Covered Defense Telecommunications Equipment or Services—Representation 252.204-7018, Prohibition on the Acquisition of Covered Defense Telecommunications Equipment or Services 252.211-7003, Item Unique Identification and Valuation 252.223-7008, Prohibition of Hexavalent Chromium 252.225-7001, Buy American and Balance of Payments Program 252.225-7002, Qualifying Country Sources as Subcontractors 252.225-7048, Export-Controlled Items 252.226-7001, Utilization of Indian Organizations, Indian-owned Economic Enterprises, and Native Hawaiian Small Business Concerns 252.232-7003, Electronic Submission of Payment Requests and Receiving Reports 252.232-7006, Wide Area WorkFlow Payment Instructions 252.232-7010, Levies on Contract Payments 252.232-7017, Accelerating Payments to Small Business Subcontractors - Prohibition on Fees and Consideration 252.243-7001, Pricing of Contract Modifications 252.243-7002, Requests for Equitable Adjustment 252.244-7000, Subcontracts for Commercial Items 252.247-7023, Transportation of Supplies by Sea

LIST OF ATTACHMENTS

ATT# DESCRIPTION DATE # OF PAGES

1 SOW AFATS Upgrade 07 JUN 2022 35 2 Appendix A – Design Guideline 13 JUN 2022 193 3 Appendix C – Safety Specifications 13 JUN 2022 3 4 Appendix F – List of Obsolete Parts 13 JUN 2022 1 5 Appendix G – Unit Under Test 13 JUN 2022 1 6 Appendix H – Certification Test Plan 13 JUN 2022 15 7 Appendix I – Calibratable Items 13 JUN 2022 7 8 Appendix J – Reliability Centered Maintenance 13 JUN 2022 10 9 Appendix K – CDRL 001 and DiD 13 JUN 2022 3 10 Appendix L – CDRL 002 and DiD 13 JUN 2022 3 11 Question/Answer doc 01 Nov 2022 1

FANNING, ELIZABETH C GS-13 USAF AFMC AFSC/PZIMC

I am not sure where appendix B is at or if there is one please verify if one exists or not

Contractors are REQUIRED to return the portion of this CSS below with the completed information and authorized signature. Contractors may also provide their company’s quotation sheet in addition to this response page. Quotes must be FOB Destination only.

SECTION 1 – CONTRACTOR INFORMATION

Company Name Address

CAGE Code and UEI Number The Government cannot enter into contracts or agreements with contractors not registered in SAM. For registration information, visit the SAM website (https://www.sam.gov/) and follow the instructions in the Quick Start Guide For SAM Registration, which can be found under the Help Tab and User Guides submenu.

Small Business Size Web Page URL Point of Contact POC Phone # and email address

SECTION 2 – SUPPLIES/SERVICES AND PRICE

CLIN Description/Product Qty Unit Unit Price Total

0001 H3TC02 FY23 AFATS Test Stand Upgrade PDR docs, Draft Manuals/Drawings, Work Plan Drawings IAW the SOW 4.6.1, 5.1, 5.5 5.2

1 EA $ $

0002 IDR docs, Calibration Procedure, 50% Installation Plan, 50% Test Plan, 75% Manuals/ Drawings IAW the SOW 4.6.2, 3.5.8, 3.4, 4.7, 5.1, 5.5

1 EA

0003 100% Installation Plan, Calibration Procedure w/IDR changes implemented, Safety Analysis Report, CDR docs, 100% Test Plan, 90% Manuals/ Drawings IAW the SOW 3.4, 3.5.8, 4.5, 4.6.3, 4.7, 5.1, 5.5

1 EA

0004 Installation of the upgrade, Certification of Code Compliance, Validation and Verification, Health Checkup (RCM), Test Readiness Review (TRR), 100% Manuals/Drawings IAW the

SOW 3.1, 3.5.2, 3.5.3, 3.5.11, 3.5.9, 3.6.1, 4.7, 5.1, 5.5

1 EA

0005 Calibration, Training, Functional Testing, Correlation Testing IAW the SOW 3.5.8, 6, 4.8.1, 4.8.2

1 EA

0006 Final Acceptance Docs: Software Test Report, Correlation Test Report, Validation/Verification Report, Warranty documentation, Final Manual/As-Built Drawings IAW the

SOW 4.9, 4.8.1, 4.8.2, 3.5.9, 3.7, 5.3

1 EA

0007 Software Licenses/Source Code IAW the SOW 4.9 1 EA

TOTAL QUOTE AMOUNT: $

Payment Terms / Discount Terms

NET 30 / _______% In _______ Days After Invoice Submission in WAWF

An example of a payment discount would be 2.5% in 7 days, which means that although we have 30 days to pay you after submission of invoices, we would receive a 2.5% discount if we paid you within 7 days.

