WI 6_Fuel Filtration Assemblies_Procurement Specification.doc

USCG SFLC – Fuel Filtration Assemblies

SPEC NUMBER: P-541-XXXX

REVISION: 0

REVISION NO. 0 . CHANGE NO. - .

PROCUREMENT SPECIFICATION

FUEL FILTRATION ASSEMBLIES

140 WTGB CLASS

P-541-XXXX

ORGINATE D BY: Carl Colditz/Andrew Dize

DATE: 05/01/2012

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

DEPARTMENT / DIVISION: Auxiliary Machinery Section (AMS)

INTERNAL REVIEWER: A. Dize

DATE: 07/27/2012

PRODUCT LINE APPROVAL:

DATE:

Table of Contents

Title

Page

1.0 SCOPE

2.0 APPLICABLE DOCUMENTS

2.1 Document Availability

2.2 Government Documents

2.2.1 Specifications, Military

2.2.2 Standards, Military

2.3 Other Government Documents

2.3.1 Code of Federal Regulations (CFR)

2.3.2 USCG Surface Forces Logistics Center (SFLC) Drawings

2.3.3 USCG Surface Forces Logistics Center (SFLC) Documents

2.3.4 USCG SFLC NE-TIMS Technical Publications

2.3.5 Naval Sea Systems Command Documents

2.3.6 Technical Manuals, Headquarters, Department of the ARMY

2.4 Commercial Documents

2.5 Order of Precedence

3.0 REQUIREMENTS

3.1 Performance and General Requirements

3.1.1 Operating Requirements

3.1.2 Fuel Transfer System Filtration Assembly

3.1.3 Fuel Service System Filtration Assembly

3.1.4 Dimensional and Weight Data

3.1.5 Cleanliness

3.2 Specific Requirements

3.2.1 Filter Pressure Vessel (Pre-Filter)

3.2.2 Filter Element

3.2.3 Coalescer/Separator Pressure Vessels

3.2.4 Coalescer Filter Element

3.2.5 Separator Filter Element

3.2.6 Automatic Drain Valve

3.2.7 3-Way Valves

3.2.8 Piping

3.2.9 Instrumentation

3.2.10 Assembly Foundations

3.2.11 Identification and Labeling

3.2.12 Resistance to Marine Environment

3.3 Training

3.4 Field Services

3.5 Departure from Specifications

3.6 Design Improvements

3.7 Technical Documentation

3.7.1 Technical Publications

3.7.2 Drawings

Table of Contents (cont)

Page

3.8 Integrated Logistics Support

3.8.1 Engineering Data for Provisioning (EDFP)

3.8.2 Recommended Spare Parts Lists

3.8.3 OEM Maintenance Requirements

3.9Tests, Inspections, and Reports

3.9.1 First Article Testing (FAT)

3.9.2 Factory Testing (FT)

3.9.3 Shipboard Test Plan

3.10 Workmanship

3.11 Notifications and Inspections

4.0 QUALITY ASSURANCE

4.1 General

4.2 Records

4.3 Calibration System

4.4 Responsibility for Inspection

4.5 Responsibility for Compliance

4.6 Quality Assurance Plan

4.7 Tests and Inspections

4.8 Failure Responsibility

4.8.1 Corrective Action Remedies

4.9 Test and Inspection Reports

4.10 Packaging Inspection

5.0 PRESERVATION, PACKING AND MARKING

6.0 NOTES

6.1 Potential Sources

6.2 Government and Commercial Document Sources

6.2.1 Government Documents

6.2.2 Commercial Documents

Attachment 1 - Fuel Filtration Assemblies Attachment 2 - Provisioning Technical Documentation (PTD)

Attachment 3 - Engineering Data for Provisioning (EDFP)

1.0 SCOPE

This Specification covers the procurement of fuel transfer system filtration assemblies and Main Diesel Engine (MDE) fuel service system filtration assemblies for 140 WTGB Class Cutter (9 total ship sets). Each fuel transfer system filtration unit will provide pre-filtering and water emulsion coalescing of diesel fuel in the fuel transfer system. Each fuel service system filtration unit will incorporate coalescer/separator assemblies to provide filtering and water emulsion coalescing of diesel fuel being fed to the main diesel engines (MDE’s). This specification DOES NOT include installation of the equipment, but DOES include limited on-site technical support to the United States Coast Guard (USCG) to ensure that the equipment is installed and functions correctly. Hardware and component items (per ship set) to be provided by the Vendor are as follows:

a. One (1) Fuel Transfer System Filtration Assembly

b. Two (2) Fuel Service System Filtration Assemblies Each fuel filtration assembly, as schematically identified in Attachment 1, shall be comprised of all ancillary components including filter housings, automatic drain valves, pressure gages, fuel shut-off valves, and foundation as required to clean Grade No. 2-D Diesel Fuel Oil and/or 5% volume Bio-Diesel Fuel (B-5).

