SOW_T-AO_LOP_Heat_Exchanger_Material_Analysis_-_6-4-18.docx

Statement of Work (SOW)

Title: T-AO Lube Oil Purifier Heat Exchanger Failure Analysis

Period of Performance: Date of award - 15 August 2018

MSC Technical Point of Contact (MSC TPOC): Bradley White

Contracting Point of Contact: Melvin Frazier and Alexandra Hiser

1. Background: Since replacement of the T-AO Class Ship’s Lube Oil Purifiers from the Westfalia OSB 35-02-066 to Westfalia OSE20-91, there has been an increased number of heat exchanger failures reported. To date, MSC N7 has documented at least nine (9) heat exchanger failures since the first class installation of the new lube oil purifier started in 2015. Originally supplied with the Westfalia OSB 35-02-066 units were shell and tube type, however the new Westfalia OSE20-91 purifiers utilize a plate type heat exchanger. Military Sealift Command (MSC) N7 Engineering Support Division is tasked to perform an Engineering Analysis into the failure modes. The Engineering Branch (N72) of Military Sealift Command (MSC) requires technical support services for the inspection; analysis and testing of four (4) lube oil purifier heat exchangers which failed in service in order to determine any possible casual factors resulting in their failure.

2. Scope of Work: The Contractor shall provide engineering services to complete the inspection, analysis and testing of four (4) lube oil purifier heat exchangers. The results of the examinations shall be documented and presented with expert analysis and opinions as to the cause of heat exchanger failure.

3. Specific Tasks: The Contractor shall perform the following tasks:

3.1. Kick-Off Meeting – Within one week of contract award the contractor will hold a kick off meeting via teleconference with all interested parties to include the Government’s technical point of contact (TPOC). The Contractor shall submit minutes from the meeting and provide them to the MSC TPOC in accordance with Section 7

3.2. MSC will arrange delivery of the subject pieces to the location desired by Kelvion. Once received, the facility that received the delivery shall provide all labor, materials, equipment, special tooling, rigging, staging, shop facilities, crane services, and additional transportation services, as necessary to accomplish all requirements of this statement of work.

3.3. Provide the services of an approved Kelvion qualified technical representative to coordinate the performance of the failure analysis on each of the four (4) heat exchangers.

3.4. Perform the inspection; analysis and testing on each of the four (4) supplied heat exchangers to determine any causal factors which resulted in their failure. Provide a written report of all findings.

The inspection; analysis, and testing shall include but not be limited to the following:

3.4.1. Provide a physical inspection and analysis of any points of failure. Perform a dimensional inspection of any visually failed or deformed pieces found during the inspection. Compare the measurements of the subject equipment dimensions to the manufacturer’s details, drawings or manufacturer’s published data. The report shall present findings in both International System of Units (SI) and Imperial Units with measurements taken to the decimal place present in the manufacturers detail drawings or manufacturer’s published data.

3.4.2. As required, compare physical testing to the manufacturer’s published data material requirements. The analysis shall examine strength and other characteristics that define the material in the material specifications.

3.4.3. Disassemble as required each heat exchanger to inspect for worn, cracked, corroded or distorted plates. Identity leak points. Separate and/or cut heat exchangers plates as required to permit further metallurgical analysis. Validate if leak causals reflect the same pattern of failure between each heat exchanger.

3.4.4. Once failure points are identified, perform a metallurgical analysis on the failure point. The metallurgical analysis shall include, but not be limited to the following tests:

- SEM - Scan Electron Microscope.

- Chemical attack with a EDS - Energy Dispersive Spectroscopy

- Fracture methodology analysis

- Material Validation Study

- Microstructural analysis to validate the grain and integrity of the material.

Note: If each heat exchanger reflects the same failure pattern, a metallurgical analysis on each heat exchanger may not be required. However, should failure patterns be different a metallurgical analysis may be required on all. Kelvion shall provide in their bid proposal pricing that reflects metallurgical testing and analysis separately for each of the four (4) heat exchangers. Any metallurgical testing not required will result in a credit back to the government.

3.4.5. Determine if any indication of material degradation can be traced to the steam/condensate liquid by sampling and analyzing what remains in the heat exchanger for any characteristics which could negatively react with the heat exchangers materials. If possible, obtain samples from areas with the least amount of exposure to the environment or which may have been contaminated with lube oil.

3.4.6. Condensate residing in the steam lines during lube oil purifier startup may create an increased potential for water water hammer to occur. Investigate whether the current T-AO Class Lube Oil Purifier design installation meets Kelvion installation and operational requirements for the model heat exchanger utilized in the Westfalia OSE20-91Lube Oil Purifier. Investigation shall include, but not be limited to, conditions resulting in water hammer, overall design of equipment directly interfacing with the heat exchanger, the steam inlet and condensate outlet sides of the heat exchanger, correct sizing and design use of the condensate trap, lack of a vacuum breaker along the steam/condensate side to permit proper drainage, lack of blowdown valves, lack of drain down points, proper pipe slope to permit gravity drainage, heat exchangers stall, whether the steam outlet valve should be left open to permit heat exchanger drainage, review of Westfalia’s operational procedure for purifier startup as it relates to the heat exchanger and whether any steps could negatively impact heat exchanger operation, comparison of new vs old heat exchanger capacities and whether there is any correlation to condensate formation.

