LWCT SOO.pdf

STATEMENT OF OBJECTIVES (SOO)

7,000 GALLON STAINLESS STEEL COLLECTION TANK

1. SCOPE

1.1. This specification describes the requirements for one 7,000 U.S. liquid gallon capacity tank. The tank shall be an ASME Boiler and Pressure Vessel Code tank constructed of stainless steel. The tank is portable and will be used in numerous locations to collect, transport, and store non-hazardous non-potable water.

2. PUBLICATIONS - All publication shall be to the latest edition unless otherwise specified.

2.1. CODE OF FEDERAL REGULATIONS

29 CFR PART 1910 - Occupational Safety and Health Administration (OSHA) Standards

29 CFR PART 1915 - OSHA for Shipyard Employment

49 CFR PART 393 - Federal Motor Carrier Safety Administration, Department of Transportation (DOT)

2.2. MIL SPECS

MIL-STD-2035 - Non Destructive Testing Acceptance Criteria

2.3. NAVAL FACILITIES ENGINEERING COMMAND

NAVFAC P-307 - Management of Weight Handling Equipment

2.4. NAVSEA SYSTEMS COMMAND

NAVSEA Technical Publication T9074-AS-GIB-010/271 - Requirements for Nondestructive Testing Methods

2.5. INDUSTRIAL - COMMERCIAL PUBLICATIONS: AMERICAN SOCIETY FOR MECHANICAL

ENGINEERS (ASME)

SECTION VIII – Boiler and Pressure Vessel Code (BPVC)

B46.1 - Surface Texture (Surface Roughness, Waviness, and Lay)

AG-1, Section FC or FK - Code of Nuclear Air and Gas Treatment

B16.5 – Pipe Flanges and Flanged Fittings

2.6. INDUSTRIAL - COMMERCIAL PUBLICATIONS: AMERICAN WELDING SOCIETY (AWS)

D1.1 – Structural Welding Code, Steel

D1.2 – Structural Welding Code, Aluminum

2.7. INDUSTRIAL - COMMERCIAL PUBLICATIONS: AMERICAN NATIONAL STANDARDS INSTITUTE

(ANSI)

N14.6-1993 for Radioactive Materials – Special Lifting Devices for Shipping Containers Weighing 10,000 Pounds or More

3. REQUIREMENTS

3.1. DESIGN - The equipment shall be new and unused, capable of performing its intended function in accordance with the operation and performance requirements specified herein. The requirements specified herein shall take precedence over any other drawings. Dimensions shall be in inches unless otherwise specified.

3.1.1. If equivalent alternatives are provided for those items herein that specify part numbers, then product information shall be submitted to PHNS & IMF for review. Vendor shall allow at least 5 working days, starting upon receipt of product information by a representative at PHNS & IMF, for approval of submittals. For camera system only, vendor shall allow at least 10 working days, starting upon receipt of product information by a representative at PHNS & IMF, for approval of submittals.

3.2. SAFETY AND HEALTH REQUIREMENTS - Covers, guards, and other safety devices shall be provided for all parts of equipment that present safety hazards. Safety devices shall not interfere with operation of the equipment. The devices shall be removable to facilitate inspection, maintenance, and repair of the parts. Machine parts, components, mechanisms, and assemblies furnished on the unit shall comply with all specific requirements of “OSHA Safety and Health Standard, General Industry (29 CFR 1910)” and “OSHA Safety and Health Standard, Shipyard Employment (29 CFR 1915)”.

3.2.1. USE OF POLYCHLORINATED BIPHENYL (PCB) - The use of polychlorinated biphenyl (PCB) on or in the furnished equipment is prohibited.

3.2.2. USE OF MERCURY - The equipment shall not contain mercury or mercury compounds, nor shall it be exposed to free mercury during manufacture, testing, and inspection.

3.2.3. USE OF ASBESTOS - The use of asbestos and materials containing asbestos on or in the furnished equipment is prohibited.

3.2.4. USE OF HEAVY METALS IN PAINTS – Paints shall be free of Lead, Chromates, or any other Heavy Metals.

3.2.5. SAFETY DATA SHEET (SDS) – Globally Harmonized System (GHS) SDSs shall be provided as required by this procurement specification. As a minimum, SDSs shall be provided for all paints, primers, adhesives, sealants, and lubricants used on the entire tank assembly.

3.3. CONSTRUCTION - The equipment shall be constructed of parts that are new, without defects and free of repair. Prior to fabrication, PHNS & IMF shall approve all final fabrication drawings. Once submittals are approved, no changes shall be made unless authorized by PHNS & IMF. Vendor shall allow at least 15 working days, starting upon receipt of fabrication drawing by a representative at PHNS & IMF, for approval of submittals.

3.3.1. WELDING, BRAZING, OR SOLDERING

3.3.1.1. Welding, brazing, or soldering shall be employed only where those operations are included in fabrication of the original design. These operations shall not be employed as repair measures for defective parts.

3.3.1.2. All weld joints/wrought material shall be inspected. Certified reports are required.

3.3.1.3. For exterior tank welds, including tank frame, all burrs and weld splatter shall be removed. Welds shall be free of slag. All rough edges shall be removed and rounded.

3.3.1.4. Any loose, splattered solder, flux, metal chips, insulation scrap, or other foreign material shall be removed from the equipment.

3.3.1.5. All structural welds, other than pressure vessel welds, shall be in accordance with American Welding Society (AWS) D1.1 Structural Welding Code, Steel, Latest Edition and American Welding Society (AWS) D1.2 Structural Welding Code, Aluminum, Latest Edition. Platform welds shall be inspected in accordance with AWS D1.1 and AWS D1.2.

3.3.1.6. All pressure vessel welding, including the shell and heads, pressure vessel piping penetrations, and all welded attachments to the pressure vessel shall be in accordance with the ASME Boiler and Pressure Vessel Code (BPVC) requirements. Use low carbon stainless steel filler metal (e.g. ER 316L) for all tank welding and pipe welding. All welders assigned to fabrication of the tank must be ASME BPVC certified, and all work must conform to the ASME BPVC specifications cited herein.

