T-AO_Foam_Procurement_Specification.docx

PROCUREMENT SPECIFICATION,

T-AO CLASS FIREFIGHTING FOAM SYSTEM

1.0 SCOPE

1.1. Provide as indicated two factory assembled Aqueous Film Forming Foam (AFFF) systems per ship for the T-AO Class Vessels of Military Sealift Command (MSC). The supplied systems are to replace the existing National Foam/Chubb/Rockwood CG6% AFFF Systems. The systems shall be designed expressly for use with USCG approved ANSULITE 3x3 Low-Viscosity AR-AFFF Concentrate. All equipment and material shall be supplied per the specifications as intended for a complete and operational system. A Factory Acceptance Test (FAT) shall be completed to the satisfaction of an American Bureau of Shipping (ABS) surveyor and MSC representative as indicated.

1.2. GENERAL DESCRIPTION

1.2..1. One AFFF system shall be provided for replacement of the existing FWD AFFF station skid (located in space 01-60-1) and one shall be provided for replacement of the existing AFT AFFF station skid (located in space 1-120-1). The existing AFFF concentrate tanks for each station as well as the supply/return piping between the existing tanks and the existing skids will be reused in the new installation.

1.2..2. The provided systems shall consist of all necessary piping, fittings, pumps, motors, valves, proportioners etc. within a single skid. Motor controllers and automation equipment shall be supplied as part of a complete system but will be mounted on bulkheads as opposed to the skids.

1.2..3. The provided systems shall replicate all existing automation in order to maintain exact system functionality as the existing systems.

1.2..4. The intended installation is to connect the various existing system side flanged piping to the new skid’s flanged piping without modification. As such the provided skids shall be manufactured to the dimensions as indicated in section 3.8 of this specification.

1.3. SUPPLIER REQUIREMENTS

1.3..1. The systems shall be of an approved design as fabricated by an approved ANSUL distributor regularly engaged in the production of commercial marine foam firefighting systems.

1.3..2. The AFFF systems shall be of the ANSUL In-Line Balanced Pressure Proportioner with Manual Foam Balancing Valves (IBP-M) type. Systems shall be designed in accordance with (IAW) ANSUL MARINE FOAM SYSTEMS DESIGN, INSTALLATION AND MAINTENANCE MANUAL (ANSUL P/N 417981-1) and USCG Type Approval No. 162.033/14/0.

1.3..3. Supplied systems including piping skids, pumps/motors, motor controllers and PLCs shall meet all ABS requirements for Steel Vessels.

2.0 APPLICABLE DOCUMENTS

2.1. REFERENCES

2.1..1. T9555-A7-MMC-010 - Technical Manual for AFFF Fire Protection System, T-AO 187 Class 2.1..2. 555-6241210(G) – T-AO 187 Class Fleet Oiler – Diagram Foam System 2.1..3. 555-8497230(-) – T-AO 187 Class Fleet Oiler – Arrangement & Schematic Diagram – Motor Controller, Forward Foam Proportioning Pump 2.1..4. 555-8497231(-) – T-AO 187 Class Fleet Oiler - Arrangement & Schematic Diagram – Motor Controller, Aft Foam Proportioning Pump 2.1..5. DA85-11-091C-004 –Foam Proportioning Pump (FWD) Programmable Controller Ladder Schematic Diagram 2.1..6. DA83-06-113D-008 – Foam Proportioning Pump (FWD) Marine Motor Controller Schematic Diagram.

2.1..7. N0723-002.00-AQ – MSC Quality Management System Procedure Manual, Programmable Logic Controller (PLC) Design Standards

Copies of government specifications, standards, drawings, and publications required by potential suppliers in connection with this specification should be obtained from the contracting activity or as directed by the contracting activity.

2.2. ORDER OF PRECEDENCE

2.2..1. In the event of a conflict between the text of this specification and the references cited herein, the text of this specification shall take precedence. Nothing in this specification, however, shall supersede applicable laws and regulations unless a specific exemption has been obtained.