CONTRACTOR’S NOTES:

SECTION 3 – CERTIFICATION OF RESPONSE

NAME OF CONTRACTOR’S REPRESENTATIVE TITLE

SIGNATURE DATE

Contractor is required to sign this document and return 1 copy to issuing office. Contractor agrees to furnish and deliver all items set forth or otherwise identified above and on any additional sheets subject to the terms and conditions specified herein. Contractor is required to provide commercial product literature for all items quoted above as required/requested.

OC-ALC/76 CMXG/MXCPM DESIGN

STANDARDS AND GUIDELINES

OC-ALC/76 CMXG/MXCPM Design Standard

Section Subject

ELECTRICAL ELECTRICAL EQUIPMENT REQUIREMENTS

Rev 0, June 26, 2002 Page 1

TABLE OF CONTENTS

Section Page

1.0 SCOPE 3

2.0 CODES AND STANDARDS 3

3.0 ELECTRICAL EQUIPMENT 3

4.0 ELECTRICAL DESIGN REQUIREMENTS 8

5.0 ELECTRICAL CONSTRUCTION REQUIREMENTS 9

6.0 TESTING AND CHECKOUT 13

Rev 0, June 26, 2002 Page 2

REVISION RECORD APPROVAL SIGNATURES

REV. DATE STATUS REMARKS INITIATOR APPROVAL

0 06/29/02 Approved J. Lane J. Lane

1 07/03/02 Approved J. Kornele J. Lane

Rev 0, June 26, 2002 Page 3

1.0 SCOPE

1.1. This specification defines the minimum requirements for the design, materials, fabrication, testing, and preparation for shipment of electrical equipment and components and systems part of packaged equipment. This specification is to be used in conjunction with and supplementary to the mechanical equipment specification that describes the function, capacity and other requirements of the package. This specification does not cover specific requirements for motors, control panels, controllers, and lighting. If the specific proposed equipment contains these or higher voltage equipment, other standards or specifications should be referenced and included with the purchase documentation.

2.0 CODES AND STANDARDS

2.1. In addition to the requirements of this specification, the electrical construction and all equipment and materials of construction shall be in conformance with the latest requirements of the following:

2.1.1. NFPA 70, National Electrical Code (NEC)

2.1.2. NEMA Standards

2.1.3. Insulated Power Cable Engineers Association (IPCEA)

2.1.4. Institute of Electrical and Electronics Engineers (IEEE) Standards

2.1.5. Instrumentation, Systems and Automation Society (ISA)

2.1.6. American Petroleum Institute (API) Recommended Practices

2.1.7. Any Federal, State or Local Enforcing Authority

2.1.8. Where a conflict exists between any of the above codes or standards, the more stringent shall apply.

2.2. When listing is available, all equipment and materials of construction shall be listed for the intended service by Underwriters Laboratories, Inc. (UL), or other Nationally Recognized Testing Laboratory (NRTL) such as CSA, ETL, or FM.

3.0 ELECTRICAL EQUIPMENT

3.1. Material Criteria

3.1.1. Electrical equipment and wiring shall be suitable for the electrical area classification in which the equipment will be installed and the jobsite climatic conditions (see data sheet).

3.1.2. All material shall be new.

Rev 0, June 26, 2002 Page 4

3.1.3. Unless otherwise agreed the vendor shall select components for the package from approved manufacturers listed in a mutually acceptable equipment list.

3.1.4. Specific substitution of materials stated in this specification or data sheets shall be submitted to OC-ALC/76 CMXG/MXCPM for approval.

3.2. Conduit and Fittings

3.2.1. All aluminum conduit and fittings shall be copper free (0.4% max. copper) aluminum and shall be installed in a manner to be isolated from steel using appropriate non-corrosive materials.

3.2.2. PVC coated conduit shall have a minimum 40 mil thickness. All beam clamps and miscellaneous attachment hardware shall be PVC coated or otherwise designed to prevent damage to the PVC coating.

3.3. Conduit Bodies, Junction Boxes, and Terminals

3.3.1. All aluminum conduit outlet bodies shall be copper-free (0.4% max. copper) aluminum.

3.3.2. All junction/terminal boxes shall be sized to allow three inches around terminals.

3.3.3. An additional 25 % spare terminal space shall be provided for all terminal boxes. All terminal strips shall be mounted on aluminum backpans.

3.3.4. Terminal blocks shall be heavy duty type, rated for 600 volts AC.

3.3.5. All NEMA 4X boxes shall have 316 stainless steel hinged covers and hardware. A 1/4" weep hole shall be drilled in the bottom of all boxes to drain moisture accumulations.

3.4. Wiring

3.4.1. All grounding wires and grounding bonding jumpers shall have green insulation.

3.4.2. An equipment grounding conductor shall be installed in all conduits containing power wiring.

3.4.3. Wire and cable used for special vibration monitoring equipment (e.g. from detector to proximeter) shall be supplied by the vibration monitoring system manufacturer.

3.4.4. Multi-conductor cable for instrumentation circuits shall have conductors grouped, twisted, shielded, and be rated with an insulation level equal to or exceeding that specified by the equipment device manufacturer. Control and shutdown circuit conductors shall be equally rated, twisted, and shielded when specified.