3.3.1.7. All weld joints shall have a 1.00 joint efficiency (100% of base metal strength) in accordance with ASME BPVC requirements.

3.3.1.8. Longitudinal and circumferential welds to assemble the tank shell and circumferential joints between the shell and hemispherical heads shall be full penetration welds (e.g., welded from the outside and inside). Welds shall be back gouged to sound metal and all slag removed prior to welding from the second side. Longitudinal weld seams shall be located near the top of the tank as shown in Plan View 1B.

3.3.1.9. Pipe hangers internal to the tank shall consist of stainless steel rods which will be cut to suit and welded to the piping and internal surface of the tank. Pipe hangers shall be positioned to avoid blocking holes in diffuser pipe. Welding shall be consistent with welding of the tank and pipe. Welds shall be welded all around, ground smooth, shall be free of slag, and shall not snag or tear a clean cloth when wiped in any direction. Kamen wiping materials #125 shop towel (100% cotton) or equal shall be used to check for surface and/or weld finish.

3.3.1.10. 100% Radiography shall be performed on all completed tank shell, shell to head, and piping butt welds.

Acceptance criteria for radiographic inspections are per ASME BPVC Section VIII, Division I, Latest Edition.

Certified report required.

3.3.1.10.1. Provide a complete set of final radiograph film, a shooting sketch, and radiograph review forms, and locator map of all weld joints to PHNS & IMF for baseline historical information and limited review to ensure in accordance with ASME BPVC. For each submission of up to 40 radiographs, allow 10 working days for review starting upon receipt of the film by PHNS & IMF. For submissions (up to 40 radiographs) received within 10 working days of each other, allow 10 working days for the review starting upon the completion of review of the prior submission. All defects or suspected defects identified by PHNS & IMF Radiograph Film Interpreter shall be repaired and re-radiographed. Film of the repaired areas shall be reviewed by the PHNS & IMF Radiograph Film Interpreter prior to hydrostatically testing the tank to ensure it meets ASME BPVC acceptance criteria.

3.3.1.10.2. Visually inspect the root and completed welds. Visual inspection acceptance criteria are no cracks or incomplete fusion and no undercut which could interfere with subsequent radiographic inspections. No slag is allowed.

3.3.1.10.3. All indications detected by radiographic inspection shall be corrected, removed, or repaired, as required per the ASME BPVC. The film increments containing the indication(s) shall be re-radiographed to verify absence of the indication(s). Indications include weld defects such as cracks, lack of penetration, film artifacts, surface defects and objects interfering with proper film interpretation. Contractor shall evaluate all radiographic film to be in accordance with the ASME BPVC.

3.3.1.10.4. Only MIL-type penetrameters are allowed for radiographic testing (wire type penetrameters are not allowed).

3.3.1.10.5. Welds that cannot be radiographically inspected due to interferences or joint design shall be PT inspected to the requirements per ASME BPVC Section VIII, Division 1, Latest Edition. Certified report required.

3.3.1.11. All piping penetrations shall be fillet welded from both sides. The minimum weld thickness for all piping penetrations shall be equal to either the pressure vessel wall thickness or the respective pipe wall thickness, whichever is less. Internal tank fillet welds shall be ground smooth.

3.3.1.12. All piping flange joints and elbow joints shall be butt-welded. Piping butt welds shall be full penetration and shall have internal surfaces that are smooth and crevice free.

3.3.1.13. Interior tank weld surface (e.g. exterior welds on pipe internal to tank and interior welds in filter demister housing) and base metal shall not snag nor tear a cleaning cloth when wiped in any direction. Kamen wiping materials #125 shop towel (100% cotton) or equal shall be used to check for surface and/or weld finish. Welds shall be free of undercut. No slag is allowed in finished welds.

3.3.1.14. The welds on the interior of the pressure vessel (e.g. exterior welds on pipe internal to tank and interior welds in filter/demister housings) and interior of piping shall be ground flush, and be free of porosity, slag, craters, cracks, tool marks, arc strikes, flux, weld splatter, scratches, burrs, and rust. The edges of the welds shall be smoothly blended with the base metal.

3.3.1.15. Welds shall be sized based on the material thickness, weld joint location, and predicable stresses.

3.3.2. FASTENING DEVICES - Screws, pins, bolts, and similar internal and external parts shall be installed with means for preventing change of tightness. Parts subject to removal or adjustment shall not be swaged, peened, staked, or otherwise permanently installed. Fastening devices shall be tightened to torque limits as established by the manufacturer's standard for tightening to preclude loosening by normal operation or vibration.

3.3.3. SURFACES - Surfaces of castings, forgings, molded parts, stampings, and welded parts shall be cleaned and free from sand, dirt, fins, sprues, flux, or other harmful, or extraneous materials. All exterior surfaces shall be smooth and all sharp edges rounded or beveled unless sharpness is required to perform a function.

3.3.4. PAINTING

3.3.4.1. The equipment shall be properly painted. Painting shall be per the manufacturer's standard practice.

Prior to painting, surfaces shall be properly prepared and primed. Painting shall provide a highly wear-resistant finish that guarantees continued protection against the specified environment under all service conditions. Refer to paragraph 3.3.10.

3.3.4.2. No yellow paint, decals, or yellow colored surfaces on any portion of the tank is allowed.

3.3.4.3. All metal parts that are not stainless steel, chrome, or aluminum shall be painted. Bimetallic welds shall be painted. No paint or similar material shall be applied to any stainless steel component. Refer to paragraph 3.3.7 for aluminum treatment.

3.3.4.4. All painting will consist of the minimum: one coat of corrosion resistant primer and two coats of durable weather resistant enamel. Prepare surfaces in accordance with the coating manufacturer’s printed instructions.

3.3.4.5. Prior to painting, provide the paint manufacturer’s information, formula, and safety data sheets to PHNS & IMF for approval. Allow 10 working days for paint evaluation, starting upon receipt of the information by PHNS & IMF. No painting shall occur until written approval is obtained from PHNS & IMF. Paint will be evaluated to ensure no heavy metals.

