Anti_Cavitation_Vavle_SOW.pdf

SOW NO. 13601-16-001A

April 24, 2018

STATEMENT OF WORK

FOR SUPPLY OF ONE (1)

1.5” Anti Cavitation Control

Valve

ARNOLD ENGINEERING DEVELOPMENT COMPLEX

ARNOLD AIR FORCE BASE, TN 37389-9998

NOT SENSITIVE

IRA # 3910

Table of Contents-1

Table of Contents

1. SCOPE

2. APPLICABLE DOCUMENTS

2.1. Government Documents

2.2. Non-Government Documents

3. REQUIREMENTS

3.1. General

3.2. Valve Design

3.3. Materials

3.4. Maintainability

3.5. Verification, Testing and Acceptance

3.6. Packaging and Delivery

3.7. Submittals

Appendix A – Submittal Procedure

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1. SCOPE

1.1. The Contractor shall provide one (1) complete assembly consisting of a 1.5” or 2” nominal pipe size (NPS), 4620 pounds per square inch, gage (psig) rated, stainless anti cavitation control valve with an industry standard certified “Grayloc” ring size 14 hub ends, a hydraulic actuator, with LVDT type position feedback, and two (2) limit switches.

Delivery shall be to Arnold Air Force Base, Tennessee.

2. APPLICABLE DOCUMENTS

2.1. Government Documents: None

2.2. Non-Government Documents:

2.2.1 American Society of Mechanical Engineers:

A. ASME B16.34-13 Valves Flanged, Threaded, and Welding End

2.2.2 American Society of Testing and Materials (ASTM) International:

B. ASTM A182-15 Forged or Rolled Alloy and Stainless Steel Pipe Flanges, Forged Fittings, and Valves and Parts for High-Temperature Service.

C. ASTM A351-15 Castings, Austenitic, for Pressure-Containing Parts

2.2.3 Fluid Controls Institute, Inc.:

A. FCI 70-2-13 Control Valve Seat Leakage.

2.2.3. National Fire Protection Association:

A. NFPA 70-14 National Electrical Code (NEC).

3. REQUIREMENTS

3.1. General:

3.1.1. The Contractor shall provide a complete valve assembly in accordance with all documents listed in Section 2-Applicable Documents and the requirements herein.

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. The valve design shall be based upon an existing design of similar size, with interchangeable repair part availability. The valve shall be manufactured within the US, and supported by established US vendors and repair centers that are authorized by the manufacturer. The design must be proven through prior service at pressures greater than 3000 psig.

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3.1.4. The valve is used for transient ignition and subsequent increasing butane flow and increasing downstream pressure to a burner. Downstream butane pressure is low, approximately 200 psig, for flow rates between 0.7 lb/s and 2.5 lb/s (burner ignition.)

Above 2.5 lb/s butane flow, pressure downstream of the valve is generally above 800 psig. The anti-cavitation design shall be capable of flowing Isobutane at 32° F without cavitation at both of the following conditions;

a. 0.7 lb/second butane at 2750 psig inlet, 200 psig outlet, approximately 4% to 5% open.

b. 8.5 lb/second butane at 2750 psig inlet, 1500 psig outlet, approximately 70% to

86% open

3.1.5. The anti-cavitation control valve shall have equal percentage type trim nominal Cv between 2.5 to 3.

3.2. Valve Design:

3.2.1. Design shall be in accordance with ASME B16.34 Class 2500. (Exception shall be made for end connection seal ring design pressure.)

3.2.2. The body configuration shall be a standard horizontal through flow (not angle body), with flow over plug, having 1-1/2” NPS Grayloc™ type hubs with size 14 seal rings.

3.2.3. Valve Actuation Rates: The hydraulic servo valve shall be sized to achieve an actuation time between 0.70 and 3 seconds.

3.2.4. Leakage: shall be in accordance with FCI 70-2 CL V. The maximum allowable through leakage is 6.9 ml/min water at 4600 psig differential and ambient temperature conditions. Hydrostatic test water may be utilized for the seat leakage test, however the valve shall be delivered dry per cleanliness requirements as stated in this SOW.

3.2.5. Service Conditions:

A. Media: Isobutane, ambient temperatures (nominally + 32⁰ to 100⁰ F).

B. Maximum design pressure: 4620 psig

1. Maximum inlet pressure: 4000 psig

2. Minimum outlet pressure: 0 psig (shutoff)

3. Maximum outlet pressure: 3500 psig (flowing)

4. Maximum differential pressure: 4620 psia

3.2.6. Operational Requirements:

A. Actuator: Shall be of a fail-closed design. The facility command voltage signal shall be rated for +/- 40 mA. The valve position feedback shall be 4 to 20 mA, with 4 mA corresponding to the fully CLOSED valve position. The actuator shall NOT have a 24 Volt “Enable” or “Failsafe” solenoid. Upon loss of the command voltage the servo valve shall drive the valve to a closed position. Loss of hydraulic supply pressure shall “lock up” the actuator supply/return ports such that the valve stem is effectively “failed in position” upon loss of hydraulic pressure. The actuator shall develop sufficient force to open the valve with internal fluid pressure

Page-5 differential as high as 4620 psig across the plug. All actuator components shall be rated for 3000 psia hydraulic supply pressure. Quintolubric 888 synthetic hydraulic fluid at a nominal supply pressure of 1500 psia will be used to actuate the valve (even though the components are requested to be rated for 3000 psia).