· The Vendor shall supply Provisioning Technical Data (PTD), Attachment 2, with their proposal response that includes certified technical manuals and drawings describing the fuel filtration assemblies to provide the United States Coast Guard (USCG) with sufficient information to produce Cutter specific installation drawings.

· The Vendor shall supply Engineering Data for Provisioning (EDFP), Attachment 3, on the system and components concurrent with the delivery of the equipment to allow the USCG to produce maintenance procedure cards (MPCs) and other logistical support documentation. Engineering data shall also include the PLC code if required for operation of the system.

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

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

2.0

APPLICABLE DOCUMENTS

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

2.2 Government Documents - The following Specifications and standards form a part of this Specification to the extent specified herein. Unless otherwise specified, the documents listed here by number and date shall be those in the current Department of Defense Index of Specifications and Standards (DODISS) and supplements therein.

2.2.1 Specifications Military

a. MIL-DTL-16884L, Detail Specification, Fuel, Naval Distillate

b. MIL-DTL-5624U, Detail Specification, Turbine Fuel, Aviation, Grade JP-4 and JP-5

c. MIL-PRF-52308J, Amendment 2, Performance Specification Filter-Coalescer Element, Fluid Pressure

d. MIL-PRF-15618G (SH), Performance Specification, Filter-Separator, Fluid, Pressure, Aviation and Distillate, Naval Shipboard

e. MIL-PRF-32148, Performance Specification, Filter Separator Elements, Fluid, Pressure, Aviation and Distillate Fuel, Naval Shipboard.

2.2.2 Standards Military

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

2.3 Other Government Documents - The following documents form a part of this Specification to the extent specified herein. The documents listed shall be by title and effective date, unless otherwise documented.

2.3.1 Code of Federal Regulations (CFR)

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

b. Code of Federal Regulations (CFR), Title 46 (Shipping), Chapter I, Subchapter F, Part 54, Pressure Vessels, (2011)

2.3.2 USCG Surface Forces Logistics Center (SFLC) Drawings

Drawing No.

Rev.

a. 101-WTGB-541-001

J

FUEL OIL SYS, DIAGRAM

b. 101-WTGB-541-002

L

FUEL OIL TRANSFER SYS, A&D

c. 101-WTGB-541-003

P

FUEL OIL SVC. SYS, A&D

d. 101-WTGB-801-002

D

TANK CAPACITY CURVES

e. 101-WTGB-201-001

H

MACHINERY ARRANGEMENT

2.3.3 USCG Surface Forces Logistics Center (SFLC) Documents

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

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

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

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

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

f. Attachment 1 – Sketch – Fuel Filtration Assemblies

g. Attachment 2 – Provisioning Technical Documentation (PTD)

h. Attachment 3 - Engineering Data for Provisioning (EDFP)

2.3.4 USCG SFLC NE-TIMS Technical Publications

a. Technical Publication No. 3460, SWBS 261, Section Identifier D, Fuel Service System, Filter / Separator- Model VFCS-194-127

b. Technical Publication No. 3469, SWBS 540, Section Identifier B, Fuels and Lubricants, Handling and Storage, Filter - Model VFCS-194-123-7

c. Technical Publication No. 3474, SWBS 261, Section Identifier A, Fuel Service System, Main Diesel Engine Fuel System

d. Technical Publication No. 3473, SWBS 233, Section A, MAIN DIESEL ENGINE, MODEL 38D8-1/8 - INSTRUCTION BOOK

2.3.5 Naval Sea Systems Command Documents

a. Naval Ships’ Technical Manual, Chapter 541, Ship Fuel and Fuel System, S9086-SN-STM-010, Revision 6, 01 June 2010

2.3.6 Technical Manuals, Headquarters, Department of the ARMY

a. TM 10-6640-221-13&P Technical Manual AQUA GLO Water Detector Model GTP-322 NSN 6640-00-2449478 2.4 Commercial Documents - The following documents form a part of this Specification to the extent specified here. The documents shall be the version listed by number and date from the referenced industry organization. Commercial documents may be listed in the Department of Defense Index of Specifications and Standards (DODISS).

2.4.1 American Society of Mechanical Engineers (ASME)

a. 2010 ASME Boiler & Pressure Vessel Code, VIII, Division 1, Rules for Construction of Pressure Vessels, 2011a Addenda, July 1, 2011 2.4.2 American Welding Society (AWS)

a. AWS D1.1/D1.1M, DATED 2008, Structural Welding Code - Steel.

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

c. AWS D1.2/D1.2M, DATED 2003, Structural Welding Code - Aluminum.