3.3.4.6. Primary and top coat paints shall be manufactured by the same manufacturer to ensure maximum compatibility.

3.3.4.6.1. Primer: Green, Formula 150, Type IV, MIL-DTL-24441/29B

3.3.4.6.2. Top Coat: Haze Gray, Formula 151, Type IV, MIL-DTL-24441/30B

3.3.5. LIFTING DEVICES – Inspect the welds by Visual Testing (VT), Magnetic Particle Testing (MT), or Liquid Penetrant Testing (PT), as specified herein, per NAVSEA technical publication (TP) T9074-AS-GIB- 010/271 with acceptance criteria per MIL-STD-2035, Class 3. No slag is allowed. Certified reports are required.

3.3.6. FERROUS PARTS - Exposed ferrous parts such as screws, bolts, nuts, washers, etc., shall resist corrosion in a salt-laden, moist, variable temperature atmosphere. Protection such as cadmium or chrome plating, galvanizing or other electrical/chemical process, or use of monel or stainless steel is acceptable. Refer to paragraph 3.3.10.

3.3.7. ALUMINUM PARTS - Aluminum parts for use outdoors shall be anodized or chemically treated followed by two coats of weather-resistant exterior paint.

3.3.8. DISSIMILAR METALS - Dissimilar metals shall not be used in direct contact with each other without suitable means for preventing electrolytic corrosion.

3.3.9. CONTROL PANELS, INSTRUMENTS, AND PLATES - Wording and numbers on all control panels, instruments, charts, and plates shall be permanently and legibly displayed in bold face, English language on a contrasting background.

3.3.10. ENVIRONMENTAL CONDITIONS - The entire tank assembly shall be suitable for marine industry use subject to salt-laden, variable temperature atmosphere, extreme moisture, humidity, and corrosive environmental conditions.

3.3.11. MANUALS, TECHNICAL, MODIFIED COMMERCIAL - These manuals are operator and shop maintenance instructions which enable an average journeyman mechanic without prior knowledge of the specific type, make, or model to maintain, repair, and overhaul the equipment.

3.3.11.1. The contents of a complete set of technical manuals shall include, at a minimum, the following:

3.3.11.1.1. Operating instructions.

3.3.11.1.2. Manufacturer’s calculations for the tank design (e.g. lift lugs, support structure design, etc.).

3.3.11.1.3. Certified reports.

3.3.11.1.4. Maintenance, service, calibration, and overhaul instructions (in addition to their respective schedules/periodicity).

3.3.11.1.5. Materials/parts list, with illustrations.

3.3.11.1.6. As built drawings (vender to include, but are not limited to, AutoCAD 2010 files in DXF format).

4. TEST AND EVALUATION REPORTS

4.1. The contractor shall provide a written test report which provides certifications and analytical data that support compliance of the equipment with the requirements specified herein. This report documents the results of all tests and inspections performed, provides assessment of equipment performance relative to its ability to adequately satisfy contract requirements, and forms a basis for recommending a safety certification. The report, test, and evaluation shall be a composite of the test and inspection requirements specified in the contract. The reports shall include, but is not limited to, the following:

4.1.1. List of all tests performed and by whom witnessed (Government and Contractor).

4.1.2. Test data results used for evaluation of equipment to meet specification requirements.

4.1.3. Tabulation of all discrepancies related to specification performance requirements.

4.1.4. Description of limitations revealed by data utilized.

4.1.5. Actions taken to mitigate each discrepancy and limitation.

4.1.6. Recommendation for subsequent actions.

4.1.7. Summary/Conclusions.

4.2. OSHA Compliance - The equipment and its components shall be in compliance with 29 CFR 1910.

4.3. OSHA Approved Certification - The equipment and its components specified herein shall be inspected, approved as defined in 29 CFR 1910.399, and labeled by a Nationally Recognized Testing Laboratory (NRTL) as defined in 29 CFR 1910.7. A satisfactory NRTL Field Evaluation Report shall be provided to the receiving activity after equipment delivery and installation, and prior to destination testing.

5. SPECIFICATIONS

5.1. GENERAL SPECIFICATIONS

5.1.1. Entire tank assembly (e.g. support structure, tank, walking platform) must fit on a flatbed within the following dimensions: Width 8 feet, Length 30 feet.

5.1.2. The contractor shall provide means of properly securing the tank to the support structure, and tank assembly to the flatbed in accordance with 49 CFR 393.

5.1.3. There shall be no penetrations at the bottom of the tank.

5.1.4. Replaceable parts shall be manufactured to definite standards, tolerances, and clearances such that parts can be replaced or adjusted without modification of the equipment.

5.1.5. The equipment shall be designed and constructed to permit maintenance personnel to service the equipment easily and effectively using a minimal number of standardized tools.

5.1.6. Nominal tank capacity shall be 7,000 U.S. liquid gallons, with an actual usable range of 0 to 6,900 (minimum) U.S. liquid gallons.

5.1.7. Materials as specified herein shall have certified reports.

5.2. TANK AND PIPING

5.2.1. General Tank and Piping

5.2.1.1. Material for tank pressure vessel and piping: 304L or 316L (Low Carbon) stainless steel per ASTM specifications.

5.2.1.2. Tank (e.g., shell and heads) shall be fabricated with plate No. 4 or finer finish.

5.2.1.3. Interior tank surface finish (including piping and components) shall have a roughness average (RA) equivalent to 30-35 micro inches or better in accordance with ASME B46.1. All pits, gouges, scratches, tool marks, weld spatter, etc. on the interior tank surface shall be faired into the surrounding surface. Keep grinding to a minimum. Certified reports are required.

5.2.1.4. Interior tank weld surface finish (including piping and components) shall have a RA equivalent to 30-35 micro inches or better per ASME B46.1. Weld surface and adjacent material shall not snag and/or tear a Kamen wiping material #125 shop towel (100% cotton) or equal when wiped in any direction. Certified report required.

5.2.1.5. Interior of the filter/demister housing and weld finish shall have a RA equivalent to 30-35 micro inches or better per ASME B46.1 and shall not snag and/or tear a Kamen wiping material #125 shop towel (100% cotton) or equal when wiped in any direction.

