Attach-1_11354-13-001A_CS_Cooler_Bundle_Spec-New.pdf

11354-13-001A NOT SENSITIVE

Specification No. 11354-13-001A 11 February 2014

EQUIPMENT SPECIFICATION

FOR

TUBE BUNDLES

ARNOLD ENGINEERING DEVELOPMENT COMPLEX

ARNOLD AIR FORCE BASE, TN 37389

NOT SENSITIVE

Attachment #1

Attachment #1

Table of Contents-1

TABLE OF CONTENTS

1. Scope

1.1 Summary

1.2 Item Description

2. Applicable Documents

2.1 Government Documents

2.2 Non-Government Documents

3. Requirements

3.1 General

3.2 Characteristics

3.3 Workmanship

3.4 Testing

3.5 Submittals

4. Verification

4.1 Post-Delivery Inspection and Testing

4.2 Acceptance

5. Packaging

5.1 Shipping Packaging

5.2 Responsibility

6. Notes

Appendix A – Submittal Procedure

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1 SCOPE

1.1 Summary: This specification is for the manufacture, verification and delivery of 5 tube bundles for the E1 and E2 surface coolers at Arnold Engineering Development Complex, Arnold AFB, TN. The Government will install the bundles.

This specification establishes build to print dimensional requirements for the tube bundles. The bundles are to be identical in height, overall length, depth and structure to the existing tube bundle configuration.

1.2 Item Description: The bundles are used to cool and dehumidify exhaust gases from turbine (jet) engine test facilities. The tube bundles will be installed for horizontal airflow with raw (tower, lake, pond) water flowing through the tubes in the assembly.

2 APPLICABLE DOCUMENTS

2.1 Government Documents:

2.1.1 Reference Drawings:

A. TUL-4316, USACE, General Arrangement of Gas Cooler-Plan View.

B. TUL-4317, USACE, General Arrangement of Gas Cooler-Side Elevation.

C. TUL-4318, USACE, General Arrangement Sections B-B, C-C, and D-D.

D. TUL-4319, USACE, Arrangement of Tube Bundle.

E. TUL-4320, USACE, Details of Waterbox.

F. TUL-4321, USACE, Details of Tube and Tube Sheets.

G. TUL-4322, USAGE, Details of Hanger and Support Pipe.

2.2 Non-Government Documents:

2.2.1 American Welding Society:

A. AWS D1.1-10 Structural Welding Code – Steel.

3 REQUIREMENTS

3.1 General:

3.1.1 Tube bundles and related components shall be fabricated and shipped to AEDC in accordance with Section 2 Applicable Documents.

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3.1.2 References in the specification to equipment, material, articles, or patented processes by trade name, make or catalog number, shall be regarded as establishing a standard of quality and shall not be construed as limiting competition.

3.1.3 Dimensional: The tube bundles shall conform to the dimensions given in the listed reference drawings.

3.2 Characteristics:

3.2.1 The Contractor shall fabricate and assemble the tube bundle to match the existing dimensions and materials in accordance with drawings TUL-4316, TUL- 4317, TUL-4318, TUL-4319, TUL-4320, TUL-4321, and TUL-4322.

3.2.2 Base Materials of Construction Coils:

A. Tubes: Admiralty Brass 443, 1-inch outside diameter by 0.049-inch wall.

B. Headers: Carbon steel (See drawing for grade)

C. Joints: Rolled

D. Casings: Steel pipe hangers and supports to fit existing unit. See drawings for grade.

E. Connections: 8-inch lap joint flanges to match existing connection locations.

F. Vents & Drains: Each coil shall have 1-1/4 inch half coupling vent and drain.

G. Supports: As required for length and weight.

H. Tubesheets: 1-1/2-inch carbon steel (See drawing for grade)

I. Waterboxes: Carbon steel epoxy coated on the inside.

3.2.3 Cleaning: After fabrication, tube bundles shall be cleaned both internally and externally to remove flux and other debris. After internal cleaning, the bundles shall be flushed and dried.

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3.3 Workmanship: Machine finished surfaces, particularly seal surfaces such as flange faces, shall be free of burrs, scratches, and sharp edges. All components shall be free from dirt and defects.

3.4 Testing:

3.4.1 The Government reserves the right to visit the Contractor and manufacturer facilities to assess manufacturing capability, readiness and/or progress or to witness the hydrostatic test of the tube bundles. The Contractor shall give a minimum notice of 10 working days to the Government to witness factory testing.

3.4.2 Testing Responsibilities: The Contractor shall be responsible for all testing of the tube bundles prior to delivery, under water with 250 psig clean air. Final results shall indicate no leaks are present. Manufacturer shall supply all interfacing equipment needed to conduct the tests.

