Spec for Pure Wtr Heaters-Rev2 final.pdf

Technical Specification Portable Inline Electric Heaters

For Deionized (DI) Water

Revision 2, Brief Descriptions of Major Changes:

- 3.2.1: Updated pressure gauge type.

- 3.2.7: Added analog bimetal thermometer.

- 3.4.1.2 and 3.4.1.3: Removed padeye design and combined platform/skid requirements into 3.4.1.1.

- 3.4.5 and 3.4.6: Moved overall dimensions into design parameters.

- 3.8.2: Simplified requirements for the skid platform and allowed other materials of construction.

- 3.6.1 and 3.6.2: Revised safety requirements to directly reference OHSA requirements and removed certification report.

- 3.9.3: Added restriction on programming method for controllers and instrumentation.

- 3.10: Removed all requirements for padeyes (i.e. lifting lugs).

- 4.3.4.2: Removed 150 psig pressure test as all piping welds will be included in vessel hydrostatic test.

- Other minor editorial changes as needed.

Rev Date Author Reviewer Concurrence Approval

0 3/11/22 Dennis Pierce

C2380.5

Trent Nelson

C2380.5

Eugene Fry

C2380.6

3/ 4 /22

Rudy Acevedo

C106

3/4/24

Bryan Payne

C2380.5

3/11/22

1 6/21/24

Dennis Pierce

C2380.5

6/11/24

Trent Nelson

C2380.5

6/20/24

Keith DuCharme

C2380.6

6/12/24

Mike Dalsfoist

C715

6/11/24

Rudy Acevedo

C106

6/21/24

Bryan Payne

C2380.5

6/21/24

2 5/27/25

Trent Nelson

C2380.5

5/27/25

Laura Wheeler

C/2380.5

6/3/25

Rudy Acevedo

C106

6/5/25

Bryan Payne

C/2380.5

6/5/25

TABLE OF CONTENTS

1. SCOPE

1.1. Scope

2. REFERENCES

2.1. General

2.2. Government Documents

2.3. Non-Government Publications

2.4. Order of Precedence

3. REQUIREMENTS

3.1. General Description

3.2. Heater Attachments

3.3. Cleanliness

3.4. Design

3.5. Construction

3.6. Safety and Environmental

3.7. Heater Assembly

3.8. Skid Platform

3.9. Electrical and Instrumentation

3.10. Lifting and Handling

3.11. Equipment Labeling

3.12. Pre-Construction Submittals

3.13. Deliverables Package

4. QUALITY ASSURANCE

4.1. Responsibility for Inspection

4.2. Classification of Inspections

4.3. Factory Acceptance Testing and Examination (Origin)

4.4. Shipment Authorization

4.5. Site Acceptance (Destination)

4.6. Contractor Certification of Compliance

5. PREPARATION FOR DELIVERY

5.1. Preparation for Delivery

5.2. Permits

5.3. Packing

5.4. Packing Material

5.5. Marking of Shipments

Table 1 - Overview of DI Water Heater Project Requirements

Technical Specification Rev. 2 (5/27/2025)

Portable Inline Electric Heaters for Deionized (DI) Water

1. SCOPE

1.1. Scope.

This specification establishes the minimum requirements of the Government to purchase portable electric inline heaters for use with deionized (DI) Water. The purchase specification set forth below describes the minimum requirements. Heaters are constructed of 316 or 316L stainless steel, electropolished and passivated, and must comply with strict requirements for internal wetted surface finish, cleanliness, and materials. Each heater will undergo inspections by the Government at the contractor’s facility and when received at PSNS & IMF to ensure all requirements herein are satisfied. Table 1 provides a high level overview of requirements. It is the Government’s intent that a single primary contractor be awarded this contract and be responsible for the provision of equipment.

2. REFERENCES

2.1. General.

Products covered in this purchase specification shall be designed, manufactured, and tested in accordance with the latest applicable standards as follows:

2.2. Government Documents.

2.2.1. Specifications, Standards, and Handbooks. The following specifications, standards, and handbooks form a part of this document to the extent specified herein. Unless otherwise specified, the issues of these documents are those cited in the solicitation or contract.

FEDERAL STANDARDS

FED-STD-H28 ------------------------------ Screw Thread Standards for Federal Service

(2024)

FED-STD-313 ------------------------------ Material Safety Data, Transportation Data and

Disposal Data for Hazardous Materials

Furnished to Government Activities (2018)

(Copies are available online at http://quicksearch.dla.mil/)

COMBINED FEDERAL REGULATIONS

29 CFR 1910 -------------------------------- General Industry, OSHA Safety and Health

(Copies are available online at https://www.osha.gov/)

EUROPEAN UNION (EU)

U 2014/68/EU ---------------------------- Pressure Equipment Directive (PED)

(Copies are available online at https://eur-lex.europa.eu/) http://quicksearch.dla.mil/ https://www.osha.gov/ https://eur-lex.europa.eu/

2.3. Non-Government Publications.

The following documents form a part of this document to the extent specified herein. Unless otherwise specified, the issues of these documents are those cited in the solicitation or contract.