5.2.1.6. The machined surface finish of gasket mating surfaces on flanges in piping systems and connected components shall be in accordance with ASME B46.1. Flanges for spiral wound (metallic) gaskets shall receive a finish with a circular lay (concentric or spiral) of 125 to 250 micro inches RA produced by machining not less than 40 serrations of uniform depth per inch of face width.

5.2.1.7. Mechanical polishing is acceptable to obtain required surface finish.

5.2.1.8. All grinding and polishing tools coming in contact with stainless steel shall be for use on stainless steel only and shall not have been previously used on any non-stainless steel surfaces. Grinding tools shall be aluminum oxide or silicon carbide. Brushes shall be stainless steel wire only.

5.2.1.9. The interior of the tank pressure vessel and piping shall be dried and wiped clean. Interior tank and piping shall be free of all scale, flux, grease, preservative, oil, dirt, filings, and other foreign or loose material. Light dust is acceptable.

5.2.1.10. Exterior tank surface finish shall be free of mill scale and surface defects.

5.2.2. Tank

5.2.2.1. The tank pressure vessel includes a shell with two dished and flanged heads, which are seamless and formed. Pressure vessel design, fabrication, and inspection shall be in accordance with the latest edition of the ASME BPVC, Section VIII, Division 1, for unfired pressure vessel. The tank pressure vessel shall be manufactured by a company possessing an ASME “U” stamp. The vendor shall deliver a copy of the ASME data sheet, signed by an ASME inspector.

5.2.2.2. The tank design pressure and temperature shall be 10 psig and 220 degrees Fahrenheit. The pressure vessel shall be designed to withstand a vacuum of 3.66 inches (-1.8 psig) of mercury.

5.2.2.3. The thickness of the tank heads and shell shall be 5/16 inch minimum.

5.2.2.4. Deleted.

5.2.2.5. The tank longitudinal seam welds shall be located near the top of the tank. The longitudinal and circumferential seam welds shall clear, to the maximum extent practicable, any tank penetrations/openings, top tank platform, and tank support structure.

5.2.3. Piping

5.2.3.1. All stainless steel (304L or 316L) piping and welded fittings shall be seamless and schedule 80. Certified report required.

5.2.3.2. All piping should have flanged ends with an associated blank flange cover.

5.2.3.3. Piping locations shall be as shown on Plan View 1B herein.

5.2.3.4. Inlet Line

5.2.3.4.1. 2 inch Nominal Pipe Size (NPS).

5.2.3.4.2. Include a repad for the piping penetration.

5.2.3.4.3. Vertical pipe with a 150 lb ASME B16.5 flanged end connection.

5.2.3.4.4. 2 inch NPS shut off ball valve. Ball valve shall be located at least 4 inches from the top of the tank platform.

5.2.3.4.5. Ball valve will be controlled with a hand wheel.

5.2.3.4.6. There shall be no piping hangers located above the tank platform.

5.2.3.4.7. Inlet piping shall extend no more than 2 inches beyond the tank penetration. Siphon breaker (e.g., 1/8 inch diameter hole) shall be located no more than 5/8 inch from the top of the tank. The siphon breaker shall face the center of the tank (e.g., siphon breaker should be visible to the camera). Certified report required.

5.2.3.4.8. See Detail 3A.

5.2.3.5. Discharge Line

5.2.3.5.1. 2 inch NPS.

5.2.3.5.2. Include a repad for the piping penetration, if needed.

5.2.3.5.3. Vertical pipe with 150 lbs ASME B16.5 flanged end connection.

5.2.3.5.4. 2 inch NPS shut off ball valve. Bottom of the ball valve shall be located at least 4 inches from the top surface of the platform.

5.2.3.5.5. Ball valve will be controlled with a hand wheel.

5.2.3.5.6. The discharge line shall extend into the tank and be located 1-1/2 inches from the welded sump cap surface. The discharge line shall also be braced at the bottom.

5.2.3.5.7. The tank shall have a low point for the discharge line (e.g. welded cap at 6” diameter).

5.2.3.5.8. The end of the discharge line tail pipe shall be enlarged to provide an area greater than 1 ½ times the inside area of the tail pipe.

5.2.3.5.9. The discharge line tail pipe location with respect to adjacent plating or other components and obstructions shall ensure a free suction area around the open end. Periphery shall not be less than 1 ½ times the inside area of the tail pipe.

5.2.3.5.10. Tank suction lines shall terminate at the lowest part of the tank.

5.2.3.5.11. The discharge pipe between the ball valve and reducer shall be one piece with no circumferential welds. Certified report required.

5.2.3.5.12. A 150 lb 2 inch IPS ASME B16.5 flanged end to Cam and Groove 1-1/2 inch Male Adapter. The Cam and Groove adapter should be welded to the flange using a full penetration weld. There should be no crevices inside the flanged adapter. Welds shall be ground smooth to eliminate crevices. There should be a 6 (+0.5/-0) inch minimum clearance between the face of the flange to the bottom of the Cam and Groove adapter. The reducer piping shall be schedule 80. See Detail 12A.

5.2.3.5.13. See Detail 6A.

5.2.3.6. Diffuser Line

5.2.3.6.1. 4 inch NPS.

5.2.3.6.2. Include a repad for the piping penetration and hanger.

5.2.3.6.3. The centerline of the diffuser pipe shall be located no more than 12 inches above the bottom surface of the tank.

5.2.3.6.4. Horizontal pipe with 600 lb ANSI B16.5 flanged end connection. Bottom of the flange shall be 5 inches from the top of tank.

5.2.3.6.5. A siphon breaker (e.g., 1/8 inch diameter hole) shall be located no more than 6 inches from the top of the tank. The siphon breaker shall also face the center of the tank (e.g., siphon breaker should be visible to the camera).

Certified report required.

5.2.3.6.6. The diffuser pipe shall extend for a minimum of 2/3 of the horizontal dimension of the tank.

5.2.3.6.7. 225 holes, which are 3/8 inches in diameter, shall be drilled in the lower quadrants of the diffuser pipe.