3.4.3 The Contractor shall supply all hardware required to perform the hydrostatic test.

This includes the equipment need to produce the pressure, the hydraulic media (municipal water is acceptable), as well as any custom fixtures required to pressurize the tube side of the bundle.

3.4.4 The Contractor shall modify tube bundles as needed, if factory tests are unsatisfactory, and repeat all tests until bundles meet test requirements.

3.4.5 The Contractor shall submit all test reports signed by personnel conducting the test and those approving the results. Do not ship bundles until test reports have been approved by Contracting Officer.

3.5 Submittals: The Contractor shall submit all documentation in accordance with

Appendix A – Submittal Procedure. A summary table of required submittals is listed in Table 1 – Required Submittal List.

3.5.1 As-built drawings: The Contractor shall red-line drawings TUL-4316, TUL-4317, TUL-4318, TUL-4319, TUL-4320, TUL-4321, and TUL-4322 to reflect the as-built condition of the bundles by the Contractor. Include the weight of the bundles and lifting points on the as-built drawing TUL-4319. The final drawings with red-line markups shall be supplied to the Contracting Officer upon delivery of the bundles to AEDC.

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3.5.2 Welding Procedures, Qualifications: Submit Welding Procedures and Welding Qualification Test Reports to the Contracting Officer as follows:

A. Welders, welding operators, and welding procedures shall be in

Accordance with AWS D1.1. The procedures shall identify the complete method of welding to prevent degradation of the components.

B. The Welding Procedure Qualification Test Report provides the data required to establish whether or not the Contractor can produce acceptable welds which meet the destructive and non-destructive test requirements for the base metals, filler metals and welding procedures involved. Welding Procedures and Qualification Test Reports shall contain the signature of the Contractor’s Quality Control Officer, report number and date.

3.5.3 Materials Certification: The Contractor shall supply all material certification for the materials used in the construction of the tube bundle assembly prior to shipment to AEDC.

3.5.4 Manufacturing Plan and Schedule with Milestones: At a minimum the plan and schedule shall include:

A. Intended test dates.

B. Ship date.

3.5.5 Warranty: The Contractor shall provide a minimum one year warranty (or manufacturer’s standard warranty) for each tube bundle to commence upon installation by Government, but not later than 60 days after delivery and Government acceptance of the coils. The warranty shall cover all repairs to the tube bundles due to defects in manufacturing or workmanship. The Contractor may reserve the right to observe installation. The Government will notify Contractor at least two weeks prior to installation.

3.5.6 Submittal Table:

Table 1 - Required Submittal List

No. Section Reference Submittal Description Due

1 3.4.1 Factory hydrostatic test date 10 working days prior to test 2 3.4.5 Certified test results and data Before shipping bundles

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No. Section Reference Submittal Description Due

3 3.5.1 As-built drawings Upon delivery to AEDC 4 3.5.2 Welding Procedures &

Qualification Prior to fabrication and welding 5 3.5.3 Materials Certification Prior to Shipment to AEDC 6 3.5.4 Manufacturing plan and schedule with milestones 2 weeks following contract award 7 3.5.5 Warranty To begin after acceptance by

AEDC

8 Appendix A Detailed list of submittals with committed dates of completion 10 business days after award

4 VERIFICATION

4.1 Post-Delivery Inspection and Testing: Upon receipt at AEDC the Government will inspect the tube bundles and all related components and equipment for any visible damage, general cleanliness, craftsmanship, and adherence to final drawings. All tube bundles found to leak on delivery will be rejected and will be repaired by the Contractor and subsequently re-tested until no leaks are found.

4.2 Acceptance: The Government will accept the assemblies, upon successful tests, within 60 days of delivery to AEDC.

5 PACKAGING

5.1 Shipping: The Contractor shall provide all preservation, packaging, and packing to ensure safe delivery of the tube bundle to AEDC. Tube bundles shall be supplied in a dry condition with a nitrogen pad of 3 psig. It shall be packaged and tagged in a manner that will protect the equipment from damage and facilitate the installation in the field. Machined and unpainted parts shall be protected from damage by the elements with the application of a strippable protective coating.

5.2 Responsibility: The Contractor shall be responsible for delivery of the tube bundle assemblies to AEDC.

6 NOTES - Not Applicable

Appendix A-1

APPENDIX A

SUBMITTAL PROCEDURE

PART 1 GENERAL

1.1 DESCRIPTION OF REQUIREMENTS. This section specifies procedural requirements for non-administrative submittals, including but not limited to product data, manufacturer’s certificate, design data, calculations, and verifications, manufacturer’s instructions, operation and maintenance manuals, and other miscellaneous work-related submittals. These submittals are required to amplify, expand, and coordinate other information contained in the contract.