AMERICAN SOCIETY OF MECHANICAL ENGINEERS

ASME B16.5 -------------------------------- Pipe Flanges and Flange Fittings: NPS ½ through NPS 24, Metric/Inch Standard (2020)

ASME B18.2.1 ----------------------------- Square, Hex, Heavy Hex, and Askew Head Bolts and Hex, Heavy Hex, Hex Flange, Lobed Head, and Lag Screws (Inch Series) (2012; R2021)

ASME B18.2.2 ----------------------------- Nuts for General Applications: Machine Screw

Nuts, Hex, Square, Hex Flange, and Coupling

Nuts (Inch Series) (2022)

ASME BPE---------------------------------- Bioprocessing Equipment (2024)

ASME B31.3 -------------------------------- Process Piping (2024)

ASME BPVC Section VIII --------------- Rules for Construction of Pressure Vessels

Division 1 (2023)

ASME BPVC Section IX ----------------- Welding, Brazing, and Fusing Qualifications

(2023)

(Copies available online at https://www.asme.org)

ASTM INTERNATIONAL

ASTM A240/A240M ---------------------- Standard Specification for Chromium and

Chromium-Nickel Stainless Steel Plate, Sheet, and Strip for Pressure Vessels and for General

Applications (2025)

ASTM A270/A270M ---------------------- Standard Specification for Seamless and Welded

Austenitic and Ferritic/Austenitic Stainless Steel

Sanitary Tubing (2024)

ASTM A312/A312M ---------------------- Standard Specification for Seamless, Welded, and Heavily Cold Worked Austenitic Stainless

Steel Pipes (2025)

ASTM A380/A380M ---------------------- Standard Practice for Cleaning, Descaling, and

Passivation of Stainless Steel Parts, Equipment, and Systems (2025) https://www.asme.org/

ASTM A967/A967M ---------------------- Standard Specification for Chemical Passivation

Treatments for Stainless Steel Parts (2025)

ASTM B912/B912M ---------------------- Standard Specification for Passivation of

Stainless Steels Using Electropolishing (2018)

ASTM D3951 ------------------------------- Standard Practice for Commercial Packaging

(2018; R2023)

(Copies available online at http://www.astm.org)

AMERICAN WELDING SOCIETY

AWS A3.0 ----------------------------------- Standard Welding Terms and Definitions (2025)

(Copies available at https://www.aws.org/)

NATIONAL ELECTRICAL MANUFACTURERS ASSOCIATION

NEMA Z535.4 ------------------------------ Product Safety Signs and Labels (2023)

NEMA 250 ---------------------------------- Enclosures for Electrical Equipment (1000 Volts

Maximum) (2020)

(Copies available at http://www.nema.org)

NATIONAL FIRE PROTECTION ASSOCIATION

NFPA 70 ------------------------------------- National Electrical Code (NEC) (2023)

(Copies available at http://www.nfpa.org)

2.4. Order of Precedence.

In event of conflict between this document and references cited herein, this document takes precedence unless otherwise noted herein or in contract. Nothing in this document, however, supersedes applicable laws and regulations unless a specific exemption is obtained.

3. REQUIREMENTS

3.1. General Description.

3.1.1. Specification. This specification covers the minimum Government requirements for each water heater and skid platform. The water heater and skid platform shall be fabricated in accordance with sections 3 and 4 of this document.

3.1.2. Heater Overview and End-Use. Each electric inline heater shall be a stand-alone unit for portable usage at shipyard docks and piers. Heaters shall provide elevated water outlet temperature at a set point selected by operator. Water flow rate to be adjusted by a separate control valve not included with heater. Duration of water flow will vary, but http://www.astm.org/ https://www.aws.org/ http://www.nema.org/ http://www.nfpa.org/ heaters must be capable of providing continuously heated water at maximum delta temperature for extended periods of time. Heater will be stored in warehouse when not in use and temporarily installed in various unheated shed buildings on the waterfront during use. Heater will be exposed to freezing temperatures during winter months. Heater will be frequently transported on a flatbed truck over a rough roadway and may be bounced about during transport. Heater will be covered by tarp during transport in incremental weather.