The holes shall extend within 4 inches of the end of the diffuser pipe.

5.2.3.6.8. A mechanical locking device shall be used to secure the threaded end cap.

5.2.3.6.9. The diffuser line shall be supported with internal hangers fabricated from CRES rod or bar stock cut to suit and welded to the pipe and internal surface of the tank. Hanger welds shall be consistent with the welding of the tank and the pipe. Welds shall be welded all around and ground smooth to eliminate crevices.

5.2.3.6.10. The vertical portion of the diffuser pipe shall be one piece and without circumferential welds. Certified report required.

5.2.3.6.11. The horizontal portion of the diffuser pipe shall be one piece and without circumferential welds.

Certified report required.

5.2.3.6.12. See Detail 2A, Detail 2B, and Section 2C herein.

5.3. HEPA FILTER/DEMISTER

5.3.1. The HEPA filter/demister housing shall be designed for an atmospheric pressure and a temperature of 220 degrees Fahrenheit.

5.3.2. Include a repad for the piping penetration.

5.3.3. The filter rated capacity shall be 140 SCFM air at 1.0 inches water gage maximum.

5.3.4. The housing shall contain a removable filter splash guard which shall have drain hole(s), be capable of being secured in place to prevent inadvertent removal, and be constructed of stainless steel. The housing should have the ability to be separated from the tank and include blank flange cover(s) (e.g., one for housing and one for penetration) when housing is removed.

5.3.5. Each component inside the housing (e.g. HEPA filter and demister) shall be removable.

5.3.6. The HEPA filter shall be designed for 99.97% efficient for filtration of 0.3 micron particles.

5.3.7. HEPA filters shall be purchased to specifications which conform to the design, construction, material, test, qualification and quality control requirements of the ASME "Code of Nuclear Air and Gas Treatment," ASME AG-1, Section FC or FK. If HEPA filter does not conform to ASME AG-1 Section FC or FK, then HEPA filter specifications will be provided to PHNS & IMF for approval. Allow 10 working days for evaluation, starting upon receipt of the information by PHNS & IMF.

5.3.8. See Elevation View 5A and Section 5B herein.

5.4. CAMERA

5.4.1. There shall be a minimum of two cameras.

5.4.2. Jointly, the cameras shall be capable of viewing the internal tank surfaces to the maximum extent practicable.

5.4.3. The camera system shall be designed for a temperature of 220 degrees Fahrenheit.

5.4.4. Internal camera and any associated components internal to the tank shall be waterproof.

5.4.5. Any external camera components shall be protected against the specified environment.

5.4.6. Camera head with extension column is an EVEREST VIT PN. PTZ6.0140SHDN04 PTZ140 SS custom kit with tool column or equivalent having the following characteristics:

5.4.6.1. Stainless Steel PTZ140 camera head with 36X optical, 12X digital zoom

5.4.6.2. NTSC format

5.4.6.3. Unitized camera head with no external wiring

5.4.6.4. Pan range +/- 180 degree

5.4.6.5. Tilt range +129 degree/ -105 degree

5.4.6.6. Two 35-watt halogen lamps w/focused dichroic reflectors (one flood, one spot)

5.4.6.7. Extension column per Everest VIT drawing 28200X2 (EVEREST VIT PN. PTZ6.0140EXTCOL) or equivalent with the following characteristics:

5.4.6.7.1. 300 series stainless steel

5.4.6.7.2. Integral charging valve and extension cable

5.4.6.7.3. 6 inch NPT 150 lbs flat face pipe flange per ASME B16.5

5.4.6.7.4. Environmental and weather proof connectors on top of column to connect PTZ6.0 main cable to tank camera and to connect external gas to charge camera via the extension column.

5.4.6.7.5. Extension column provided preassembled on camera head and pressurized at 18 (+2, -0) psi.

5.4.6.8. The camera stop point shall be oriented toward the side of the tank, which reduces the interruption of camera panning in the main part of the tank during inspection.

5.4.6.9. Camera control unit (Version 7.0 with S-video output) and 15 foot cable. Pendant control with cable.

5.4.6.10. Digital Video Recording (DVR) capabilities (e.g., DVD format).

5.5. SPRAY DOWN SYSTEM

5.5.1. There shall be a minimum of two separate spray down systems.

5.5.2. The spray down system and associated piping shall be designed for a pressure of 100 psig and a temperature of 220 degrees Fahrenheit.

5.5.3. Rotating spray head is a LECHLER PN. 577.289.17.BN or equivalent with the following characteristics:

5.5.3.1. Free spinning

5.5.3.2. Type 316 stainless steel with Teflon bearings

5.5.3.3. 1 inch NPT female connection

5.5.3.4. 360 degrees coverage

5.5.3.5. 60 psi maximum pressure

5.5.3.6. 20 psi operating pressure at inlet

5.5.3.7. 10 foot wash range

5.5.3.8. Coarse stream spray pattern

5.5.3.9. 35 (+/- 5) gpm flow rate at normal operating pressure

5.5.4. Flat fan nozzle is a LECHLER PN. 688.722.16.BE or equivalent with the following characteristics:

5.5.4.1. 303 stainless steel

5.5.4.2. 3/8 inch NPT male connection

5.5.4.3. 1.75 (+/- 0.25) gpm flow rate at 35 psi operating pressure

5.5.4.4. 30 degree fan angle spray pattern

5.5.4.5. 27 degree deflection angle

5.5.5. Solid stream nozzle is a LECHLER PN. 544.720.16.BE or equivalent with the following characteristics:

5.5.5.1. 303 stainless steel

5.5.5.2. 3/8 inch NPT male connection

5.5.5.3. 1.75 (+/- 0.25) gpm flow rate at 35 psi operating pressure

5.5.5.4. Solid stream spray pattern

5.6. MANWAY COVERS

5.6.1. Each manway cover will be fabricated to support a camera and spray down system.

5.6.2. The manway cover shall be made of type 304L or 316L stainless steel with a gasket made of Buna-N rubber.

5.6.3. The camera system shall have the ability to be separated from the manway cover without removing the entire manway cover assembly. Refer to paragraph 5.4.6.7.3.