2.4.3 American Society for Quality Control (ASQC)

a. ANSI/ASQC 9001-2008 – Quality Management Systems - Model for Quality Assurance in Design, Development, Production, Installation, and Servicing Requirements 2.4.4 National Conference of Standards Laboratories (NSCL)

a. ANSI/NCSL Z540.3-2006, Requirements for the Calibration of Measuring and Test Equipment 2.4.5 Society of Naval Architects and Marine Engineers (SNAME)

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

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

2.4.6 American Society for Testing & Materials (ASTM)

a. ASTM D975, 2011-Standard Specification for Diesel Fuel Oils

2.4.7 International Maritime Organization (IMO)

a. ISO 8217:2010 Revised Specification of Marine Fuels

2.4.8 American Petroleum Institute (API)

a. EI 1581, 5th Edition, Specification and Qualification Procedures for Aviation Jet Fuel Filter / Separators 2.5 Order of Precedence - In the event of a conflict between the text of this Specification and the references cited herein, this Specification shall take precedence. The Vendor is required to notify the Contracting Officer (KO) in writing for a resolution of any ambiguity or conflict found in these specifications.

3.0

REQUIREMENTS

The Vendor shall provide all labor and material to provide new marine grade fuel filtration assemblies for both the fuel transfer (1 assembly required per ship set) and fuel service (2 assemblies required per ship set) systems as defined herein. The US Coast Guard will install the new fuel filtration units on the 140 WTGB Class Cutters. Any materials and components sub-contracted for shall be the responsibility of the Vendor. The vendor proposal in response to the requirements stated herein shall include the technical data as described in Attachment 2, Provisioning Technical Documentation (PTD)

3.1 Performance and General Requirements

3.1.1 Operational Requirements

a. All equipment furnished shall be suitable for use indoors and below decks in a marine environment.

b. Ambient air temperature for the equipment operation shall range from 40°F to 140°F.

c. The operation of the filter and coalescer/separators pressure vessels with filters installed shall operate at a maximum flow rate of 15 GPM of No. 2 diesel oil or 5% Bio-Diesel fuel with a specific gravity of between 0.81 and 0.88 at a maximum operating pressure of 150 PSIG.

3.1.2 Fuel Transfer System Filtration Assembly Each fuel transfer system filtration assembly shall consist of a pre-filter (filter pressure vessel and companion filter element) connected to a single coalescer/separator pressure vessel. The pre-filter is used for removal of solid contaminates. The coalescer/separator is used to remove moisture from the fuel. Each fuel transfer system filtration assembly provided shall meet the operational and performance requirements defined herein.

The following components as described herein shall be used for the required Fuel Transfer System Filtration Assembly:

a. Filter Pressure Vessel and Filter Element

b. Coalescer/Separator Pressure Vessel

c. Coalescer Filter element

d. Separator Filter element

e. Automatic Drain Valve

f. Valves, Fittings, Instrumentation, and Piping to connect the Filter and Coalescer/Separator Pressure Vessels.

g. Foundation/Base

Attachment 1 provides a schematic of a fuel transfer system filtration assembly with the items described above.

3.1.3 Fuel Service System (MDE) Filtration Assembly

The fuel service system filtration assembly is used to remove moisture from fuel prior to feeding this fuel to the main diesel engines (MDE). Each fuel service system filtration assembly shall consist of a pair of single coalescer/separator pressure vessels configured in a duplex arrangement. Each fuel transfer system filtration assembly provided shall meet the operational and performance requirements defined herein.

The following components as described herein shall be used for the required Fuel Service System Filtration Assembly:

a. Coalescer/Separator Pressure Vessels (2 units)

b. Coalescer Filter element (2 filters)

c. Separator Filter element (2 filters)

d. Automatic Drain Valve (2 valves – 1 for each pressure vessel)

e. 3-way valves for isolation of each pressure vessel with common manual control lever.

f. Valves, Fittings, Instrumentation, and Piping to connect the Coalescer/Separator Pressure Vessels.

g. Foundation/Base

Attachment 1 provides a schematic of a fuel service system filtration assembly with the items described above.

3.1.4 Dimensional and Weight Data (not to exceed) 3.1.4.1 Fuel Transfer System Filtration Assembly

a. Depth: 32.0 inches

b. Width: 32.0 inches

c. Height: 42.0 inches - 65 inches including filter removal clearance

d. Dry Weight: 400 pounds 3.1.4.2 Fuel Service System Filtration Assembly

a. Depth: 22.0 inches

b. Width: 44.0 inches

c. Height: 42.0 inches unit – 65 inches including filter removal clearance

d. Dry Weight: 400 pounds

3.1.1 Cleanliness

After completion of testing and in preparation for preservation and shipping, all component, internal piping, and fluid connection points shall be cleaned, sealed and protected from entry of dirt and moisture.