3.1.3. Design for Cleanliness. Heater must be designed for use with deionized (DI) pure water. Interior stainless steel surfaces in contact with DI water shall be electro polished smooth with No. 4 finish (i.e. 30 RA or better). Commercial off the shelf items (e.g.

sanitary caps) that are 32 Ra or better are also acceptable. Pressure gauge in paragraph

3.2.1 is exempt from surface finish requirements. There shall be no crevices, pockets, blind holes, undrainable cavities, hidden surfaces, or other areas in which dirt, cleaning solutions, or sludge might lodge or become trapped. All wetted interior surfaces must be easily accessible for cleaning and inspection upon disassembly of component. Design and fabrication of wetted components shall use ASME BPE for biopharmaceutical equipment or 3-A sanitary standards as guidance to eliminate crevices and inaccessible areas.

Certification of BPE or 3-A compliance is not required.

3.1.4. Heater Control and Operation General Description. The heater control unit shall have the following operation and control features at a minimum:

3.1.4.1. Heater must continuously heat at least 10 GPM of deionized water from 40°F inlet temperature to a maximum outlet temperature of 115°F at 100% duty cycle. Heat output must automatically be adjusted by a controller to achieve outlet temperature set point at variable flow rates and inlet water temperatures (within design parameters).

3.1.4.2. An adjustable controller shall control the outlet water temperature.

3.1.4.3. The heater must prevent water from freezing during no flow conditions in winter months. An operator shall lower the set point (e.g. 45 °F) while the energized unit is in standby (i.e. no flow condition) to provide freeze protection.

3.1.4.4. The heater unit shall have a high temperature fault shut-off with audible alarm and visual alarm lights. The high temperature fault and alarm shall be adjustable and set by the operator.

3.1.4.5. Instrumentation on the electrical panel shall display (1) water outlet temperature

(process variable) and (2) heater electrical current output in kilowatts or percentage of maximum (control variable). The contractor shall provide additional indicators, switches, emergency stop, and other equipment for operators to safely operate and monitor the heater.

3.2. Heater Attachments.

3.2.1. Pressure Gauges. Provide 1 EA analog pressure gauge on the heater assembly of size and configuration determined by the contractor. Install the pressure gauge in location determined by the contractor. Pressure gauge shall have all 316 or 316L wetted surfaces.

Pressure gauges shall meet calibration requirements of paragraph 3.9.4. Process connection shall be ¼ inch MNPT and installed with PTFE tape.

3.2.1.1. Pressure gauge is the only wetted component allowed to be NPT and omitted from

32 Ra surface finish, this is due to historical malfunction and risk of freezing with fluid filled sanitary diaphragm style pressure gauges.

3.2.2. Temperature Transducers, Switches, and Transmitters. Temperature instrumentation (e.g. thermocouples or RTDs) in contact with system fluid shall have tri-clamp connections. All wetted surfaces shall be easily accessible for cleaning and inspections. Tapered pipe threads are prohibited. Thermal wells are discouraged due to slower response time. Measurement display units shall be removable for periodic calibration. Outlet temperature transducer shall send a signal to the main temperature controller. Electrical connection on outlet temperature transducer shall be plug in type (e.g.

M12) or similar. All electrical components shall be UL or CSA listed. Instrumentation shall meet IP67 at minimum or be housed in NEMA 4X enclosure. Temperature instrumentation shall meet calibration requirements of paragraph 3.9.4.

3.2.3. Heater Elements. Immersed heater elements must be 316 or 316L stainless steel with smooth surfaces. Elements within a bundle must have sufficient clearance between elements to enable cleaning and inspections of all surfaces. Base junction of heater elements must also be smooth without crevices, cracks, or seams where foreign material may become trapped.

3.2.4. Pressure Relief. A rupture disk shall be installed for pressure relief at design pressure of 150 psi or other pressure as dictated by ASME BPVC design. The rupture disk must be compliant with ASME BPE or 3A standards. Rupture disk shall be attached with a tri-clamp ferrule, or ASME 150LB RF flange to enable easy disassembly for cleaning and inspections of wetted surfaces.

3.2.5. Vent and Drain Ports. A drain port shall be located at bottom of heater vessel for draining of water. A vent port shall be located at high point of vessel for venting air. Both caps shall be 316 or 316L stainless steel and employ a ¾ inch or larger tri-clamp fitting with stainless steel cap. Vent port may be omitted if the inlet or outlet process connections are at the high point of the heater unit. Drain port may be omitted if the inlet or outlet process connections are at the low point of the heater unit.

3.2.6. Spare Port. A spare port shall be located on heater vessel adjacent to pressure relief port. The port shall be a 1 inch tri-clamp ferrule. Provide clearance around the port to accommodate a future pressure relief valve or pressure gauge.