3.0 REQUIREMENTS

3.1. RELIABILITY

3.1..1. The requirements of this specification are imposed exclusively to obtain equipment of utmost reliability for the service intended. The assurance of maximum reliability shall be the paramount controlling principle in the design, fabrication, assembly and testing of this equipment. Users of, and contractors to, this specification are urged to communicate to the customer any findings related to the requirements or lack of requirements of this specification whereby improvement of equipment reliability can be achieved.

3.2. DESIGN PARAMETERS

In order to assure a complete and operational system in accordance with the ship’s existing AFFF solution delivery requirements, system data sheets for the proposed systems shall be provided to the customer for verification of system design.

3.2..1. The FWD and AFT systems shall deliver ANSULITE 3x3 Low-Viscosity AR-AFFF IAW the existing system flow demand and pressure parameters as indicated in references 2.1..1 and 2.1..2.

3.2..2. The AFT system shall have the following system piping connections:

· (1ea) 4” NPS seawater supply inlet, flanged

· (1ea) 4” NPS foam solution outlet, flanged

· (1ea) 2-1/2” NPS foam concentrate transfer, flanged

· (1ea) 3” NPS foam concentrate pump suction, flanged

· (1ea) 2” NPS foam concentrate return to tank, flanged

· (2ea) 1-1/2” flushing, hose 3.2..3. The AFT system shall have a single proportioner sized to deliver the required 3% solution flow rates to the Helo Dk. Sprinklers and Helo Rescue Station hose reels as indicated by references 2.1..1 and 2.1..2.

3.2..4. The AFT system shall have an electric motor operated, quarter-turn, open/shut, proportioner cut out ball valve. The valve shall be automatic with manual override. See Section 3.4 3.2..5. The FWD system shall have the following system piping connections:

· (1ea) 4” NPS seawater supply inlet, flanged

· (1ea) 4” NPS foam solution outlet, flanged

· (1ea) 8” NPS seawater supply inlet, flanged

· (1ea) 8” NPS foam solution outlet, flanged

· (1ea) 2-1/2” NPS foam concentrate transfer, flanged

· (1ea) 4” NPS foam concentrate pump suction, flanged

· (1ea) 3” NPS foam concentrate return to tank, flanged

· (2ea) 1-1/2” flushing, hose 3.2..6. The FWD system shall have two proportioners. One proportioner shall be sized to deliver the required 3% solution flow rates to the Cargo Tank Top Zone sprinklers as indicated by references 2.1..1 and 2.1..2. One proportioner shall be sized to deliver the required 3% solution flow rates to the Fueling at Sea (FAS) foam monitors, portable hand nozzles and hose reels as indicated by references 2.1..1 and 2.1..2.

3.2..7. Each of the proportioners for the FWD system shall have a single electric motor operated, quarter-turn, open/shut proportioner cut out ball valve. Valve shall be automatic with manual override. See Section 3.4.

3.3. PIPING

3.3..1. All on skid piping to be brass IAW ANSUL Technical Bulletin Number 59.

3.3..2. On skid piping wall thickness shall be sufficient for system design pressure IAW ABS Rules for Steel Vessels.

3.3..3. All piping connections between skids and existing shipboard piping shall be ANSI B16.5, Class150, raised face flanges.

3.4. VALVE ACTUATORS

3.4..1. The skid mounted proportioner cut out valve actuators shall be Keystone Model EPI-2 electric actuators or equal.

3.4..2. Actuator enclosure shall be NEMA 4X.

3.4..3. Operating voltage shall be 120VAC, single phase.

3.5. PUMPS and MOTORS

3.5..1. AFFF concentrate pumps shall be approved for marine service, properly sized to deliver the required 3% solution flow rates as indicated by references 2.1..1 and 2.1..2.

3.5..2. AFFF concentrate pump motors shall be 460VAC, 60Hz. Motors shall be Totally Enclosed Fan Cooled (TEFC), UL Listed Marine Duty IEEE-45 for below deck service and ABS Type Approved. Certificates shall be supplied to customer with delivery of equipment.