Non-work-related submittals are addressed elsewhere in the contract rather than in the specification and may include items such as: contract progress schedule, permits, payment applications, performance and payment bonds, insurance certificates, and progress reports.

The Contracting Officer may request submittals in addition to those specified when deemed necessary to adequately describe the work covered in the respective sections of the specification or statement of work.

1.2 SUBMITTAL PROCEDURE

A. Definition: For the purposes of this section, the term “Contractor” denotes the prime contractor.

B. Listing: At the end of the Specification is a summarized listing of item submittals requiring approval for the work. The listing is included for the convenience of users of the contract documents. The listing may not be all inclusive and additional item submittals may be required. Within 10 days after receiving contract award, Contractor shall submit a copy of the summarized submittal listing with calendar dates assigned to each item submittal indicating when submittal will be received by the Government. If contract requires a pre-construction conference, Contractor may submit completed submittal listing at the conference.

C. Risk: Do not proceed with the part of the work covered by an item submittal including purchasing, fabricating, and delivering until approval is received. Machinery, equipment, material, and articles that do not have the required approval shall be installed or used at the risk of subsequent rejection. Any fabrication or other work performed in advance of the receipt of accepted item submittals and approvals shall be entirely at the Contractor’s risk and expense.

D. Transmittal Timing: Coordinate the preparation and processing of item submittals with the performance of the work. Prepare and transmit each item submittal to the Contracting Officer sufficiently in advance of the

Appendix A-2 performance of related work and other applicable activities. Transmit related item submittals for the same unit of work so that processing will not be delayed by the Government's need to review submittals concurrently for coordination. No delay damages or time extensions will be allowed for time lost in late submittals.

E. Content: Each submittal shall be complete and in sufficient detail to allow ready determination of compliance with contract requirements. Complete AF Form 3000 and attach as cover sheet for each submittal. Contractor may include multiple item numbers on an AF Form 3000.

F. Language: All item submittals shall be written in English, including documents, notes on drawings, sketches, and/or samples, calculations, manuals, and all other instances of written text and communication.

G. Units: All item submittals shall be marked or show dimensions and values in the same units as specified in the contract documents.

H. Review Time: Allow sufficient time so that contract performance will not be delayed as a result of the time required to properly process submittals, including time for re-submittals, if necessary. Allow 10 working days for initial Government processing of each submittal. No extension of time will be authorized because of the Contractor's failure to transmit submittals to the Government sufficiently in advance of the work.

I. Contractor Certification: All submittals shall be carefully reviewed by an authorized representative of the Contractor prior to submission to the Government. Each submittal shall be dated, signed, and certified by the Contractor as being correct and in strict conformance with the contract documents. No consideration for review by the Government of any Contractor’s submittal will be made for any items which have not been so certified by the Contractor. All noncertified submittals will be returned to the Contractor without action taken by the Government, and any delays caused thereby shall be the total responsibility of the Contractor.

J. Deviations: Should any item submittals required by the contract documents show deviations from the contract requirement, the Contractor shall make specific mention of such deviations in the letter of transmittal, including stating cost effects, and product and system limitations which may adversely affect the work, in order that if acceptable, suitable action may be taken for proper adjustment of the contract; otherwise the Contractor will not be relieved of the responsibility for executing the work in accordance with the contract documents and the approved submittals.

Contractor shall clearly mark the proposed variation in all documentation and specifically point out deviations from contract requirements in transmittal letters. Failure to point out deviations may result in the Government requiring rejection and removal of such work at no additional

Appendix A-3 cost to the Government. Deviations from contract requirements require Government approval and will only be considered when advantageous to the Government. When proposing deviations, deliver written request to the Contracting Officer, with documentation of the nature and features of the deviation and why the deviation is desirable and beneficial to the Government. If lower cost is a benefit, include an estimate of the cost savings. In addition to documentation required for deviation, include the submittal information required for the item. Allow an additional 10 working days beyond normal submittal review period for consideration by the Government of submittals with deviations.

K. Approved Submittals: The part of the work covered by the approved item submittal may proceed provided it complies with the requirements of the contract documents. Final acceptance will depend upon that compliance.

The term “Approved” shall only indicate that there is no exception taken to the submittal. Approval of the item submittal shall not be construed as a complete check, and indicates only that the general method or other information appears to meet the contract requirements. Approval does not relieve the Contractor of the responsibility for any error which may exist.

After item submittals have been approved by the Contracting Officer, no resubmittal for the purpose of substituting materials or equipment, or changes to any other information will be considered unless accompanied by an explanation of why a substitution or change is necessary.