3.2.7. Thermometer. Install an analog bimetal thermometer adjacent to digital temperature instrumentation in paragraph 3.2.2 that measures outlet temperature. Size and configuration of the thermometer is per the contractor’s design. Thermometer shall have all 316 or 316L wetted surfaces. Thermometer shall meet calibration requirements of paragraph 3.9.4. Process connection shall be tri-clamp connection of size determined by the contractor. Thermometer is required as a secondary verification of outlet temperature and to verify water is a safe temperature for draining if power is disconnected.

3.3. Cleanliness.

3.3.1. Equipment Cleanliness. Equipment and piping shall be easily disassembled for cleaning and inspection. Interior corners of metal surfaces in contact with DI water shall be rounded with a minimum radius of 1/8 inch. Weld surfaces shall be smooth without cracks, deep scratches, or crevices. Mechanical flanges shall connect components or piping where necessary for easy disassembly.

3.3.2. Welding and Surface Finish. All equipment and piping (excluding attachments) in contact with system fluid must be fully welded prior to final polishing and passivation.

Interior welds must be sanded smooth without crevices, pits, or deep scratches.

Components welded after final polishing shall be repolished and passivated prior to assembly or installation. Surface finish requirements are included in paragraph 3.7.4.

3.3.3. Cleaning. All wetted surfaces of stainless steel hardware (excluding attachments) shall be electropolished per ASTM B912 and passivated per ASTM A380 or ASTM A967.

3.4. Design.

3.4.1. Design. The contractor shall provide the following design services.

3.4.1.1. Heater Design. Design heater per the parameters of paragraph 3.4.2 and to meet the requirements of sections 3 and 4 of this specification. The contractor shall design the heater assembly and temperature controls. Nozzles shall facilitate heater attachments per sections 3.1.4.5 of this specification. The interior surfaces of the heater shall be accessible for cleaning per paragraph 3.3.1. The heater shall be mounted on a portable frame or skid compatible with forklift or pallet jack.

3.4.1.2. DELETED (REV. 2)

3.4.1.3. DELETED (REV. 2)

3.4.1.4. Design Submittals. Design drawings and calculations for heater unit shall be submitted for government approval prior to starting fabrication. Design submittals are specified in paragraph 3.12.1.

3.4.2. Design Parameters

System Fluid .................................................. Demineralized Water

Flow Rate (gpm) .................................................................... 0 to 10

Water Temperatures

Inlet Temperature (°F)

Outlet Temperature (°F)

Temperature Rise (°F)

Operating Pressure (psig)

Duty Cycle (%) ................................................................... 0 to 100

Heater Environment ............................. Shipyard Marine Waterfront

Electrical Terminal

Enclosure........................................ NEMA 4X, Type 304 SST

Safety Switch ................................................... Circuit Breaker

Electrical Supply:

Kilowatts ...................................................................... 120 KW

Voltage ....................................................................... 480 VAC

Number of Phases ........................................................ 3- phase

Water Connections:

Inlet Connection ............ 1-1/2’’ – 150# RF Flange, ANSI B16.5

Outlet Connection ......... 1-1/2’’ – 150# RF Flange, ANSI B16.5

Vessel Construction:

Design Code ....................................... ASME BPVC or EU PED

Design Temperature (°F)

Design Pressure (psig)

Material ....................................................... Type 316/316L SST

Corrosion Allowance (in)

Vessel Connections:

Inlet/Outlet .................... 1-1/2’’ – 150# RF Flange, ANSI B16.5

Relief ...................... Tri-Clamp or 150# RF Flange, ANSI B16.5

Spare Port .............................................................. 1’’ Tri-Clamp

Temperature Sensors ................................................... Tri-Clamp

Control System

Temperature Controller .............................. 24VDC or 110 VAC

Process Temperature Sensors .................. Thermocouple or RTD

Maximum Dimensions

Length.................................................................................... 84’’

Width ..................................................................................... 50’’

Height .................................................................................... 72’’

3.4.3. Equipment. All equipment shall be new and unused. Equipment shall include all components, parts, and features necessary to satisfy performance requirements specified herein. All parts subject to wear, breakage or distortion shall be easily accessible for adjustment, replacement, and repair. Equipment shall incorporate current field proven design, capacity, and performance characteristics proven through actual field application.

The structure shall withstand operation of heater assembly at maximum rating and capacity without distortion.

3.4.4. Ease of Inspection. The heater and associated piping and tubing system shall be designed to facilitate disassembly and ease of access for visual and wipe cloth inspections.

3.4.5. DELETED (REV. 2)

3.4.6. DELETED (REV. 2)

3.4.7. Controls. All electrical and mechanical controls shall be placed at locations convenient to the operator.

3.4.8. Durability. All equipment and fabrications shall be sufficiently durable design and construction to withstand rough handling as typically encountered in an industrial marine environment.