3.4.5. Current transformer circuit leads shall be not less than #10 AWG, and terminated at short circuiting type terminal blocks.

3.4.6. Extra flexible wiring (increasing number of copper strands) shall be provided at door hinges or other locations where leads may be subject to flexing.

Rev 0, June 26, 2002 Page 5

3.4.7. All cable assemblies shall be capable of passing IEEE, standard 383, flame test.

3.4.8. Single pair instrument, control, alarm and shutdown wiring shall be colored black and white and enclosed in a neoprene or PVC overall jacket. Instrumentation wiring shall be twisted and shielded with drain wire. Control, alarm and shutdown wiring shall be twisted and shielded with drain wire when specified. Triad (three wires) wiring shall be colored black, white, and red, twisted, shielded with drain wire enclosed in a neoprene or PVC overall jacket. 600 volt rated cable for control, alarm and shutdown shall be colored red and black.

3.4.9. Multiple pair instrument, control, alarm, and shutdown wiring shall have each pair numbered.

3.5. Instrumentation Sensing Devices

3.5.1. All instruments used in process measurement (e.g. flow, pressure, differential, etc.) in hydrocarbon service shall be double barrier devices per article 501-5 f(3) of the NEC.

3.5.2. Instruments located in Class 1 Division 1 or Division 2 areas that require maintenance, calibration or adjustments that would expose energized parts shall be listed and installed utilizing the intrinsically safe methodology if possible.

3.5.3. Contractor shall comply with ANSI/ISA RP-12.6-95, Wiring Practices for Hazardous (Classified Locations) Part 1: Intrinsic Safety in the selection and installation of all intrinsically systems.

3.5.4. Indicating instruments shall be semi-flush mounted panel type with expanded scales

3.5.5. Pressure Transmitters

3.5.5.1. Pressure Range: Various, includes gauge, absolute and differential

3.5.5.2. Turndown: 200:1

3.5.5.3. Transmitter Output: 4 – 20 mA DC w/ HART protocol.

3.5.5.4. Construction: SST flange, 316L SST isolating diaphragm, TFE O-rings, silicon fill fluid, polyurethane-covered aluminum housing

3.5.5.5. Mounting: 2” Pipe

3.5.5.6. Accuracy: 0.04% or 0.075% of Span as required

3.5.5.7. Process connections: ¼” NPT

3.5.5.8. Approvals: FM Intrinsic Safe and Explosion Proof

3.5.5.9. Approved Mfgrs: Rosemount., Foxboro

3.5.6. Flow Meters

Rev 0, June 26, 2002 Page 6

3.5.6.1. Selection: Mass flow shall utilize the coriolis measurement principle. Volume flow meters may use coriolis, turbine, pitot tube orifice type meters.

3.5.6.2. Turndown: 100:1 for coriolis, 10:1 for all others.

3.5.6.3. Transmitter Outputs: 2 each 4 – 20 mA DC

HART or Profibus as specified 1 each Pulse output, 0-10 Khz, 24 VDC

3.5.6.4. Construction: Stainless Steel, elastomers shall be Teflon or Viton

3.5.6.5. Accuracy: 0.50% of rate or as specified by Technical Order specifications.

3.5.6.6. Approvals: Class I Divison 1 Group D, FM Intrinsic Safe or Explosion Proof

3.5.6.7. Approved Mfgrs: Mass Flow: Endress & Hauser. All other.

3.6. Contact Making Devices

3.6.1. Contacts for use in low energy circuits shall be gold plated or gold flashed and listed in the Manufacturer's catalog as suitable for dry circuit applications.

3.6.2. Contacts for use in control and instrument switches located outdoors shall be hermetically sealed, where available, to provide maximum protection against dust and corrosion and allow for use of Division 2 rated equipment.

3.7. Indicating Lights

3.7.1. Indicating lights shall be the heavy-duty, oil-tight, full voltage type.

3.8. Digital Displays

3.8.1. 4 – 20 mA input.

3.8.2. Loop powered with 5.2VDC maximum drop @ 20 mA.

3.8.3. 0.56” minimum digit size. Red LED readout preferred.

3.8.4. NEMA 4/4X rated, surface mount enclosure.

3.8.5. FM approval, Class I, II, III; Div 2, Groups A, B, C, D, F, G.

3.9. Control Panels

3.9.1. Control panels shall be designed and built according to UL 508A Outline of Investigation for Industrial Control Panels”

3.9.2. Enclosure

Rev 0, June 26, 2002 Page 7

3.9.2.1. Programmable Logic Controller (PLC) enclosure shall be a UL labeled, NEMA 4, painted steel enclosure for Class I Divion 2 Group D areas.