3.2 Specific Requirements

3.2.1 Filter Pressure Vessel (Pre-Filter)

The filter pressure vessel is used only on the fuel transfer system filtration assembly. The filter pressure vessel shall meet the following requirements:

a. Constructed in accordance with 2010 ASME Boiler & Pressure Vessel Code, VIII, Division 1, Rules for Construction of Pressure Vessels, 2011a Addenda, July 1, 2011.

b. Consist of a vertically orientated cylindrically shaped tank(s) designed specifically to remove solid contaminates such as dirt, rust scale, sand and metal particles.

c. Equipped with a removable access opening cover used to facilitate the replacement of the filter elements contained in the inside of the main body of the pressure vessel and to permit cleaning the interior of the pressure vessel.

d. Equipped with mounting supports as necessary to fabricate the fuel transfer system assembly as described herein.

e. Sized to install the filter element described in 3.3.2.

f. Inlet, outlet, vent and drain connections shall be provided and permanently labeled by affixed metallic label plates or steel stamping.

g. The size, type and location of the connections are to be sized and arranged to suit the installation requirements. All inlet and outlet connections shall be 1-1/2” NPS 150# ANSI flange.

3.2.2 Filter Element

The purpose of the filter element is to remove solid contaminates in the fuel. One (1) filter element shall be used and provided with each filter pressure vessel.

3.2.2.1 Filter Element Configuration and Solid Removal Capabilities

a. Filter elements are to be of uniform size to permit interchangeability as operating needs change.

b. Filter element shall be similar to or equal to National Stock Number (NSN) 2940011080124, as described below.

c. The filter element shall have an outside diameter of six inches (6.0 inches) and an inside diameter of three and one half inches(3-1/2 inches) and shall be fourteen and one half inches long (14-1/2 inches).

d. The filter element shall be capable of a 0.5 micrometer nominal solid removal from the fuel oil fluid flow at a maximum flow rate of 15 GPM.

e. Dimensional deviations from the above design are permitted as long as the specified 0.5 micrometer nominal solid removal at 15 GPM of the system is not compromised.

f. The filter element shall be capable of withstanding a 75 PSIG differential pressure without any structural failure to the filter element.

g. All gaskets used in the filter element shall be made from Buna N, per Mil-R-6855, Class I, Grade 60.

h. Structural component of the filter element shall be carbon steel with dry powder epoxy coating or 300 series stainless steel.

3.2.2.2 Fluid Flow through the Filter Element The fuel oil fluid stream shall flow into the filter pressure vessel from a side entry port near the top of the pressure vessel and shall then flow to the outside diameter surface of the filter element, then thru the filter element to the inside diameter surface; to provide the highest degree of filtering action and then out of the filter pressure vessel through a port in the side of the filter pressure vessel near the bottom.

3.2.3 Coalescer/Separator Pressure Vessels Coalescer/separator pressure vessels will be used on both the fuel transfer system filtration assembly (one - coalescer/separator pressure vessel) and on the fuel service system filtration assembly (two - coalescer/separator pressure vessels configured in a duplex arrangement). Each coalescer/separator pressure vessel shall meet the following requirements:

a. Constructed in accordance with 2010 ASME Boiler & Pressure Vessel Code, VIII, Division 1, Rules for Construction of Pressure Vessels, 2011a Addenda, July 1, 2011.

b. Configured as a vertically orientated cylindrically shaped tank designed specifically to remove solid contaminates such as dirt, rust scale, sand and metal particles as well as remove all of the emulsified, free and entrained water from the liquid diesel fuel oil flow stream.

c. Equipped with a removable access opening cover used to facilitate the replacement of the filter elements contained in the inside of the main body of the pressure vessel and to permit cleaning the interior of the pressure vessel.

d. Equipped with mounting supports as necessary to fabricate the fuel transfer and fuel service system filtration assemblies as described herein.

e. Sized to install both a coalescer filter element and a separator filter element (Note: The separator filter element fits into the coalescer filter element to create filter assembly).

f. Inlet, outlet, vent and drain connections shall be provided and permanently labeled by affixed metallic label plates or steel stamping.

h. The size, type and location of the connections are to be sized and arranged to suit the installation requirements. All inlet and outlet connections shall be 1-1/2” NPS 150# ANSI flange.

i. Each coalescer/separator pressure vessel shall be equipped with an automatic drain valve as defined herein for removal of moisture.

3.2.4 Coalescer Filter Element

The purpose of the coalescer filter element is to combine small particles of water into large drops and to filter out solid contaminates. One (1) coalescer filter element shall be used and provided with each coalescer/separator pressure vessel.

3.2.4.1 Coalescer Filter Element Configuration and Solid Removal Capabilities

a. The coalescer filter elements are to be of uniform size to permit interchangeability as operating needs change.

b. Coalescer filter element shall be similar to or equal to National Stock Number (NSN) 4330003636122, as described below.

c. The coalescer filter element shall have an outside diameter of seven and five-eighth inches (7-5/8) and an inside diameter of five and five-eighth inches (5-5/8) and shall be between thirteen and five eights long (13-5/8) and thirteen and three quarters inches long (13-3/4).

d. The coalescer filter element shall be capable of a 1 micrometer nominal solid removal from the fuel oil fluid flow at a maximum flow rate of 15 GPM.

e. Dimensional deviations from the above design are permitted as long as the specified 1 micrometer nominal solid removal at 15 GPM of the system is not compromised.

f. The coalescer filter element shall be capable of withstanding a 75 PSIG differential pressure without any structural failure to the filter element.

g. All gaskets used in the coalescer filter element shall be made from Buna N, per Mil-R-6855, Class I, Grade 60.

h. Structural component of the coalescer filter element shall be carbon steel with dry powder epoxy coating or 300 series stainless steel.