3.6. AFT MOTOR CONTROLLER

3.6..1. The AFT motor controller shall be an EATON, 3-phase custom booster pump controller or equal IAW the schematic shown on reference 2.1..3, sheet 2. See reference 2.1..3 for the AFT AFFF system description of operation.

3.6..2. The AFT motor controller cabinet shall be NEMA 4X. The controller cabinet shall be no more than 21” wide by 32” tall. Cabinet depth is not critical but shall be minimized to the maximum extent practicable.

3.6..3. The AFT motor controller shall have the following additional components mounted to the front panel:

· power ON light

· foam pump RUN light

· elapsed time meter (ETM)

· space heater OFF/ON selector switch

· pump RUN button

· STOP button

· Helo Sprinkler Activate button

· Helo Sprinkler Activate light

· Hose Reels Activate button

· Hose Reels Activate light

3.7. FWD MOTOR CONTROLLER and PLC

3.7..1. The FWD motor controller shall be an EATON, 3-phase custom booster pump controller or equal IAW the schematic shown on reference 2.1..4, sheet 2. See reference 2.1..4 for description of AFT AFFF system operation.

3.7..2. The FWD motor controller cabinet shall be NEMA 4X. The controller cabinet shall be no more than 24” wide by 30” tall. Cabinet depth is not critical but shall be minimized to the maximum extent practicable.

3.7..3. The FWD motor controller cabinet shall have sufficient space for field installation of separate 480V/120 VAC, 1.5KVA step down transformer as shown on reference 2.1..4.

3.7..4. The FWD motor controller shall have the following additional components mounted to the front panel:

· power ON light

· foam pump RUN light

· elapsed time meter (ETM)

· space heater OFF/ON selector switch

· pump RUN button

· STOP button 3.7..5. The FWD motor controller shall interface with a Programmable Logic Controller (PLC) system located in a separate cabinet to be provided as part of complete FWD AFFF system delivery. The PLC system shall be Rockwell Automation P/N M-R1USU00098-0002 or equal. See reference 2.1..4 for the new FWD AFFF system description of operation which has been updated specifically for the aforementioned Rockwell Automation P/N. See references 2.1..5 and 2.1..6 for the existing FWD AFFF system ladder logic and controller schematic.

3.7..6. The PLC cabinet shall have the following additional components mounted to the front panel:

· power ON light

· ZONE 1 Activate button

· ZONE 1 Activate light

· ZONE 2 Activate button

· ZONE 2 Activate light

· ZONE 3 Activate button

· ZONE 3 Activate light

· FAS Activate button

· FAS Activate light

· STOP button

3.7..7. The PLC shall use 120VAC control power to be supplied from step down transformer located inside FWD motor controller. See Section 3.7..3.

3.7..8. The delivered PLC system shall comply with reference 2.1..7. As such the following deliverables shall be provided upon delivery of completed system:

· Licensed copies of the PLC and HMI compilation programs (software) to be loaded on to the Chief Engineer’s maintenance laptop at time of installation.

· Programmer’s manual as described in 3.1.1.D of reference 2.1..7

· PLC and HMI project files, as applicable (software)

· Administrative password delivered to be provided to Chief Engineer at time of installation. This will allow crew to reprogram the PLC.

· Ladder logic diagram with commenting to describe the action(s) of the routines in PDF format.

· Revision list of any changes made to previous baseline in PDF format.

· HMI software in hardcopy as described in 3.1.6 of reference 2.1..7

· Compact disc of the latest project file for each PLC to be stored in PLC cabinet at time of installation.

· Compact disc of the latest project file for each PLC to be provided to the Chief Engineer at time of installation.

· Installation disc of the compilation software for the Ship’s Engineering Log Office.