3.4.7. The MSC TPOC will supply Kelvion with required Government Furnished Information (GFI) to permit review of the lube oil purifier installation drawings.

3.4.8. Provide the manufacturers technical specifications of the heat exchanger.

3.5. In the final report Kelvion shall provide as supported by the information presented in the report the following:

3.5.1. Kelvion approved expert analysis as to the cause(s) of the failure.

3.5.2. Kelvion approved expert analysis as recommendations moving forward to mitigate further failures.

4 Deliverables

4.1 Kelvion shall provide one (1) preliminary electronic copy of the report in MS Word via email. Kelvion shall perform a quality assurance check prior to submittal.

4.2 Kelvion shall provide written responses to all MSC review questions. If further testing or analysis is required that is beyond the scope of the original order, a quote per the contract terms shall be included in the response. Kelvion shall incorporate resolutions to MSC questions, comments, and corrections into the final product.

4.3 Kelvion shall submit all final deliverables in both hard copy format and electronic format. Kelvion shall provide two (2) full size color hard copies of the final report. Kelvion shall provide electronic copies of all final deliverables via email or other suitable method of electronic delivery if email is unsatisfactory.

4.4 Kelvion shall provide a test plan. The test plan shall include, at a minimum, a description of the test or inspection, applicable test or inspection standard, location of test, and name of testing activity, and applicable certifications / qualifications of the testing facility. The test plan shall also include the name(s) of the personnel actually performing or supervising the test or inspection and their respective pertinent certifications and qualifications.

4.5 Kelvion shall provide a test and inspection schedule. Kelvion shall inform the MSC TPOC of upcoming tests and inspections 10 business days prior to the event to afford ample opportunity for MSC or MSC’s designated representative to witness the event should they so choose. The test and inspection schedule shall be updated every two weeks and sent to the MSC TPOC via e-mail. The test and inspection schedule shall also be updated upon completion of each major task.

5 Other Task Requirements:

5.1 MSC shall arrange delivery of the heat exchangers to Kelvion. Once received, Kelvion shall provide all labor, materials, equipment, special tooling, rigging, staging, shop facilities, crane services, and transportation services, as necessary to accomplish all requirements of this statement of work.

5.2 Any information provided or regarding this investigation should be kept in confidence and is not for public distribution. Any discussions with third parties shall be authorized by the MSC TPOC or persons authorized by MSC N72 or the MSC Contracting Officer.

5.3 Kelvion shall allow MSC representatives to Kelvion facilities, including sub-contractor facilities, for the purpose of witnessing tests and inspections of the subject parts and materials if they so choose.

5.4 Kelvion and sub-contractors shall maintain physical custody of the test subject(s) at all times. Kelvion shall dispose of the test subject(s) upon completion of all requested work described herein.

5.5 All work performed by the Contractor under the Contract shall become the exclusive property of MSC in which the Government shall have unlimited rights. The Contractor shall not deliver or otherwise provide to the Government technical data or computer software, to include the deliverables under the Contract, with restrictions, including those as to use, modification, reproduction, and transfer, or with restrictive markings. The Contractor agrees to promptly provide to the Government at no additional cost such documents, codes or other materials and information that are necessary to permit the Government's full enjoyment of its rights in the deliverables as described above.

5.6 The products of this tasking are to be considered unclassified defense technical data and are subject to security restrictions of the contract. Subject to the requirements of the contract, all products produced for this tasking should be marked as follows:

Distribution Statement D. Distribution authorized to the Department of Defense and U.S. DoD contractors only.

"WARNING: THIS DOCUMENT CONTAINS TECHNICAL DATA WHOSE EXPORT IS RESTRICTED BY THE ARMS EXPORT CONTROL ACT (TITLE 22, U.S.C. SEC. 2751 ET SEQ.) OR EXECUTIVE ORDER 12470. VIOLATIONS OF THESE EXPORT LAWS ARE SUBJECT TO SEVERE CRIMINAL PENALTIES."

5.7 All meetings will be held at Kelvion facilities or via teleconference.

6 Review Process: All work package deliverables described in Sections 3 & 4 shall be submitted in accordance with the following process:

6.1 The Contractor shall submit Deliverables in accordance with the delivery schedule below for MSC TPOC review and comment. The MSC TPOC shall have a period to review Deliverables in accordance with timeframe identified in the delivery schedule. If the MSC TPOC takes longer than days allocated in delivery schedule to complete review, the schedule will be adjusted accordingly. NOTE: A deliverable is only fully approved by MSC after all technical comments and issues have been addressed. A deliverable submitted with numerous errors or lacking required information could be returned without the report being fully reviewed by the MSC TPOC. MSC’s review is not to be used as the contractor’s quality assurance review.

6.2 The contractor shall incorporate all comments from the MSC TPOC’s review to create the Final Deliverable. The final deliverable shall incorporate all updates and fully answer all comments made in MSC’s review of the P1- deliverables.

7 Schedule/Delivery Schedule:

Within five (5) BD after Order Issuance.

*BD = Business Day(s) **NLT = No Later Than

8 Place of Performance:

8.1 Work shall be performed primarily at the Contractor’s site.

9 Period of Performance:

9.1 Date of award through 15 August 2018

10 Government Furnished Information (GFI): Contactor shall contact the MSC TPOC for all GFI

11 Other Pertinent Information or Special Considerations – None Additional