3.2.4.2 Fluid Flow through the Coalescer Filter Element

a. The fuel oil fluid shall flow into the coalescer/separator pressure vessel from a side entry port near the top of the pressure vessel and shall then flow to the inside diameter surface of the coalescer filter element, then thru the coalescer filter element to its outside diameter surface; to provide the highest degree of coalescing action.

b. The fluid flow stream shall then flow down the gap between the coalescer/separator pressure vessel and the outside diameter of the coalescer filter element and then flow into the bottom of the coalescer element and to the outside diameter surface of the nested separator filter element.

c. The flow stream shall then flow thru the separator element (See Section 3.3.5) to its inside diameter surface, where the flow stream shall then exit then out of the coalescer/separator pressure vessel through a port in the side of the pressure vessel near the bottom.

3.2.5 Separator Filter Element

The purpose of the separator filter element is to act as a companion backup filter to the main coalescer filter element and to filter out solid contaminates.

3.2.5.1 Separator Filter Element Configuration and Solid Removal Capabilities

a. The separator filter elements are to be of uniform size to permit interchangeability as operating needs change.

b. Separator filter element shall be similar to or equal to National

Stock Number (NSN) 4330003636128, as described below:

c. The separator filter element shall have an outside diameter of four and one-eighth inches (4-1/8) and an inside diameter of one and seven-eighth inches (1-7/8) and shall be ten and one-half inches long (10-1/2).

d. The separator filter element shall be capable of a 5 micrometer nominal solid removal from the fuel oil fluid flow at a maximum flow rate of 15 GPM.

e. Dimensional deviations from the above design are permitted as long as the specified 5 micrometer nominal solid removal at 15 GPM of the system is not compromised.

f. The separator filter element shall be capable of withstanding a 75 PSIG differential pressure without any structural failure.

g. All gaskets used in the separator element shall be made from Buna N, per Mil-R-6855, Class I, Grade 60.

h. Structural component of the separator filter element shall be carbon steel with dry powder epoxy coating or 300 series stainless steel.

3.2.5.2 Fluid Flow through the Separator Filter Element

a. The separator filter element shall be (nested) inside of the coalescer filter element and configured within each coalescer/separator pressure vessel to facilitate fuel oil fluid flow initially to the outside surface of the separator element and then to its inside diameter to provide the highest degree of separation action.

b. The fluid stream shall then exit the bottom of the coalescer/separator pressure vessel after being filtered through the separator element.

3.2.6 Automatic Drain Valve

An automatic drain valve shall be installed on each coalescer/separator pressure vessel. The automatic drain valve shall be a free floating lever dual gravity drain valve manufactured by Armstrong Co., Model 33-DG or equal. The purpose of the automatic drain valve is to allow water to drain automatically from each pressure vessel. The installation and operation of each automatic drain valve shall be as follows:

a. The pipe size connection between the pressure vessel and the automatic drain valve to the pressure vessel shall permit continuous normal operation of the coalescer/separator at a flow rate of 15 GPM.

b. Size of orifice in the automatic drain valve shall be as is needed to permit continuous normal operation of the coalescer/separator at a flow rate of 15 GPM of No. 2 diesel oil or 5% Bio-Diesel fuel with a specific gravity of between 0.81 and 0.88 at a maximum operating pressure of 150 PSIG.

c. Float weight in the automatic drain valve shall be as is needed to permit continuous normal operation of the coalescer/separator at a flow rate of 15 GPM of No. 2 diesel fuel or 5% Bio-Diesel fuel with a specific gravity of between 0.81 and 0.88 at a maximum operating pressure of 150 PSIG.

d. Material of the body of the automatic drain valve shall be forged steel.

e. Material of the Fuel Shut off Valve shall be carbon steel and have flange connections or socket welded connections.

3.2.7 3-Way Valves

a. Coalescer/separator pressure vessels used in a duplex configuration as a fuel service system filtration assembly shall be equipped with two (2) TYPE LL 90 degree, 1-1/2” NPS 150# ANSI flange connection 3-way valves. The purpose of the 3-way valves is to allow selection of either coalescer/separator pressure vessels for operation or cleaning.

b. A mechanical bar shall be installed to join the handles of each 3-way valve to allow simultaneous actuation to divert flow from one port of the 3-way valve to the other port of the other 3-way valve while isolating the other associated pressure vessel.

c. The piping and flanges which make up the manifold of the 3-way valve shall be made from carbon steel and all connections of pipe shall be butt or socket welded to meet the welding standards sighted in the references of this purchase specification.

3.2.8 Piping

a. Design of piping on the fuel transfer system and fuel service system filtration assemblies shall permit full access to the individual components for maintenance access.

b. All piping, materials, and fittings shall be in accordance with CFR Title 46, Chapter I, Subchapter F, Part 56, Piping Systems and Appurtenances. Metric piping connections shall not be used.