3.9.2.2. Enclosure bodies and doors shall be 14-gauge steel.

3.9.2.3. Paint shall be ANSI 61 gray polyester powder coating inside and out over phosphatized surfaces.

3.9.2.4. Seams shall be continuously welded and ground smooth, no holes or knockouts.

3.9.2.5. External mounting feet shall be supplied.

3.9.2.6. Collar studs shall be provided inside for mounting the backpan.

3.9.2.7. Enclosure door shall be grounded via a copper grounding-strap attached at one end to a stud on the enclosure door, and at the other end to the panel ground.

3.9.2.8. In order to exclude liquids and contaminants, construction shall include a rolled lip around three sides of the door and all sides of any enclosure opening.

3.9.2.9. An oil resistant door gasket attached with oil-resistant adhesive shall be held in place with steel retaining clips.

3.9.2.10. Twelve stainless steel door clamps shall be on three sides of the door in order to insure a watertight seal.

3.9.2.11. Removable door hinge shall be of stainless steel.

3.9.2.12. Hasp and staple shall be provided for padlocking.

3.9.2.13. A high-impact, thermoplastic data pocket shall be included on the inside surface of the door.

3.9.3. Terminals

3.9.3.1. Modular, single level, 6 mm wide, compression clamp-style.

3.9.3.2. 600 VAC, 30 A.

3.9.3.3. 35 mm, DIN rail-mount.

3.9.3.4. Rated to accept #22 to #10 AWG wire.

3.9.3.5. UL recognized.

3.9.3.6. Colors

3.9.3.6.1. Circuit terminals: Gray.

3.9.3.6.2. Grounding blocks: Green/Yellow.

Rev 0, June 26, 2002 Page 8

3.9.4. Appropriate hardware and accessories, such as end plates, jumpers, and end clamps, shall be provided, as required, to make a complete system.

3.10. Intrinsic Safety Barriers

3.10.1. Intrinsic safety barriers shall provide galvanic isolation. Zener diode barriers are unacceptable.

3.10.2. All intrinsic safety barriers shall be DIN rail mountable.

3.10.3. When integrating the intrinsic safety barriers into the control panel, the Contractor shall follow all the manufactures recommended installation procedures. Utmost care must be taken to separate intrinsically safe wiring from other wiring.

3.10.4. Approved manufacturers

3.10.4.1. Pepperl+Fuchs

3.10.4.2. Phoenix Contact

3.10.4.3. Entrelec

3.11. Isolators

3.11.1. Optical Isolators shall be provided between the PLC system and the computer.

3.11.2. Optical isolators shall:

3.11.2.1. Provide 2500 V isolation between inputs and outputs

3.11.2.2. Consist of a DIN rail mountable, terminal block-style socket base and a pluggable optical coupler module.

3.11.2.3. The pluggable optical coupler module shall be available separately.

4.0 ELECTRICAL DESIGN REQUIREMENTS

4.1. Early in the design phase plot plans and section views of the facility shall be marked with the proposed electrical area classification. For enclosed locations with mechanical ventilation systems, the electrical area classification around air intakes and exhausts shall identified on the plot plans and section views. The marked plot plan and any supporting data shall be submitted to OC-ALC/76 CMXG/MXCPM for approval per the project documentation requirements.

4.2. The electrical area classification shall be based on the latest edition of NFPA 70.

4.3. A table shall be provided that lists all flammable and combustible gases, vapors, and liquids that may be present. The group, auto-ignition temperature, and the NEC temperature identification number shall be shown in the table.

Rev 0, June 26, 2002 Page 9

4.4. Control and electrical rooms should normally be located in unclassified locations.

4.5. Existing electrical area classification drawings shall be reviewed and revised as necessary whenever modifications or new additions to a facility are made.

4.6. Control, alarm and shutdown circuits shall be fail-safe. The sensing or output device will be de-energized on loss of control power or open circuit which should provide a safe mode of failure.

4.7. Electrical devices shall be selected on the basis that a momentary voltage fluctuation up to 20% of nominal operating voltage shall not cause the equipment to shutdown unless otherwise specified.

4.8. Suitable circuit protection shall be supplied for controls so that any one electrical fault does not affect more than one unit or system.

4.9. A disconnecting means shall be provided to permit servicing of individual systems or control components.

4.10. Elementary and wiring diagrams shall be furnished for all control circuits. Elementaries shall be drawn in the form of ladder diagrams with line numbers marked for each rung of the ladder. Relay contact usage shall be indicated in the margin adjacent to the relay coils with the line number where the contact appears (NC contact identified by underlining of line number). A unique wire number for wiring between all devices shall be assigned and identified on the drawings.

5.0 ELECTRICAL CONSTRUCTION REQUIREMENTS

5.1. Aluminum Mounting

5.1.1. Aluminum shall not be fastened directly to steel or other dissimilar metal.

5.1.2. In locations (i.e., gulf coast, cooling towers, etc.) requiring aluminum to reduce corrosion problems, aluminum boxes and bodies shall be isolated using insulating standoffs or 1/8 in.

thick PVC sheet between the aluminum and the steel. They shall be fastened using 316 stainless steel bolts and nuts with insulating washers.