3.4.9. New Developments. The contractor shall identify any new developments that would improve the efficiency, accuracy, productivity, or decrease operating costs of equipment.

The contractor shall notify the Contracting Officer and technical POC of new developments that may, at Government's option, be included in equipment. Reports of such developments shall be addressed to the Contracting Officer.

3.4.10. Interchangeability. All parts subject to future replacement shall be manufactured to specified dimensions and tolerances. Replacement parts shall be interchangeable without requiring modification. Tooling and accessories supplied as standard items are also considered replacement parts. Foreign-sourced replacement parts shall be interchangeable with domestically supplied components and be readily available from a domestic source.

3.4.11. Maintainability. Equipment shall be designed and constructed to permit maintenance personnel to easily service with a minimal number of tools. The contractor shall provide any special tools required to service the unit.

3.4.12. Product Data. Manufacturer’s product data for all equipment items shall be submitted for approval by PSNS &I MF prior to procurement of equipment. This applies to all equipment in contact with water, and those used in heater controls. Submittal of product data is presented in paragraph 3.12.2.

3.5. Construction.

3.5.1. Restrictions on Materials and Tools. Apply the following restrictions to prevent inclusion or embedding of ferrous materials on inner surfaces of heater pressure vessel and associated piping and tubing system:

3.5.1.1. Grinding and Polishing Tools. Grinding and polishing tools coming in contact with stainless steel shall be exclusively designated for use on stainless steel only, and not previously used on non-stainless steel surfaces. Grinding tools shall be aluminum oxide or silicon carbide. Brushes shall be stainless steel wire only. Surface finishing tools, hand tools, and handling equipment shall not have been previously used on antimony, bismuth, cadmium, lead, tin, or zinc, or alloys containing these elements (such as solder).

Use of carbon, low alloy, or tool steels on stainless steel requires written approval of

PSNS & IMF.

3.5.1.2. Rolling and Forming Machinery. Inner surfaces of the heater pressure vessel and associated piping and tubing components shall be free of embedded ferrous metal particles resulting from rolling and/or forming. Rollers and/or forming equipment used exclusively on stainless steel shall be used to form the heater pressure vessel, unless specifically approved in writing by PSNS & IMF. Use of rollers or other forming machines previously used on ferrous or aluminum metals, requires special precautions to ensure a satisfactory barrier exists between the rollers/forming machinery and the Heater pressure vessel or piping and tubing components.

3.5.2. Castings and Forgings. All castings and forgings shall be free of defects, scale, and mismatching. No processes such as welding, peening, plugging, or filling with solder or paste shall be used for reclaiming any defective part.

3.5.3. Fastening Devices. All screws, pins, bolts, and other fasteners shall be installed to prevent unintentional loosening. Fastening devices subject to removal or adjustment shall not be permanently installed.

3.5.4. Threads. All threaded parts, either US or SI, shall conform to FED-STD-H28A and the applicable "Detailed Standard" section referenced therein. Hex bolts shall conform to

ASME B18.2.1 and hex nuts shall conform to ASME B18.2.2.

3.5.5. Surfaces. Surfaces shall be clean and free of harmful or extraneous materials. All edges shall be either rounded or beveled unless sharpness is required to perform a necessary function. Interior surfaces of wetted components shall meet the requirements of paragraph 3.7.4.

3.5.6. Welding. Weld requirements for heater and piping are listed in paragraph 3.7.5. Weld requirements for the skid platform and frame are listed in paragraph 3.8.3.

3.5.7. Weld Repairs. Welding shall be employed only where specified in original design.

Welding shall not be employed as a repair measure for defective parts.

3.5.8. Corrosion Control.

3.5.8.1. Ferrous Parts and Fasteners. Exposed ferrous parts and fasteners such as screws, bolts, nuts, washers, etc., shall resist corrosion in a salt-laden, moist, variable temperature atmosphere. Protection such as chrome plating, hot dip galvanizing or other electrical/chemical process, or use of Ni-Cu alloys (e.g. Monel) or stainless steel is acceptable. Fasteners shall not be painted.

3.5.8.2. Dissimilar Metals. Dissimilar metals shall not be used in direct contact with each other without suitable means for preventing electrolytic corrosion, unless specifically approved in writing by PSNS & IMF. Contact of nickel-copper alloys (Monel) and stainless steel alloys is acceptable.