3.2.9 Instrumentation

a. Gauges shall be commercially available, marine grade gauges with direct action, multi-wound bourdon tube elements, with an accuracy of 1 percent. Read outs shall be in PSI.

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

c. Thermometers if provided shall be installed using thermo wells.

d. Sight glasses if provided shall be able to be isolated using valves.

3.2.10 Assembly Foundations

a. All items of a fuel transfer system filtration assembly and a fuel service system filtration assembly shall be shop assembled and mounted onto dedicated steel base plate foundations.

b. The foundations shall be capable of being modified to allow bolting of each Assembly to the ship deck or an installed foundation.

3.2.11 Identification and Labeling Pressure vessels for the filter assembly and the coalesce/separator components used for the fuel transfer filtration and fuel service filter units shall be provided with label plates permanently affixed to the pressure vessels. The label plates shall be corrosion resistant metal with engraved information showing the following information as a minimum:

a. Manufactures Model No.

b. Maximum Operating Pressure 150 PSIG

c. Maximum Operating Temperature 250 degrees F

d. Serial Number

e. Year Built

f. National Board Number

g. Head Gasket Part No.

h. Differential Pressure Maximum for Filter Element Replacement

i. Maximum Allowable Differential Pressure

j. Maximum Flow Rate 3.2.12 Resistance to Marine Environment Any portion that requires painting shall be preserved per Commandant Instruction M10360.3C, Coatings and Color Manual unless the original coating treatment is specifically accepted by the Contracting Officer in advance.

3.3 Training

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

a. review of maintenance documentation

b. review of start-up and operational procedures

c. safety

d. settings and adjustments

e. interpretation of displayed data

f. emergency procedures

g. troubleshooting

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

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

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

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

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

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

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

b. An additional day rate for any potential future technical support required after the completion of this contract. The quoted rate shall be good for one year after installation of the first Systems.

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

3.5 Departure From Specification – Departure from the Specifications will not be allowed unless there is a direct benefit to the Government.

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

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

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

3.6 Design Improvements Proposals submitted for design improvements to equipment or process to simplify or improve reliability and/or maintainability, and to improve performance, are encouraged. Such proposals may be submitted at any time during the contract using the Specification departure procedures as outlined herein.

3.7 Technical Documentation

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

3.7.1 Technical Publications

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

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

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

3.7.2 Drawings

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

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

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

3.8 Integrated Logistics Support The Vendor shall provide the following logistical support and information for the fuel transfer and service filtration assemblies. Revised documentation in response to the Government’s initial review shall be deliverable prior to any subsequent deliveries. Modifications made to the equipment provided during the term of the contract must be accompanied by updates of all the following that relate to those changes.

3.8.1 Engineering Data for Provisioning (EDFP) The Vendor shall be provide Engineering Data for Provisioning (EDFP) in accordance with Attachment 3 and shall include a parts list containing all of the installed parts, the original equipment manufacturer (OEM), OEM part or assembly numbers, the OEM’s name and address, the OEM’s cage code, quantity used in each equipment, and shall be keyed to the provided drawings. All spare parts necessary for overhaul of a unit shall be identified in the printed technical documents supplied.

3.8.2 Recommended Spare Parts List

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

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

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

3.8.3 OEM Maintenance Requirements

The Vendor shall provide OEM maintenance recommendations, in addition to the maintenance recommendations in the Technical Publication, to allow for USCG the development of Maintenance Procedure Cards. Guidance for providing this information can be found in Chapter 5 of the USCG Planned Maintenance System Development Process Guide, CGTO PG-85-00-230-S.

The Vendor shall identify at least the following line items:

a. Applicable Maintenance Task Code

b. Maintenance Procedure Title

c. Maintenance Procedure Interval

d. Maintenance Procedure Description

e. Maintenance Procedure Sequenced Tasks

f. Maintenance Procedure

g. Maintenance Procedure Task Type

h. Associated Parts LCN

i. Associated Parts Name

j. Associated Parts Part Number

k. Quantity of Parts per Maintenance Task

l. Associated Parts Unit of Issue

m. Associated Parts Shelf Life

n. Associated Parts Unit Price

o. Special Tools and Equipment Nomenclature

p. Special Tools and Equipment Cage

q. Special Tools and Equipment PN/NSN Task Descriptions 3.9 Tests, Inspections, and Reports The Coast Guard reserves the right to witness any or all of tests performed. The Vendor shall retain records of all tests and submit them to the Contracting Officers Representative (COR). The performance of tests and the preparation of reports shall follow the guidance of SNAME T&R Bulletin 3-39, Guide for Shop and Installation Tests.