The hydraulic servo valve shall be sized to achieve an actuation time between

0.70 and 3 seconds.

B. Micro mechanical limit switches shall be provided at the fully open and fully closed travel position of the valve. Eaton model E47BCC06 or similar switches designed for outdoor use, and compatible with PC I/O card mA power levels are preferred.

Limit switches shall have sufficient resolution of valve stroke to trigger OPEN and CLOSED only within 15% of true fully OPEN and CLOSED stroke. The use of a cantilevered limit switch trip paddle connected to the actuator coupling block to increase valve travel resolution is acceptable.

C. Position feedback shall be a LVDT type, with 24 Volt facility excitation, and 4 to 20 mA signal. 4 mA shall correspond to the closed position. The LVDT shall be removable from the cylinder while hydraulic fluid pressure is on. The LVDT transducer shall be a Balluff BTL5 series with DEXC explosion proof rating LVDTs or equal.

D. Servo valves shall be two stage proportional type, Moog G761-3000 model series or equal. Coils shall be +/- 40 mA, dual/ parallel 80 ohm coils. Internal pilot type shall be high response. The servo connector shall be a 4 pin military type MS 3106F14S-2S.

E. Environment: The LVDT and micro mechanical limit switch terminations shall be housed within a NEMA 8 rated (meeting requirements of NFPA 70-08 Class I, Division 2, Group D and suited for indoor/outdoor location) enclosure. All parts of the complete valve assembly shall be suitable for conditions of operation including: operating temperature; vibration caused by valve positioning; vibration caused by fluid flow; as well as exterior environments of 0 F to 110 F with weather conditions including rain, snow, humidity and heat.

3.2.7. Electrical components:

A. All electrical components on the valve assembly shall be suited for outdoor use and;

B. Shall be housed within a NEMA 8 rated (meeting requirements of NFPA 70-08 Class I, Division 2, Group D and suited for indoor/outdoor location) enclosure.

3.2.8. Reliability: The valve shall be designed with projected life cycle for the valve assembly shall be 200 cycles/year over 20 years. A full cycle is defined as Closed-Open- Closed.

3.3. Material:

3.3.1. The valve body and bonnet shall be made from austenitic stainless steel and be ASME

B16.34 Class 2500. (Exception shall be made for end connection seal ring design pressure

3.3.2. The manufacturer shall specify the hub face to hub face take out length of the valve at time of proposal. Valve body connections shall be interchangeable with 1.5” NPS Grayloc™ size GR14 ring sized pipeline hub faces.

3.3.3. Stem and plug materials shall be stainless, nickel-stainless alloys, 17-4 PH, or similar.

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Hard facing (electroless nickel, stellite, or similar) on the stem and materials at the plug to cage seating interface is preferred.

3.3.4. The valve seat ring and trim shall be replaceable through removal of the bonnet.

3.3.5. Trim characteristic shall be equal percent type, with a solid, non-balanced plug.

3.3.6. Seals and packing material shall be PTFE, glass filled PTFE, PEEK, bronze, or graphite.

3.4. Maintainability

3.4.1. All actuator component and limit indication related components that may require replacement shall be replaceable with the valve in line.

3.4.2. Maintainability Plan shall be submitted for valve assembly, including the following:

A. Spare Parts Data: Include recommended spare parts list, manufacturer’s name, part number, current unit price, and support vendor for each item.

B. Estimated mean number of cycles between failures.

3.5. Verification, Testing, and Acceptance

3.5.1. The Contractor shall be responsible for all testing and inspections of the valve assembly. Contractor shall supply all interfacing equipment needed to conduct the tests.

3.5.2. The Contractor shall modify valve(s) and related components of the assemblies as needed until all tests have met the requirements, and repeat all tests until valve assemblies meet test requirements.

3.5.3. Valve body assembly shall be hydrostatically tested to 1.5 times Maximum design pressure and seat leakage tested to Class V.

3.5.4. A factory test shall demonstrate that the actuator will open the valve with maximum design pressure (hydrostatic or pneumatic) across the valve. This test can be done with the actual hydraulic actuator, or by utilizing a test hydraulic actuator producing the same force as the actual actuator will produce at the minimum hydraulic pressure.