3.5.8.3. Painting. Carbon steel hardware shall be painted or zinc plated to prevent corrosion in marine environment. Stainless steel components shall not be painted or plated unless specifically approved in writing. Exposed carbon steel surfaces shall be properly painted using a duplex system or zinc rich primer. Prior to painting, surfaces shall be primed with a zinc rich primer or galvanized with zinc. Painting shall provide a highly wear-resistant finish that guarantees continued protection against the specified environment under all service conditions. The manufacturer’s standard color shall be provided. When choosing a color options, do not select yellow or magenta paint, decals, or other colored surfaces. Prepare surfaces in accordance with the coating manufacturer’s instructions. Primer and paint shall be free of lead, chromium and cadmium (less than 100 mg/kg, 0.01% of these elements). Documentation of all paint, including specification sheet and safety data sheet, shall be provided in deliverables package of section 3.13.

3.5.9. Workmanship. Workmanship of water heater and skid platform shall satisfy all requirements of this specification, with a quality equal to prevailing manufacturers producing similar equipment.

3.5.10. Materials. The contractor is responsible for providing all material to fabricate and assemble the water heater and skid assembly as a complete and functioning unit.

3.6. Safety and Environmental.

3.6.1. Occupational Safety and Health Administration (OSHA). Equipment installation and its component parts must be in compliance with the applicable OSHA regulation in accordance with 29 CFR Part 1910 and installed in accordance with National Electric Code

(NEC) and National Fire Protection Association requirements.

3.6.2. DELETED (REV. 2)

3.6.3. OSHA Approved NRTL Certification. Equipment 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. An NRTL field evaluation label, complete with reference number, shall be affixed to the electrical equipment. An NRTL certification for the deliverables package is listed in paragraph

3.13.4.

3.6.4. Safety Signs and Labels. Safety signs and labels in accordance with NEMA Z535.4 shall be securely attached in visible locations, at the point of hazard(s). Any safety precautions to be observed by the operator or maintenance personnel shall be permanently marked on the signs.

3.6.5. Safety Guarding. Covers, guards, or 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 prevent unintentional contact with the guarded part and 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 29 CFR 1910 OSHA Safety and Health Standards, General Industry that are applicable to the equipment itself. Additional safety and health requirements shall be as specified in other paragraphs of this specification.

3.6.6. Hazardous Material Exclusions. Supplies or materials being provided as part of the equipment shall be free of known hazardous materials. Hazardous materials shall not be brought on site without prior approval of the Government Point of Contract and cognizant shipyard personnel. Hazardous materials not needed for this project are prohibited.

Definitions of hazardous materials are specified in the latest version, including revisions adopted during the term of the contract, of FED-STD-313. Notwithstanding any other hazardous material usage permitted in this contract, radioactive materials or instruments capable of producing ionizing radiation as well as materials which contain asbestos, mercury, cadmium, lithium, methylene chloride, lead (= or >0.06%), or polychlorinated biphenyls (PCB’s) are prohibited. Nickel Metal Hydride and lithium batteries are permissible for memory backup. Class I Ozone Depleting Substances as defined in 40 CFR

Part 82 shall not be used in the performance of this contract, or be provided as part of the equipment. Exceptions to the prohibition of these materials must be referred to the

Contracting Officer in writing, for consideration, not later than 60 calendar days after effective date of contract and prior to any work being performed.

3.6.7. Mercury Control. Mercury or mercury containing compounds shall not be intentionally added or come in direct contact with hardware or supplies furnished under this contract. To meet this requirement, the contractor shall provide copies of all procurement documents per paragraph 3.6.7.1. The contractor shall provide a final mercury exclusion certificate verifying mercury contamination was not introduced during fabrication of heater. The mercury exclusion certificate shall be provided prior to shipment per paragraph

3.13.7.

3.6.7.1. Mercury Control during Procurement. For material and equipment with wetted surfaces, the contractor shall include the following standard mercury exclusion statement in procurement documents to suppliers:

“Mercury or mercury containing compounds must not be intentionally added or come in direct contact with hardware or supplies furnished under this material order.”

3.6.7.2. State Regulations. The heater assembly shall comply with hazardous material regulations of the states of California and Washington in addition to federal regulations.

3.6.8. Environmental Protection. Under the operating, service, transportation, and storage conditions described herein, the water heater and skid platform shall not emit materials hazardous to the ecological system as prohibited by Federal, state, or local statutes in effect at the point of installation.

3.7. Heater Assembly.

3.7.1. Outfitting. At a minimum, the heater assembly system shall be outfitted with:

(1) Instantaneous electrical heater and attachments,

(2) Electrical power terminal connection box,

(3) Thermostatic temperature controller mounted in electrical enclosure,

(4) A skid platform to support all equipment.

3.7.2. Heater Design. Pressure vessel design, fabrication and inspection shall be in accordance with ASME “Boiler and Pressure Vessel Code”, or European Union “Pressure

Equipment Directive”. Design pressure and temperature shall be 150 psig and 250 degrees

Fahrenheit.