5.6.4. The manway cover shall be capable of being lifted via a 3 point lift utilizing ½ inch safety/swivel hoist rings. Each threaded hole shall be load tested to 50% (+5%/-0%) of the entire weight of the manway cover assembly (e.g., includes the weight of the camera, manway cover, and spray down system). The threaded holes shall be designed with a factor of safety greater than 10 to 1 on yield strength.

5.6.5. The manway cover shall be oval in shape and have a minimum dimension of 32 inches to allow personnel access.

5.6.6. All crevices in the manway construction shall be seal welded and ground smooth to match the surrounding areas.

5.6.7. Plan View 1B shows approximate location of manways covers. However, manway openings shall be positioned so the intent of paragraph 5.4.2 is met. Manway openings may be staggered or off centered as needed.

5.6.8. Manway cover shall have a vent assembly.

5.6.9. See Plan View 4C, Elevation 4D, and Elevation 4E herein.

5.7. LIQUID LEVEL & TEMPERATURE INDICATOR

5.7.1. The range of the liquid level indicator band shall be 0 to 7,000 U.S. liquid gallons.

5.7.2. The range of the temperature band shall be 20 to 240 degrees Fahrenheit.

5.7.3. Shall not be a glass gauge or dipstick type indicator.

5.7.4. Liquid level gauge is a MTS Level Plus RefineME liquid level transmitter (model LPR2D1B11A1CFFAU*****S) or equivalent with resistance temperature detector (RTD) installed 16 inches from the bottom of the sensor assembly. The sensor pipe shall be rigid, secured at the top and bottom of the tank, and have a 3/4 inch NPT process connection and compression fitting. All wetted parts on the sensing element shall be 316 stainless steel.

5.7.4.1. Sensor pipe length shall be based on the height of the tank and ordered per manufacturer directions.

5.7.5. Liquid level float is a MTS float (Model 201248-1 or equivalent) made of 316L stainless steel and has a magnet located at the top of the float to provide indication of liquid at the lowest level possible.

5.7.6. Process meter for the tank level (inches) is a precision digital universal process meter (Model PD6000- 6R0 or equivalent) with a red display.

5.7.7. Process meter for the tank volume (gallons) is a precision digital universal process meter (Model PD6000-6R5 or equivalent) with a red display. This meter provides the 24 VDC loop-power to the liquid level gauge and two relay outputs and one 4-20 mA transmission output.

5.7.8. Process meter for the tank temperature (degrees Fahrenheit) is a precision digital universal process meter (Model 6000-6R0 or equivalent) with a red display.

5.7.9. Bar graph indicator for the percent tank full is an M-System vertical bar graph indicator (Model 48V- 1RVA-K or equivalent). The bar graph indicator shall indicate percent full by volume of the tank. The bar graph indicator scale shall read from 0 to 100% with 50 divisions (every 2%) and starting with 0% have every 10% accentuated (longer lines) and labeled (numbered).

5.8. GAUGE MANWAY COVER

5.8.1. The gauge manway cover will be fabricated to support the liquid level and temperature indicator.

5.8.2. Any external indicating equipment/components shall be protected from the specified environment.

5.8.3. The gauge manway cover shall have two brackets which are designed to lift the cover with the liquid level and temperature indicator attached. The brackets shall be designed with a factor of safety greater than 10 to 1 on yield strength. The brackets shall be load tested to 150% (+5%/-0%) of the weight of the entire gauge manway cover assembly (e.g., includes the weight of the liquid level and temperature indicator, sensor pipe, and gauge manway cover).

5.8.4. A gauge guard shall also be provided to protect the instrumentation from physical damage, while allowing the tank instrumentation to still be visible.

5.9. INSTRUMENT ENCLOSURE

5.9.1. Instrument enclosure is a Hoffman (Model CSD201610WSS or equivalent) concept 304 stainless steel wall-mount enclosure housing with a Lexan window and a NEMA 4X rating. The rear instrument enclosure shall be of 12 gauge or thicker stainless steel and mounted at the discharge end of the tank assembly as shown in Detail 9A/9B, Plan View 9C, and Elevation 9D. The housing shall have a lockable handle/latch (Hoffman Cat. No.

CWHPTO or equivalent). The housing shall include a steel panel (Hoffman Cat. No. CP2016 or equivalent) and a swing-out stainless steel panel (Hoffman Cat. No. CSP2016 or equivalent) with a lockable handle/latch (Hoffman Cat. No. CWHPTO or equivalent). The housing shall be mounted to the instrument enclosure with stainless steel mounting bracket kits (Hoffman Cat. No. CMRKSS or equivalent) and fasteners. Instrument enclosure (e.g., electrical wiring, component mounts, and enclosure mounts, etc.) will be subjected to vibration during transportation of tank and shall be designed accordingly.

5.9.2. Provide an inner lip all around the door opening and provide gaskets to form a weather tight seal when the doors are closed.

5.9.3. The instrument enclosure shall have the three process meters, bar graph indicator, surge suppressor, and a power cord installed.

5.9.4. See Detail 9A, Detail 9B, Plan View 9C, and Elevation 9D herein.

5.10. TANK PLATFORM, SAFETY RAILS, AND LADDERS

5.10.1. Tank platform, safety rails, and ladders shall meet all requirements of the 29 CFR 1910 and 29 CFR 1915.

5.10.2. Platform structure is a walking deck for the top of the tank. The platform structure shall be designed to provide a distributed load capacity of 50 pounds per square foot with a concentrated load at any location consisting of a 200 lb person with 50 lbs of tools.

5.10.3. The permanent deck structure shall provide 3 inches (+/- ½ inch) clearance around all piping (e.g., inlet and discharge piping) to allow removal of the platform. The platform decking shall be removable panels and fabricated from stainless steel. In addition, no permanent deck or deck structure shall be closer than 6 inches (measured horizontally) to the outside diameter of the flanges. A removable structure shall be provided to support bringing the deck as close to the flanges, inlet and discharge piping as practicable. All deck grating shall have a clearance of at least 2 inches from any fluid boundary of the tank penetrations.