3.7..9. Per ABS, PLC systems in this application are assigned with a Category III systems classification. Accordingly, the development procedures, software quality plan, evidence of software testing, and software version record are to be maintained such that these could be made available to the Surveyor when requested as per ABS Steel Vessel Rules 4-9-3/7.1 and 4-9-3/Table 2. The following tests are to be specifically witnessed by an ABS Surveyor as required by the ABS Steel Vessel Rules 4-9-3/9.3.4. i) Integration test, Fault Simulation and Factory Acceptance Test (4-9-3/Table 2 items 3.5, 3.6 and 3.7), ii) On board tests (4-9-3/Table 2 items4.1 & 4.2).

3.8. SKID DIMENSIONS

3.8..1. The overall skid dimensions and locations of flanged connections to existing shipboard piping shall be as indicated by reference 2.1..1.

3.9. SKID AND FRAME ASSEMBLIES

3.9..1. The AFFF components shall be assembled and built on welded skids or frames constructed of structural steel.

3.9..2. The FWD skid and frame shall be constructed such that it can be partially disassembled in order to fit through a 5ft x 5ft access.

3.9..3. The AFT skid and frame shall be constructed such that it can be partially disassembled in order to fit through a 30” wide doorway.

3.9..4. The skid frames shall be sandblasted and powder coated or finish painted with a high solids epoxy overcoat.

4.0 FACTORY ACCEPTANCE TEST (FAT)

4.1. The complete systems shall go through a FAT in the presence of an MSC rep and ABS surveyor. The FAT shall demonstrate satisfactory functionality of all components and simulated operational scenarios. The PLC system, specifically, shall be tested IAW Section 3.7.9 of this specification.

5.0 LOGISTICS and SUPPORT

5.1. INSTRUCTIONS

5.1..1. A set of three (3) complete installation, operation, and maintenance manuals shall be provided in hard copy and electronic PDF formats. As-built general arrangement, process and instrument, and electrical drawings shall be included. All component data, manuals and calibration documents shall also be included. Copyrights for reproduction of the technical manual and included data for the purposes of supporting installation, maintenance, repair, and operation of the equipment shall not be restricted.

5.1..2. A recommended shipboard spare parts list shall be provided.

6.0 WARRANTY

6.1. The manufacturer shall provide, at a minimum, a 12 month materials and workmanship warranty from the date of equipment installation including commissioning. The warranty shall provide for parts, labor, and materials.

6.2. The manufacturer shall provide a 3 month labor, material, and workmanship warranty for repairs made after the original warranty period has expired and/or resulting from the original warranty period.

7.0 FIELD-SERVICE

7.1. On site startup or service shall be made available from the manufacturer or manufacturer’s representative. Technical service phone support and spare parts must also be available from the manufacturer.

8.0 SUPPORTABILITY

8.1. All consumables or other parts designed for regular replacement shall be regularly stocked OEM parts or commonly available through multiple commercial outlets. Consumables or other parts designed for regular replacement shall not be slated for obsolescence without directly interchangeable replacement for a period of no less than 10 years from the purchase of the AFFF systems.

9.0 PRE-AWARD DELIVERABLES

9.1. The contractor shall provide the following items for consideration in determining technical acceptance of proposals:

9.1..1. Schematic diagrams of piping skids including pipe sizes and components.

9.1..2. Dimensioned CAD drawings of skids showing that proposed designs meet all dimensional requirements of this specification. Drawings shall include plan and section/elevation views. Isometric views may be included but are not required.

9.1..3. Detailed parts breakdown of entire systems including OEM part numbers for all major components (MOVs, proportioners, balancing valves, pumps, motors, motor controllers, PLC etc.).

9.1..4. Design documents showing that the proposed systems will meet the flow demand and pressure parameters of this specification.

10.0 POST-AWARD DELIVERABLES

10.1. The contractor shall provide the following deliverables after receipt of the contract upon completion of ABS/USCG approval:

10.1..1. One complete ABS and USCG approved FWD AFFF system IAW this specification.

10.1..2. One complete ABS and USCG approved AFT AFFF system IAW with this specification.

10.1..3. Technical manuals and spare parts list IAW Section 5.0 of this specification.

10.1..4. All PLC deliverables IAW Section 3.7.8 of this specification.