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

3.9.1 First Article Testing (FAT)

The Vendor shall develop a First Article Testing procedure and perform the First Article Testing and inspection on a fuel transfer system filtration assembly and a fuel service system filtration assembly constructed and supplied under this Contract. The Vendor shall develop a First Article Test Procedure in accordance with American Petroleum Institute EI 1581, 5th Edition, Specification and Qualification Procedures for Aviation Jet Fuel Filter/Separators.

All pressure vessels shall be hydrostatically tested. The hydrostatic test pressure shall be recorded on the equipment label plate. The hydrostatic test pressure shall also be recorded in the FAT report. Operational testing as complete Assemblies shall be performed to measure operating temperature, pressure, and differential pressure. Information shall be recorded at 10 minute intervals for up to 30 minutes at flow rates of 4, 10, and 15 GPM. The automatic drain valves shall also be verified for proper operation. The test procedure shall be provided to the KO for review and approval prior to performing the FAT. A USCG representative will witness the test for First Article unit. A FAT report shall be provided.

3.9.2 Factory Testing (FT) Each complete filtration assembly supplied after the first article shall be factory tested and inspected. The testing and inspection shall include but not be limited to the following:

a. Operation of the complete filtration assembly for one (1) hour. Operating temperature (F), Factory Test Procedure flow rates (GPM) and system pressure (PSIG) shall be monitored and recorded on 10 minute intervals.

b. The automatic drain valves shall also be verified for proper operation.

c. Factory Test reports shall be provided for each fuel system filtration assembly tested.

3.9.3 Shipboard Test Plan The Vendor shall develop an Installation Test Plan for use by the installing activity for Shipboard Testing. The Installation Test Plan shall fully address all features and capabilities of the equipment and shall fully demonstrate the proper installation, startup, and operation of the equipment.

Shipboard testing for each fuel filtration assembly shall include the testing requirements of SNAME T&R 3-47 Guide for Sea Trials and the following:

a. Operation of the transfer and MDE fuel service filtration systems. Each system shall be monitored for required operational functions.

b. The automatic drain valves shall also be verified for proper operation.

c. Test Report data for the systems tested.

The Government will provide the labor and equipment for performance of the installation tests. Installation testing support by the Vendor shall be provided as a part of the Field Services 3.10 Workmanship

a. All workmanship, materials, and components must be of the highest quality in every respect and of new manufacture and in full conformance with this Specification and associated drawings and documents.

b. All materials and components must be of first quality in every respect and of new manufacture. No used materials or components will be permitted.

c. Welded parts shall be free of weld splatter, porosity, undercuts and other defects.

d. Work on all critical and or load bearing parts shall only be performed by properly certified craftsmen. Certificates shall be made available upon request.

e. All parts shall be free of burrs and sharp or ragged edges.

3.11 Notifications and Inspections – The Vendor shall notify the Contracting Officer in writing at least fourteen (14) calendar days prior to the performance of any inspections or testing.

4.0

QUALITY ASSURANCE

4.1 General - The Vendor shall maintain an inspection system which shall insure that each item offered to the Coast Guard for acceptance or approval conforms to the contract requirements. The inspection system shall be documented and available for review by the Coast Guard.

4.2 Records - The Vendor shall maintain records of all inspections and tests. The records as a minimum shall indicate the nature and number of observations made, the number and type of deficiencies found, and the corrective action taken. The Vendor shall provide the CG Quality Assurance Inspector with completed copies of the certification testing results upon completion of testing. A copy of the test certification, including any tests by outside vendors or tests of subcontracted materials, shall be provided to the Contracting Officer Representative (COR) and the quality assurance inspector when issued.

4.3 Calibration System - The Vendor shall maintain a test equipment calibration program in compliance with ANSI/NCSL Z540.3-2006. The program shall be documented and traceable to the National Institute of Standards (NIST).

4.4 Responsibility for Inspection – The Vendor shall be responsible for the performance of all inspection requirements specified herein. The Vendor shall provide space, personnel, and test equipment for the conduct of all inspection requirements. All inspection and testing shall be performed at the Vendor’s plant or at other facilities acceptable to the Coast Guard. The Coast Guard reserves the rights to verify or have performed any of the inspections that are deemed necessary to assure that supplies and services conform to the prescribed requirements.

4.5 Responsibility for Compliance – All items shall meet the provisions of Sections 3, 4 and 5 of this Specification. The inspections set forth in this Specification shall become part of the Vendor’s overall inspection system or quality program. The absence of any inspection requirements in the Specification shall not relieve the Vendor of the responsibility of assuring that all products or supplies submitted to the government for acceptance comply with all requirements of the contract. Sampling for quality conformance does not authorize submission of known defective material (either indicated or actual) nor does it commit the government to acceptance of defective material.

4.6 Quality Assurance Plan – The Vendor shall maintain a Quality Assurance Plan in accordance with ANSI/ASQC Q9001-2008 which shall insure that each item offered to the Coast Guard for acceptance or approval conforms to the contract requirements. The inspection system shall be documented and available for review by the Contracting Officer/Quality Assurance Representative.