5.10.4. A non-slip surface shall be applied to the platform deck and ladder rungs.

5.10.5. Removable safety rails shall be fabricated from stainless steel. The safety rail must be removable with hand tools and in sections weighing less than 50 lbs.

5.10.6. Removable toe boards for the platform shall be provided and fabricated from stainless steel.

5.10.7. Swing gates shall be provided at the ladders openings. Ladders shall not be placed near the ends of the tank. Ladders shall be fabricated from stainless steel.

5.10.8. See Front Elevation 8A herein.

5.11. TANK SUPPORT STRUCUTRE

5.11.1. The tank support structure shall be completely separable from the tank. Contractor shall provide a means to secure tank to the support structure in accordance with 49 CFR 393.

5.11.2. The tank support structure should be designed with a high and low end (e.g. slight incline/slope). The lower end shall be on the discharge side of the tank.

5.11.3. The tank support structure shall be load tested to 150% (+5%/-0%) of the complete tank assembly utilizing a 4 point lift (e.g., each lug bearing a quarter of the total load). The complete tank assembly includes the following: the actual measured empty weight of the tank with all permanently installed components (e.g., manway covers, piping, blank flanges, etc.), tank support structure, tank platform (with handrails and toe boards), ladders, tank cage, and the weight of 7,000 gallons of water. Perform lifting and handling configuration in accordance with NAVFAC P-307 Naval Facilities Engineering Command.

5.11.4. The lift lugs and frame shall have a minimum design factor of safety of 10 to 1 based on yield strength of the material.

5.11.5. The hole in the lift lug shall be equal to or greater than a 2-1/4 inch diameter to accommodate a 1-3/4” 25T shackle. The lift lug thickness shall be designed to accept a 1-1/2” 30T shackle.

5.11.6. Lift lugs shall not be above the horizontal centerline of the tank and shall not be more than 6 inches below the centerline. Lift shall be performed utilizing only slings and shackles totaling 16 feet without the use of a spreader bar. The horizontal sling angle shall be 60 degrees or greater while maximizing stability.

5.11.7. The load bearing members of the tank frame shall meet the requirements of ANSI N14.6-1993 (Only the 1993 revision is applicable. Note that this specification has been withdrawn by ANSI.). This requires a drop weight test per ASTM E208 or a charpy impact test per ASTM A370 as specified in paragraph 4.2.6 of ANSI N14.6-1993.

The anticipated minimum service temperature for the tank frame is 20 degrees Fahrenheit, therefore, the transition temperature shall be a minimum of -20 degrees Fahrenheit. Certified records are required for each of the load bearing members of the tank frame.

5.12. TANK CAGE

5.12.1. A cage consisting of lockable/removable metal panels/screens on the bottom of the tank (e.g., approximately bottom 1/4 to 1/3 of the tank). Each panel/screen must be easily removable with hand tools and in sections weighing less than 50 lbs.

5.12.2. The tank cage shall be designed to preclude access to the bottom of the tank using stainless steel expanded metal.

5.12.3. Holes shall be 5-1/2 inches in diameter every 10 inches on the center of the hole.

5.12.4. All gaps (e.g., space between the tank cage to the tank surface) shall be greater than 1 inch but less than or equal to 5 inches.

5.12.5. No parts of the tank cage shall be connected or fastened to the tank (e.g., similarly to the tank support structure, the entire tank cage shall remain completely separable from the tank).

5.12.6. The tank cage may be supported by the tank support structure with additional framing.

5.12.7. See Elevation 7A, Section 7B, Inlet End Elevation 7C, and Discharge End Elevation 7D.

6. OPERATIONAL TEST

6.1. TESTING - The equipment shall be operated in a manner and for a time frame suitable to demonstrate and verify operation of the equipment and all of its respective parts, relative to the design, construction, and performance criteria established herein.

6.1.1. For all tests performed, if test fails or defects are noted, then repair as required and re-preform test.

6.1.2. All pressure indicating devices and load indicating devices used for hydrostatic test and/or load test shall be in current calibration and traceable to the National Bureau of Standards.

6.1.3. Hydrostatic Test

6.1.3.1. Hydrostatically test the 4 inch NPS vertical inlet pipe to 600 (+18/-0) psig for 30 minutes minimum after installation into the tank, but prior to installation of the diffuser pipe and drilling of siphon breaker hole shown in Detail 2A. Test boundary is shown in Detail 10A. No leakage or permanent deformation is allowed. Certified report required.

6.1.3.1.1. The spiral wound gasket must be used for the hydrostatic test. After completion of test, a 1/8 inch Buna-N gasket may be substituted. Spiral wound gaskets shall not be re-used if the joint is broken and remade.

6.1.3.2. Hydrostatically test the 2 inch NPS inlet pipe and valve to 225 (+7/-0) psig for 30 minutes minimum after installation onto the tank but prior to drilling of siphon breaker hole shown in Detail 3A. Test boundary is shown in Detail 10B. No leakage or permanent deformation is allowed. Certified report required.

6.1.3.2.1. The spiral wound gasket must be used for the hydrostatic test. After completion of test, a 1/8 inch Buna-N gasket may be substituted. Spiral wound gaskets shall not be re-used if the joint is broken and remade.

6.1.3.3. Hydrostatically test the completed tank after the following conditions are met: 1) The frame is secured to the tank, 2) Completion of all non-destructive testing associated with the tank shell, 3) Review/approval of final radiographic film by a PHNS & IMF radiograph film interpreter.

6.1.3.3.1. Hydrostatically test the completed tank at 15 (+1/-0) psig for 30 minutes minimum with inlet and discharge valves open and ensure camera purge pressure is 18 to 20 psi during test. Use either dry nitrogen or welding grade argon purge gas to pressurize camera. Inspect all welds. Dry and wipe clean internals. No leakage or permanent deformation is allowed. The vendor shall provide certification of satisfactory test results, which document the pressure rating, 30 minute minimum hydrostatic test duration, and a positive statement that there was no leakage or permanent deformation. Certified report required.