5.2. Conduit Systems

5.2.1. Threaded joints on conduit shall have at least five full threads engaged.

5.2.2. All threaded connections on conduit, fittings, boxes, and box covers shall be treated with a thread lubricant suitable for maintaining a conductive path between the various components and shall be suitable for the application.

5.2.3. Devices requiring replacement or removal for maintenance shall have a union located at the device. If a seal is required, the union shall be installed between the device and the seal, unless the device has pigtails, in which case the seal shall be installed between the device and the union.

Rev 0, June 26, 2002 Page 10

5.2.4. Conduit drains or drain seals shall be installed at each low point where moisture is likely to collect.

5.2.5. Conduits shall only be installed in the sides or bottom of all boxes in outdoor areas subject to moisture or condensation.

5.2.6. All grounding connectors shall be bonded together with bonding jumpers.

5.2.7. All PVC coated conduit shall be made up with a strap wrench. All damaged areas of the coating shall be repaired according to manufacturer's guidelines.

5.2.8. Conduits shall be grounded with grounding bushings in electrical areas that are classified as hazardous.

5.3. Grounding

5.3.1. The enclosure backpan shall include a grounding-stud.

5.3.2. The enclosure door shall be bonded to the backpan grounding-stud.

5.3.3. An isolated grounding bar shall be included on each panel.

5.3.4. The equipment grounding terminal of each device shall be bonded with a green wire, routed to an isolated grounding bar.

5.3.5. Equipment grounding conductors shall not jump from device to device, but shall be individually routed to the isolated ground bar.

5.3.6. The isolated grounding bar shall be bonded with one green wire, routed to the panel ground stud.

5.3.7. Analog signal connections to the pressure transmitter and to the digital display shall be isolated via intrinsically safe barriers.

5.4. Seals

5.4.1. All electrical seals shall be installed with the pouring compound and other materials manufactured by the same seal manufacturer. Conduit seals shall be installed as required but not filled with sealing compound before final equipment inspection and approval by OC- ALC/76 CMXG/MXCPM. Seals in vertical conduits that are longer than 4 ft shall be of the drain type.

5.5. Wiring

5.5.1. Where shielded instrumentation and thermocouple extension wire is provided by vendor, the drain wires shall be terminated on separate terminals adjacent to the signal terminals.

The drain wire terminals shall not be grounded. Drain wire will be grounded at other end of cable by others. Shielding for signal wires shall be maintained as close as practical to terminal connections. The shield shall be continuous from end to end. The shielding shall

Rev 0, June 26, 2002 Page 11 be grounded only at the power supply end unless recommended otherwise by the manufacturer. The ungrounded end shall be insulated with tape.

5.5.2. Except for lighting circuits, all wiring shall be run in continuous lengths from point of origin to destination. Any splices or taps shall be approved by OC-ALC/76 CMXG/MXCPM both as to type and location.

5.5.3. Splices in conductors of lighting circuits shall be made with connectors such as Scotchlok type "Y, R, G, and B".

5.5.4. For termination of devices with leads, splices shall only be made with insulated, compression type butt connectors with OC-ALC/76 CMXG/MXCPM's approval only.

5.5.5. Each cable shall be tagged with the cable number using a laminated, engraved phenolic tag (black lettering on white background) fastened to the cable with a plastic cable tie at each end.

5.5.6. Minimum size for signal wires shall be #18 AWG. All signal wiring shall be properly shielded and grounded.

5.5.7. Minimum size for power conductors shall #14 AWG except where the equipment manufacturer requires a smaller wire gauge.

5.5.8. Wire shall be UL listed. MTW wire shall be used for control panel wiring and THHN shall be used for general power wiring.

5.6. Color Coding

5.6.1. Power Wiring

5.6.1.1. AC Single Phase

5.6.1.1.1. Hot Black

5.6.1.1.2. Neutral White

5.6.1.1.3. Ground Green

5.6.1.2. DC

5.6.1.2.1. Positive Blue

5.6.1.2.2. Negative Yellow

5.6.1.2.3. Ground Green

5.6.1.3. Discrete Signal Wiring

5.6.1.3.1. AC switched Brown

Rev 0, June 26, 2002 Page 12

5.6.1.3.2. DC switched Red

5.6.1.4. Analog Signal Wiring

5.6.1.4.1. Analog (+) Purple

5.6.1.4.2. Analog (-) Gray

5.7. Wire markers

5.7.1. White, shrink-on type.

5.7.2. Characters shall be machine applied, not handwritten.

5.7.3. Raychem “Shrinkmark” or Tyton “Shrink Tag” or equal.

5.8. Wireway

5.8.1. All panel wiring shall be routed in slotted, PVC, wire duct.

5.8.2. All duct will be the same color, either white or gray,

5.8.3. All duct shall be supplied with matching cover.

5.9. Panels

5.9.1. Panels shall be assembled according to UL508A.

5.9.2. Equipment mounting:

5.9.2.1. All equipment mounted inside the enclosure shall be mounted on the enclosure backpan, not onto the enclosure itself.