3.7.3. Materials.

3.7.3.1. Metals. All metal components contacting system fluid must be alloy 316 or 316L stainless steel.

3.7.3.2. Piping and Flanges. Piping shall comply with ASME B31.3, Chapter X, for High

Purity Piping. Flange joints shall be butt weld. Bolted flanges shall be class 150 per

ASME B16.5. Tri-clamp flanges (hygienic clamps) shall comply with ASME BPE and have high pressure bolted clamps. Tri-clamps shall not be wing-nut style. Piping shall comply with ASTM A312. Metallic tubing shall comply with ASTM A270. Tapered pipe threads are forbidden to be in contact with system fluid.

3.7.3.3. Spare Softgoods. Contractor will provide one (1) package of spare softgoods (i.e.

Gaskets, Valve Seats and Seals, Pump Seals, etc.) for each heater. Spare softgoods shall be packaged with the deliverables of section 3.13.8. Spare softgoods will be installed during final cleaning at PSNS & IMF.

3.7.3.4. Sealants and Lubricants: All sealants or lubricants (i.e. pipe goop, RTV, Teflon tape, etc.) are prohibited at joints in contact with system fluid. Colloidal graphite in isopropyl alcohol (i.e. Neolube MIL-L 24131) is permitted for lubrication and anti-galling.

3.7.3.5. Nonmetals. Only approved materials are allowed to contact system fluid.

Prohibited materials include Viton, Neoprene, and all polymers with halogens in the chemical structure, except Polytetrafluoroethylene (PTFE, Teflon). Examples of where this requirement applies includes: Gaskets, Valve Seats and Seals, Pump Seals, Nonmetallic Tubing, and etc.

3.7.3.6. Approved Nonmetals. Only those nonmetal materials listed below are approved for use with system fluid. Solid film lubricants or coatings of any material composition are prohibited. All other nonmetal materials are prohibited from being in contact with system fluid without PSNS & IMF approval prior to installation.

i. Polyethylene, including ultra-high molecular weight polyethylene

(UHMWPE)

ii. Polypropylene

iii. Polyisocyanate-polyether or polyester

iv. Polytetrafluoroethylene (PTFE, Teflon)

v. Polyamide (Nylon)

vi. Silicone Rubber

vii. Ethylene Propylene (EPM or EPDM) Rubber

viii. Polysiloxane (Silicone)

ix. Polyaramid (Kevlar)

x. Polycarbonate (Lexan)

xi. Delrin

xii. Polyetheretherketone (PEEK), provided no fluorocarbons are added to the formulation

xiii. Polyurethane

xiv. Derakane (Dow Chemical 470-36 styrene and vinyl ester epoxy)

xv. Silicon Carbide

xvi. Tungsten Carbide

3.7.3.7. Insulation. The heater shell shall be insulated and jacketed per the manufacturer’s standard method. Jacketing shall be stainless steel. Insulation shall be 1 inch minimum thickness. Insulation near mechanical joints (e.g. heater head, flanges, tri-clamps, drain plug, etc.) shall be removable for ease of joint disassembly and leak checks.

3.7.4. Heater Material and Surface Finish. The heater shall be 316 or 316L stainless and meet the following material and surface finish requirements:

3.7.4.1. Material. Stainless steel used in construction of heater pressure vessel shall comply with ASTM A240/A240M or equivalent specification. Piping shall meet ASTM

A312 and tubing shall meet ASTM A270.

3.7.4.2. Procedure Submittals. The contractor shall request approval of final polishing and passivation procedures. Procedures shall include, but not limited to, electropolishing, passivation, final rinse, and a list of all chemicals used. These submittals are listed in paragraph 3.12.3.

3.7.4.3. Final Surface Finish. Wetted stainless steel surfaces of the pure water heater shall be a No. 4 finish (i.e. 30 micro-inches) or smoother. Welding shall be completed prior to electropolishing and passivation. Interior wetted surfaces shall be smooth and free of crevices: e.g. cracks, deep scratches, weld joint seams, etc. Presence of crevices is cause for rejection during Government inspection.

3.7.4.4. Electropolish. Electropolishing shall be performed per ASTM B912.

3.7.4.5. Passivation. Passivation shall be performed per ASTM A380 or ASTM A967.

3.7.4.6. Final Rinse. After completion of final passivation, the contractor shall flush the system with deionized water until outlet conductivity is within 0.5 µS/cm of inlet conductivity, and outlet conductivity not exceeding 2.0 µS/cm.