L. Disapproved Submittals: Contractor shall correct disapproved item submittals and resubmit for approval within timeframe noted. If no date is given, Contractor shall submit corrected submittal within 10 working days.

If the Contractor considers any correction or notation on the returned submittal to constitute a change to the contract drawings, specification, or statement of work the Contractor shall notify the Contracting Officer.

M. Responsibility: The Government’s review of Contractor submittals shall not relieve the Contractor of the entire responsibility for the correctness of details and dimensions and conformance to the specifications. The Contractor shall assume all responsibility and risk for any mistakes and/or costs due to any errors in submittals.

N. Inconsistencies: If a conflict or inconsistency arises between an approved item submittal and the contract documents, the contract documents shall govern.

1.3 SPECIFIC SUBMITTAL DESCRIPTIONS AND REQUIREMENTS: Submittal requirements for individual units of work are specified in the applicable specification section or Statement of Work (SOW). Except as otherwise indicated in the individual specification sections or SOW, comply with the following requirements for each type of submittal.

Appendix A-4

A. Shop Drawings: These are technical drawings and data specially prepared for this contract including fabrication and installation drawings, setting and seaming diagrams, and coordination drawings (for use on-site). Shop drawings include drawings, diagrams and schedules specifically prepared to illustrate some portion of the work, diagrams and instructions from a manufacturer or fabricator for use in producing the product and as aids to the Contractor for integrating the product or system into the project, or drawings prepared by or for the Contractor to show how multiple systems and interdisciplinary work will be coordinated. Information required on shop drawings includes dimensions, identification of specific products and materials which are included in the work, compliance with specified standards, and notations of coordination requirements with other work.

Provide special notations of dimensions that have been established by field measurements. Highlight, encircle, or otherwise indicate deviations from the contract documents on the shop drawings. Furnish one hard copy and one electronic copy.

B. Product Data: This data includes standard printed information on manufactured products that has not been specially prepared for this contract, including manufacturers' product specifications illustrating size, physical appearance and other characteristics of materials, installation instructions, standard color charts, catalog cuts, illustrations, schedules, standard wiring diagrams, standard product operating and maintenance manuals, and samples of warranty language when the contract requires extended product warranties. General information required specifically as product data includes manufacturers' standard printed recommendations for application and use, compliance with recognized standards of trade associations and testing agencies, the application of their labels and seals (if any), special notation of dimensions which have been verified by way of field measurement, and special coordination requirements for interfacing the material, product, or system with other work. Furnish three hard copies and one electronic copy.

C. Design Data: Design data includes design calculations, analyses or other data pertaining to a part of work. Refer to individual sections of the specification or statement of work for required quantities, formats, and signatures or certifications required. Furnish three hard copies and one electronic copy.

D. Test Reports: These include reports signed by an authorized official of a testing laboratory that a material, product or system identical to the material, product or system to be provided has been tested in accordance with the specified requirements. Testing shall have been within three years of date of contract award for the project. Reports also include findings of tests required to be performed by the Contractor on an actual portion of the work or prototype prepared for the project before shipment to the job site, findings of tests made at the job site or on a sample taken

Appendix A-5 from the job site, investigation reports, daily logs and checklists, and final acceptance test and operational test procedures. Furnish three hard copies and one electronic copy of each such report required.

E. Manufacturer’s Instructions: Preprinted material describing installation of a product, system or material, including special notices and Material Safety Data sheets concerning impedances, hazards and safety precautions.

Furnish three hard copies and one electronic copy.

F. Operation and Maintenance Data: Data furnished by the manufacturer, or the system provider, to the equipment operating and maintenance personnel, including manufacturer’s help and product line documentation necessary to maintain and install the equipment, and needed by operating and maintenance personnel for the safe and efficient operation, maintenance, and repair of the item. The data is intended to be incorporated in an operations and maintenance manual or control system.

Furnish two hard copies and one electronic copy.

G. Final Design Drawings and Documentation: Final design documentation including drawings, specifications, estimates, and other required deliverables. Electronic documentation submitted shall include every associated component file of drawings and other documentation, including raster images, jpeg, tiff, Excel, and any related items required to view, modify, or manipulate the electronic files. Furnish a CD-ROM of all final design documentation, and drawings in AutoCAD 2005 format or later, to the Contracting Officer for approval prior to applying for final payment.

H. Miscellaneous Submittals: These are work-related, non-administrative submittals that do not fit in the previous categories, including the following:

1. Project photographs. Furnish both hard copies and digital files.

2. Qualification certificates. Furnish one hard copy and one electronic copy.

3. Warranties.

END OF SPECIFICATION AND APPENDICES