5.9.2.2. The backpan will be drilled and tapped only. Through-holes with nuts on the back of backpan are unacceptable.

5.9.2.3. Self-tapping screws are unacceptable.

5.9.2.4. All wire will be routed in wireway.

5.9.2.5. AC and DC wiring will be segregated as much as possible and where they must cross shall do so at 90 degree angles.

5.9.2.6. Each end of every wire shall be permanently marked with the destination of the other end of the wire.

5.9.2.7. All wire labels shall be completely shrunk down prior to shipment from the manufacturer’s facility.

5.9.3. Installation of wiring devices:

Rev 0, June 26, 2002 Page 13

5.9.4. Wire ferrules, fork terminals, or ring terminals shall be used at each and every wire end.

5.9.5. The wiring devices shall be fully crimped with the tool recommended by the manufacturer of the device.

5.9.6. Only one wire shall be crimped into each device, unless that device is specifically designed for more than one wire.

5.9.7. Only one wire will be permitted per device terminal, unless that terminal is specifically designed to accept more than one wire.

6.0 TESTING AND CHECKOUT

6.1. The Government shall have the option to witness any and all testing, both at the Contractor’s facility and on-site. The Government POC shall be notified at least 48 hours prior to testing.

6.2. All panels and general wiring shall be thoroughly tested at the manufacturer’s facility, and documentation shall be provided to show that the testing was completed. The testing documentation shall bear the following information:

6.2.1. Description of the test

6.2.2. Equipment identification number

6.2.3. Equipment Service

6.2.4. Equipment model number.

6.2.5. Equipment manufacturer

6.2.6. Drawing Number

6.2.7. Test Date

6.2.8. Initials of the tester.

6.3. The manufacturer’s testing for PLC installations shall include:

6.3.1. Verifying all digital inputs from the field terminal blocks via the PLC processor’s input table

6.3.2. Verifying all digital outputs from the field terminal blocks via the PLC processor’s force table

6.3.3. Checking zero, span, and midrange of all analog inputs from the field terminal blocks via the PLC processor’s input table.

6.3.4. Checking zero, span, and midrange of all analog outputs from the field terminal blocks via the PLC processor’s output table.

Rev 0, June 26, 2002 Page 14

6.4. General Wiring

6.4.1. All system circuit wiring resistance to be tested phase to phase prior to hook-up. Megger voltages shall be at least the nominal working voltage of the system. Resistance readings shall be provided to the Government for approval.

6.4.2. All system circuit wiring to be tested phase to ground minimum resistance prior to hook

up. Megger voltages shall be at least the nominal working voltage of the system. Resistance readings shall be provided to the Government for approval.

VESSELS AND TANKS PRESSURE VESSELS -GENERAL

REQUIREMENTS

SECTION PAGE

1.0 SCOPE

2.0 CODE AND STANDARDS REQUIREMENTS

3.0 DESIGN AND CONSTRUCTION

4.0 NAME PLATES

5.0 INSPECTION AND TESTING

6.0 PREPARATION FOR SHIPMENT

7.0 VENDOR DATA REQUIREMENTS

8.0 VENDOR DATA MATRIX

0 06/26/02 Approved J. Lane J. Lane

1.1 The purpose of this specification is to cover the general design, fabrication, testing, and preparation for shipment of carbon steel pressure vessels operating at or above 15 psig in accordance with the ASME Boiler and Pressure Vessel Code Section VIII, Division 1 (the Code).

1.2 This general specification, combined with specific equipment specifications, data sheets, and supplementary specifications is appropriate for use in specifying production separators, scrubbers, freewater knockouts, filters, emulsions treaters, dehydration contactors and regenerators, pulsation bottles, etc. In case of conflict between documents, notify GOVERNMENT and clarification will be issued.

1.3 If Jurisdictional Rules require approval and/or inspection of vessels, drawings or calculations, the Vendor shall obtain any such approval and include the documentation noted in Section 8.0, Vendor Data Matrix.

2.0 CODE AND STANDARDS REQUIREMENTS

2.1 The vessels shall be designed, fabricated, tested, and stamped in accordance with the Code. The vessel shall be designed to withstand the loadings exerted by internal or external pressure, weight of the vessel and its contents, wind, earthquake, reaction of supports, and when specified, loads imposed by connecting piping. Derivation and application of earthquake load shall be as directed in the Uniform Building Code (UBC). Other loads, such as wind and roof live load, shall be derived and applied according to ANSI/ASCE 7-88, "Minimum Design Loads for Building and Other Structures", unless a) compliance with local building codes is required, and b) the local codes require use of UBC for all loads. Local codes shall always be considered, however, since there may be some required modifications to the methods described in either the UBC or ASCE 7-88, based on local conditions.

The design shall also be adequate for transportation and erection loads.