4.7 Tests and Inspections – The inspections/tests as defined in this specification are the minimum required and are not intended to supplant any controls, examination, inspections or tests normally employed by the Vendor to assure the quality of the item in question.

4.8 Failure Responsibility – If the specified item fails to pass any inspection/test the Vendor shall provide a Corrective Action Report (CAR) to document the failure and the recommended fix to the Contracting Officer. If approved, the corrective action on the materials or processes shall be taken in accordance with this Section.

4.8.1 Corrective Action Remedies

a. The Contracting Officer reserves the right to totally reject any failed item without considering any suggested corrective action.

b. The inspection/test shall be discontinued until all corrective action has been taken.

c. After all corrective actions have been taken the inspection/test shall be continued or repeated at the option of the Contracting Officer.

d. Acceptance shall be withheld until re-inspection has been shown that the corrective action was successful and the item satisfactorily passes all inspections and tests.

e. All corrective actions shall be documented as part of the Vendor’s inspection system and submitted for approval to the Contracting Officer.

f. Each CAR shall include, but not be limited to the cause of each defect, corrective action suggested, and the steps taken to prevent a recurrence of each defect.

4.9 Test and Inspection Reports – One (1) copy of any required inspection, test or tolerance check shall be sent to the Contracting Officers Representative. A copy of any test, inspection or tolerance report shall be turned over to the Quality Assurance Representative upon arrival at the Vendor’s plant.

4.10 Packing Inspection – The Contracting Officer shall be notified prior to the packaging and marking of the completed units in accordance with Section 5.0 of this Specification.

5.0

PRESERVATION, PACKING, AND MARKING

a. The fuel transfer and fuel service filtration systems shall be preserved, packaged and marked for shipping as an Equipment Unit in accordance with SFLC-D-084-0481. The Systems shall be packaged in a minimum number of shipping containers suitable for shipment to the Government as directed, temporary storage uncovered in the weather, and then reshipment by the Government (within CONUS) to the installing activity.

b. Parts supplied under this contract shall be preserved, packaged and marked for shipping as Parts in accordance with SFLC-D-084-0481.

c. The Vendor shall prepare a Preservation, Packaging and Marking Plan in accordance with SFLC-D-084-0481. The plan shall be provided to the Government Quality Inspector prior to the preservation, packaging and marking of the first Fuel Filtration System delivery order. The plan shall discuss the proposed preservation and packaging methods, and spare parts. The plan shall also have draft samples of all proposed markings.

d. The intent is for the Quality Inspector to review and advise the Vendor of potential issues, prior to the preservation, packaging and marking of the first units. The Government reserves the right to inspect the preservation, packaging and marking of all units and parts, prior to release for shipment.

6.0

NOTES

6.1 Potential Sources - Manufacturers meeting the technical requirements of this Specification are as follows but are not limited to the following:

a. Facet International, Inc.

b. WM. W. Nugent & Co.

6.2 Government and Commercial Document Sources

6.2.1 Government Documents

a. DOD & Navy Publications and Forms (Other Than DODISS) Naval Publication and Forms Center 5801 Tabor Ave.

Philadelphia, PA. 19120

215-697-2000

b. Specification and Standards (DODISS Documents)

Standardizations Document Order Desk

700 Robbins Avenue

Building #4, Section D

Philadelphia, PA. 19111-5094

215-697-1187 http://assist.daps.dla.mil/quicksearch/

c. USCG Surface Forces Logistics Center

2401 Hawkins Point Road

Baltimore, MD 21226-5000

ATTN: Auxiliary Machinery Section 410-762-6764

d. Code of Federal Regulations (CFR)

U.S. Government Printing Office

732 N. Capitol Street, NW

Washington, DC 20401

866-512-1800 http://www.gpoaccess.gov/cfr/index.html 6.2.2 Commercial Documents

a. American National Standards Institute (ANSI)

25 West 43rd Street, 4th floor

New York, NY 10036

212-642-4900

FAX 212-398-0023

b. American Society for Quality Control (ASQC)

600 North Plankinton Avenue

Milwaukee, Wisconsin 53203

800-248-1946

FAX 414-272-1734

c. American Society for Testing & Materials (ASTM)

100 Barr Harbor Drive

West Conshohocken, PA. 19428-2959

610-832-9585

FAX 610-832-9555

d. American Welding Society (AWS)

550 N. W. Lejeune Road

Miami FL. 33126

305-443-9353

FAX 305-443-7559

e. International Organization for Standardization (ISO)

1, ch. de la Voie-Creuse, Case postale 56 CH-1211 Geneva 20, Switzerland

41-22-749-01-11 Fax 41-22-733-34-30

f. National Conference of Standards Laboratories (NCSL)

2995 Wilderness Place, Suite 107

Boulder, Colorado 80301-5404

303 - 440-3339

FAX 303 - 440-3384

g. The Society of Naval Architects and Marine Engineers (SNAME) 601 Pavonia Avenue Jersey City, New Jersey 07306 800-798-2188 Fax 201-798-4975

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