3.5.5. A factory actuator test shall be performed with the complete actuation/positioning system mounted to the valve, and Quintolubric 888 synthetic hydraulic fluid. The manufacturer shall provide all test equipment necessary to operate the valve a minimum of 6 times.

3.5.6. The factory actuator test shall also demonstrate Fail Closed behavior upon loss of 4-20 mA control signal

3.5.7. The factory actuator test shall demonstrate fail in position type behavior upon loss of hydraulic supply pressure.

3.5.8. A factory test shall demonstrate that the valve assembly utilizing the actual actuator

Page-7 and servo valve achieves actuation time between 0.60 and 3 seconds.

3.5.9. The Government reserves the right to witness factory testing. Contractor shall notify Government in writing 30 days prior to any factory test.

3.5.10. Submit 2 sets of certified test results on required testing per ASME B16.34 and FCI 70-

2.

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

3.5.12. Inspection: Upon receipt at AEDC, the Government will inspect the valve assembly and all related components and equipment for any visible damage, general cleanliness, craftsmanship, and adherence to final drawings.

3.5.13. Acceptance: The Government will accept the valve assembly and all related components and equipment upon satisfactory operation after installation at AEDC.

3.6. Packaging and Delivery

3.6.1. The valve assembly shall be delivered to AEDC as a complete unit. The Contractor shall be responsible for packaging necessary to ensure safe and damage-free delivery.

3.6.2. All packaging shall provide environmental protection of the valve assembly and shall allow the valve assembly to be stored outdoors on pallets.

3.7. Submittals:

3.7.1. Engineering Analysis and Calculations shall be submitted for valve assembly:

A. Valve datasheet and Cv curve.

B. Calculations and supporting information verifying design and actuator sizing, valve body, and components.

3.7.2. Drawings for valve assembly shall be submitted and include the following:

A. Final assembly bill of materials (BOM) level drawings for the valve, actuator, and related mounting hardware.

B. Bills of material component details, and assembly information for the end user replacement of parts.

C. Valve assembly weight including estimated actuator weight.

D. Manufacturer’s bulletins, cut sheets, and descriptive data for each piece of equipment, i.e. actuator, limit switch, and valve assembly.

3.7.3. Operating and maintenance instructions including actuator troubleshooting instructions.

3.7.4. Warranty: The Contractor shall provide a one year warranty for the valve assembly, stating that it is free from any manufacturer defects. The warranty period will begin after Government acceptance at AEDC.

3.7.5. The Contractor shall submit all documentation as listed in the table below and in accordance with Appendix A – Submittal Procedure.

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Table I. Required Submittal List

No. Section Reference Submittal Description Due 1 3.4.2 Maintainability Plan Before shipment 2 3.5.9 Notification of Factory Test 30 days prior to test 3 3.5.10 Certified test results Before shipment 4 3.7.1 Engineering Analysis Before shipment 5 3.7.2 Drawings Before shipment 6 3.7.3 Operations and Maintenance

Instructions Before shipment

7 3.7.4 Warranty At Shipment

Appendix A-1

PART 1 GENERAL

APPENDIX A

SUBMITTAL PROCEDURE

1.1 DESCRIPTION OF REQUIREMENTS. This section specifies procedural requirements for non-administrative submittals, including but not limited to shop drawings, product data, manufacturer’s certificate, design data, calculations, and verifications, manufacturer’s instructions, manufacturer’s field service reports, samples, 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: The statement of work contains 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.

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 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.

Appendix A-2

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 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

Appendix A-3 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 Statement of Work (SOW). Except as otherwise indicated in the SOW, comply with the following requirements for each type of submittal.

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

Appendix A-4 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 two hard copies and one electronic copy.

C. Design Data: Design data includes design calculations, mix designs, analyses or other data pertaining to a part of work. Refer to statement of work for required quantities, formats, and signatures or certifications required. Furnish two 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 from the job site, investigation reports, daily logs and checklists, and final acceptance test and operational test procedures. Furnish two hard copies and one electronic copy of each such report required.

E. Certificates: These include statements printed on the manufacturer’s letterhead and signed by the responsible officials of the manufacturer of a product, system or material attesting that the product, system or material meets specification requirements. Certificates include documentation required of the Contractor, or of a manufacturer, supplier, installer or subcontractor through the Contractor, to further demonstrate the quality of orderly progressions of a portion of the work by documenting procedures, Appendix A-5 acceptability of methods or personnel qualifications. Certificates shall be dated after award of the project contract and clearly name the project.

Furnish three hard copies and one electronic copy of each certificate required.

F. 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.

G. 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 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.

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

1. Maintenance agreements. Furnish one hard copy and one electronic copy.

2. Maintenance tools, spare parts, and overrun or maintenance stock.

Refer to SOW for required quantities of spare parts, extra and overrun stock, maintenance tools and devices, keys, and similar physical units to be submitted.

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

4. Warranties.

END OF SOW