6.1.3.4. After satisfactory hydrostatic test of the tank, the tank shall be dried and wiped clean. Interior tank and piping shall be free of all scale, flux, grease, preservative, oil, dirt, filings, and other foreign or loose material. Light dust is acceptable. Camera lens window shall be cleaned with a delicate (to prevent scratches) cloth suitable for camera lens to prevent water spots from forming on lens window.

6.1.3.5. Leak test completed filter/demister housing with filter and demister removed. Fill housing with potable water at ambient temperature for a minimum of 30 minutes. Inspect all welds. No leakage allowed. Certified report required.

6.1.3.5.1. After satisfactory leak test of filter/demister housing, towel dry interior. Internals shall be free of all scale, flux, grease, preservative, oil, dirt, filings, and other foreign or loose material. Light dust is acceptable.

6.1.3.6. Hydrostatically test each of the spray washing manifold piping to 150 (+10/-0) psig for a minimum of 30 minutes. Hydrostatic test may be done prior to installation of piping components downstream of the check valves, with the manway positioned upside down, and with the valves open. Test boundary is shown in Section 10C. No leakage or permanent deformation is allowed. Certified report required.

6.1.4. Contractor shall verify proper operation of liquid level gauge and thermometer prior to performing hydrostatic test. PHNS & IMF representative(s) will provide testing procedure and/or on site assistance to perform operational check of liquid level gauge and thermometer. The contractor shall provide a minimum of 10 working days advance notice when testing procedure is required. PHNS & IMF on site assistance is at PHNS & IMF discretion. Certified report required.

6.1.5. Contractor shall verify proper operation of each camera prior to performing hydrostatic test of tank.

PHNS & IMF representative will provide testing procedure and/or on site assistance to perform operational check of cameras. Testing will include, but is not limited to the following parameters: zooming, panning, tilting, pressure monitoring, temperature monitoring, picture clarity, light operation, video recording capability, and still picture capability. The contractor shall provide a minimum of 10 working days advance notice when testing procedure is required. PHNS & IMF on site assistance is at PHNS & IMF discretion. Certified report required.

6.1.6. Use water from a source with less than 50 ppm chloride for all testing. Certified report of test results is required.

6.2. Load test lifting lugs.

6.2.1. Prior to load testing the lifting lugs, visually inspect (1X) the welds to verify they are the required size, and are free of defects such as cracks, incomplete fusion, slag inclusion, undercut, corrosion, distortion, worn, and loose parts. Certified report required.

6.2.2. Prior to load testing, MT the lifting lugs, gussets and load bearing welds (e.g., attachment welds, including heat affected zones of the base metal of load bearing parts, and foundation plates) IAW T9074-AS-GIB- 010/271 to verify no defects. Acceptance criteria shall be in accordance with MIL-STD-2035, Class 3. Certified report required.

6.2.3. PHNS & IMF recommends prior to load testing, Liquid Penetrant (PT) inspect the lifting lug & saddle assembly welds IAW T9074-AS-GIB-010/271 to verify no defects. Acceptance criteria shall be in accordance with MIL-STD-2035, Class 3. Certified report required.

6.2.4. Test the lifting lugs of the tank support structure to 150% (+5%/-0%) of the load. Refer to paragraph

5.11.3 for guidance on load testing. Ensure the load test simulates actual lift conditions. Test load shall be held in a static condition for a minimum of 10 minutes. Certified report required.

6.2.5. Following the load test, visually inspect (1X) the lifting lugs, the welds, and adjacent structure to verify no deformation, or damage to the equipment such as broken, worn, twisted, bent, corroded, cracked, loose, binding, arc strikes. Certified report required.

6.2.6. Following the load test, MT the lifting lugs, gussets and load bearing welds (e.g., attachment welds, including heat affected zones of the base metal of load bearing parts, and foundation plates) IAW T9074-AS-GIB- 010/271 to verify no defects. Acceptance criteria shall be in accordance with MIL-STD-2035, Class 3. Certified report required.

6.2.7. Following the load test, PT inspect the lifting lug and saddle assembly welds IAW T9074-AS-GIB- 010/271 to verify no defects. Acceptance criteria shall be in accordance with MIL-STD-2035, Class 3. Certified report required.

6.3. Load test of gauge manway cover brackets.

6.3.1. Prior to load testing the gauge manway cover brackets, visually inspect (1X) the welds to verify they are the required size, and are free of defects such as cracks, incomplete fusion, slag inclusion, and undercut. Certified report required.

6.3.2. Prior to load testing, visually inspect (1X) the guard manway cover brackets base material to verify no defects, deformation, or damage. Certified report required.

6.3.3. Prior to load testing, PT the gauge manway cover brackets and load bearing welds (e.g., attachment welds, including heat affected zones of the base metal of load bearing parts, and foundation plates) IAW T9074-AS- GIB-010/271 to verify no defects. Acceptance criteria shall be in accordance with MIL-STD-2035, Class 3.

Certified report required.

6.3.4. Test load shall be aligned in plane with the gauge manway cover brackets and held in a static condition for 10 minutes. The test load will be 150% (+5%/-0%) of the load. Refer to paragraph 5.8.3 for guidance on load testing. Certified report required.

6.3.5. Following the load test, visually inspect (1X) the gauge manway cover brackets, the welds, and adjacent structure to verify no deformation, or damage to the equipment such as broken, worn, twisted, bent, corroded, cracked, loose, binding, arc strikes. Certified report required.

6.3.6. Following the load test, visually inspect (1X) the guard manway cover brackets base material to verify no defects, deformation, or damage. Certified report required.

6.3.7. Following the load test, PT the gauge manway cover brackets and load bearing welds (e.g., attachment welds, including heat affected zones of the base metal of load bearing parts, and foundation plates) IAW T9074-AS- GIB-010/271 to verify no defects. Acceptance criteria shall be in accordance with MIL-STD-2035, Class 3.

Certified report required.

6.4. Load test manway cover threaded holes.

6.4.1. Prior to load test, visually inspect (1X) the threaded hole to the maximum extent practical. No signs of cracks, permanent distortion, or other damage is permitted. Certified report required.

6.4.2. PHNS & IMF recommends prior to load test, perform liquid penetrant…