2.2 The vessels, and all accessories, shall comply with applicable OSHA, state, or local regulations.

Caged ladders, or acceptable safety slide devices, shall be provided when climbing height exceeds 20 ft.

2.3 The vessel shall be registered with the National Board of Boiler and Pressure Vessel Inspectors when specified.

2.4 Any piping provided beyond the vessel limits shall be designed and fabricated per ANSI B31.3 Chemical Plant and Petroleum Refinery Piping, unless otherwise specified.

3.0 DESIGN AND CONSTRUCTION

3.1 General

3.1.1 The pressure limiting component shall be identified on Vendor's drawings.

3.1.2 The minimum thickness of shells and heads shall be 1/4 in.

3.1.3 Internals shall have a minimum thickness of 1/4 in. Attachment of internals to the vessel shall be made by a full fillet weld with a minimum leg size of 1/4 in. Internals shall be constructed of a material compatible with the vessel shell.

3.2 Welding Procedures

3.2.1 Vendor shall prepare and qualify Welding Procedure Specifications (WPS) in accordance with the ASME Code, Section IX, which shall be available to and followed by all welders.

3.2.2 Copies of all applicable welding procedure specifications, procedure qualification records, and welder performance qualification tests specified in the Vendor Data Matrix, shall be submitted for approval prior to start of fabrication.

3.2.3 The Vendor will be responsible to be certain that the Essential Variables specified on the WPS are followed during production welding. Variables which will affect weld and heat affected zone (HAZ) hardness include, but are not limited to: ambient temperature, preheat temperature, interpass temperature, travel speed, total heat input, post weld heat treat, etc. When specified in the Vendor Data Matrix, the Vendor shall maintain records of these essential variables during production welding. Any such records shall become a part of Vendor's pressure vessel file.

3.3 Connections

3.3.1 Nozzles NPS 3 and larger shall be flanged. Connections NPS 1½ and smaller shall be threaded. Nozzles NPS 2 shall be flanged or threaded as specified on the data sheet. Flanged nozzles shall utilize weld neck or long weld neck flanges or H-neck forgings. When threaded connections are used for process inlets or outlets, relief valves, or are subject to external loading, they shall be made with 3000# full couplings. On vessels not in vibrating service, 3000# thredolets may be used for instrument connections or drains not subject to external loading. 3000# half couplings may be used when shorter nozzles are required for instruments. Special nozzle connections are to be used when indicated on the data sheet.

3.3.2 Pipe wall thickness for nozzles and extensions shall be at least extra-strong (XS).

3.3.3 Unless noted otherwise on the data sheet, flanges rated ANSI Class 600 and lower shall be raised face, and flanges rated ANSI Class 900 and higher shall be ring type joint.

3.3.4 Flanged nozzles, manways, and inspection ports shall extend at least 6 in. from the shell to the face of the flange. Full couplings for threaded connections shall extend at least half coupling length outside the shell. For insulated vessels, these minimum nozzle extensions shall be increased by the thickness of the insulation and the protective covering.

3.3.5 Stud bolt lengths shall be per ANSI B16.5 where applicable. In other cases, stud lengths shall be such that the last thread on all nuts is engaged and the studs do not extend more than 1/4

in. beyond the nuts.

3.3.6 The use of elbows connected directly to the vessel should be avoided. When used, weld elbows shall be long radius.

3.3.7 A drain shall be provided for each compartment of the vessel. Drains shall be at least NPS 2 unless otherwise specified or approved by GOVERNMENT.

3.3.8 When specified on the data sheet, vortex breakers shall be furnished on all liquid outlets except siphon type outlets.

3.3.9 Nozzles entering the bottom of vertical vessels shall be avoided. When nozzles must enter the bottom, they shall be piped at least 6 in. beyond the skirt with butt weld seamless pipe and fittings.

3.3.10 Vessels specified to be in corrosive service shall be provided with inspection openings as required by the Code paragraph UG46 or as specified on the data sheet. Inspection openings or manways may also be specified on the data sheet for vessels in non-corrosive service. Lifting aids shall be furnished with each manway or inspection opening cover as follows:

Cover Weight Lifting Aid Example (lbs) >87 Davit NPS 16 Class 150

Blind Flange 30 thru 87 Two Handles NPS 6 Class 600

15 to 30 One Handle NPS 6 Class 150

<15 No Aid Required 8" x 10" Oblong

Plate 3/4" Thick

3.3.11 Flange bolt holes shall straddle horizontal and vertical centerlines.

3.3.12 All flanged connections (other than H-neck forgings) on pressure vessels specified to be in vibrating services shall have mechanical reinforcement in the form of weld pads. The cross sectional area of the reinforcing pad [ A5 per Code Figure UG-37.1] shall be at least equal to the total cross sectional area of reinforcement required [ A ]. (Extra thickness in vessel wall [ A1 ], extra thickness in nozzle [ A2 ], internal nozzle projection [ A3 ], internal welds [ A43 ] and external welds [ A41 ] shall not be included as available for reinforcement.)

3.3.13 Nozzles for instruments which require fixed center dimensions shall be set with jigs.

3.4 Attachments

3.4.1 Where required for structural integrity, vessels shall have distribution pads under lifting lugs. Lifting lugs on insulated vessels shall project far enough for shackles to clear the insulation and protective covering.

3.4.2 Reinforcements, saddles, and lifting lugs forming closed areas on the vessel external surface shall have at least one NPS ¼ threaded vent hole. Longitudinal seams shall be located to clear openings, their reinforcing pads, and saddle wear plates. Circumferential seams of shell shall be located to clear openings, their reinforcing pads, tray and insulation support rings, and saddle wear plates. When the covering of circumferential seam by reinforcing pad is unavoidable, the seam shall be ground flush and examined prior to welding the reinforcing pad in place.

3.4.3 Vertical vessels shall be provided with skirts with minimum thickness of ¼ in. Skirts 4

ft. in diameter and less shall have at least one access opening at least 4 in. ID. Skirts larger than 4

ft. shall have two 18 in. OD access openings. Two vents shall be provided in the upper part of the skirt. All skirt openings shall be reinforced. Pipe penetrating skirt openings shall have a 1 in.

annular space between the pipe and the opening reinforcement. The base ring shall be continuously welded to the skirt.

3.4.4 When specified, horizontal vessel saddles shall be provided with a minimum ¼ in. thick wear plate continuously welded to the shell.

3.4.5 Unless the vessel is specified to be welded to a deck or skid, the skirt or saddles shall have holes for anchor bolts. Anchor bolt holes shall be at least 7/8 in. in diameter.

3.4.6 Ladders, platforms, walkways and other external attachments shall be supported by the vessels with welded tabs. On insulated vessels, the tabs shall extend far enough to allow insertion and make-up of bolts and nuts without damaging the insulation or protective covering.

3.5 Materials of Construction

3.5.1 All material used in fabrication shall comply with the material requirements of the Code. Materials with specified minimum tensile strength over 70,000 psi shall not be used unless the Vendor justifies in writing as an option in his quotation that the higher strength materials are suitable for the specific service environment and application and GOVERNMENT approves that justification by accepting the option for higher strength materials in the purchase order.

3.5.2 All materials of construction shall meet the requirements of the Code paragraphs UCS 66 and 67, for the specified minimum design metal temperature and coincident pressure.

3.5.3 All pipe and pipe fittings shall be seamless.

3.5.4 Metallurgy of non-pressure containing attachments and associated weld filler metal shall be compatible with shell and head materials to which attached.

3.5.5 Platforms, ladders, and walkways shall be open steel serrated bar grating. When specified, they shall be hot dip galvanized.

3.6 Construction

3.6.1 Backing strips or rings shall not be used.

3.6.2 Nozzles, manways, and inspection ports shall be installed by inserting the neck of the flange, the coupling, or the pipe nipple through the vessel wall and welding with full penetration welds. Internal joints and projections shall be ground smooth or to a radius to minimize flow resistance. Reinforcements shall be attached at the nozzle with full penetration welds. Fillet groove welds for thredolets shall have weld thickness tw of at least 1/4 in. and at least as thick as schedule 160 pipe [see Code UW-16(f)(4)]. The weld shall have a concave surface to blend smoothly between the vessel wall and the thredolet.

3.6.3 Welded internal or external attachments, except insulation support rings, shall be attached with continuous fillet seal welds. Insulation support rings may be skip welded. Lifting lugs and tabs for ladders and platforms shall not be welded over vessel seams. All attachments shall be welded to the vessel prior to post weld heat treatment (PWHT) if required, pressure testing, and internal coating.

3.6.4 Sharp edges on internal and external surfaces shall be removed by grinding to reduce risk of personal injury during fabrication, handling, and inspection. Additional grinding and special fabrication requirements for vessels to be internally coated shall be per the referenced supplementary specification.

3.6.5 Threaded openings shall be re-tapped prior to pressure testing.

3.6.6 Nozzles shall be located from the base line and the centerline of the vessel within the following tolerances:

• Distance from base line to nozzle centerline: + 1/8 in..

• Angular rotation of nozzle centerline around centerline of vessel: + 1/8 in..

• Projection of nozzle face from vessel centerline: + 1/8 in..

These tolerances may be exceeded on large vessels (> 48 in. diameter) with GOVERNMENT approval.

3.6.7 Alignment of flange faces and ends of couplings used for nozzles shall be checked by placing a straight edge across the nozzle. They shall not deviate more than 1/16 in. per ft from planes parallel or perpendicular to the centerline of the vessel.

4.0 NAME PLATES

4.1 The markings required by the Code are to be provided and in addition, the nameplate shall include GOVERNMENT's purchase order number, equipment tag number, diameter, seam-to-seam length, the date tested, National Board registration number (when required), Testing Authority (if applicable), the manufacturer's name and the manufacturer's serial number.

4.2 The nameplates are…