3.7.5. Welding of Heater.

3.7.5.1. Piping Welds. Pipe welds shall comply with ASME BPVC as stated below:

3.7.5.1.1. Joint design. Weld design for joining pipe to pipe shall be full penetration butt welds with smooth interior surface without crevices.

3.7.5.1.2. Sulfur Content. Sulfur content limitations of base materials shall be based on welding procedure qualification.

3.7.5.1.3. Crevice Free. Weld designs with an interior crevice such as socket welds are prohibited. Joints may be used if crevices are fully seal welded.

3.7.5.1.4. Filler Material. Weld filler material shall comply with ASME BPE section

MM-5.3.

3.7.5.1.5. Purge Requirements. Purge gas shall be filtered argon per MIL-A-18455 or equivalent specification. Dew point and oxygen limits shall be based on welding procedure qualification. Purge gas shall be free of oil and foreign material.

3.7.5.1.6. Qualifications. Welding parameters and procedures shall be qualified per

ASME BPVC, Section IX. Welder and welding operator performance qualifications shall comply with ASME BPVC, Section IX.

3.7.5.1.7. Visual Inspection. Welds shall be visually inspected by qualified individuals to meet the visual acceptance criteria of ASME B31.3 and AWS D18.1, Section 6.

3.7.5.1.8. Weld Prior to Polishing. Polishing and passivation is required after welding of hardware. If welding is performed on polished hardware, then hardware shall be repolished and passivated.

3.7.5.2. Pressure Vessel Welds. Pressure vessel welds shall comply with ASME BPVC or

European Union Pressure Equipment Directive (EU PED) as stated below:

3.7.5.2.1. Pressure Vessel Welding Qualifications. Welding parameters and procedures shall be qualified per ASME BPVC, Section IX. Welder and welding operator performance qualifications shall comply with ASME BPVC, Section IX. All welders assigned to fabrication of pressure vessels must be ASME certified, and all work must conform to the ASME specifications herein.

3.7.5.3. Pressure Vessel and Storage Tank Piping Penetrations. All pressure vessel and storage tank nozzles shall comply with ASME BPVC, or European Union PED.

Minimum weld thickness for all piping penetrations shall equal the pressure vessel wall thickness or respective pipe wall thickness, whichever is less. All nozzle piping flange joints shall be butt-welded.

3.7.5.4. Welding Joint Design. Weld design and finish quality shall allow for cleaning and inspection. Welds that meet ASME BPE are sufficient for cleaning and inspection.

3.7.5.5. Interior Welds. All welds on interior of pressure vessels and storage tanks shall be continuous (not intermittent). Joint seams on interior of pressure vessel shall be seal welded and ground smooth to match the surrounding area. Welds on wetted interior surfaces shall be free of porosity, slag, craters, cracks, tool marks, arc strikes, flux, weld splatter, scratches, burrs, and rust. Edges of welds shall be smoothly blended with base metal.

3.7.5.6. Weld Prior to Final Polishing. Welding of wetted hardware shall be performed prior to final polishing and passivation. If welding is performed on polished surfaces, then hardware shall be repolished and passivated.

3.8. Skid Platform.

3.8.1. Outfitting. The skid platform and frame shall support all heater equipment and enable transport by fork lift, pallet jack, and truck in an industrial shipyard environment.

3.8.2. Skid Platform Materials. The skid platform and frame shall be constructed of stainless steel, galvanized carbon steel, or painted carbon steel per the contractor’s design.

3.8.3. Skid Platform Welding. Skid platform and frame structural welding shall be per the contractor’s design.

3.8.3.1. Joint Design. Joints designs shall be in accordance with contractor’s design drawings. Butt joints shall have complete joint penetration.

3.8.3.2. Continuous Weld. Welded portions of the skid platform and frame shall be continuous welded, unless specified otherwise. Skip welds are not allowed on the skid base and frame, unless the material thickness is less than or equal to 0.10 inch.

3.8.3.3. Inspection. Visually inspect all completed welds for size, completeness, and to ensure they are free of cracks. All welds shall be free of surface defects such as porosity, slag, craters, tool marks, arc strikes, flux, and weld splatter.

3.8.3.4. Sulfur Content. Sulfur content limitations of base materials shall be based on welding procedure qualification.

3.9. Electrical and Instrumentation.

3.9.1. Electrical System. All electrical equipment shall conform to NFPA 70. The available electrical power source is 120KW at 200 amps of 480 VAC - 3 phase. The electrical system shall be tolerant of voltage fluctuation of ± 10 percent. See paragraph 3.1.4 for requirements for control system operation.

3.9.1.1. Solid-State Components. Solid-state design shall be employed throughout for electronic components. Use of selenium and other similar aging devices shall be permitted only in the application of voltage surge protection to other solid-state components. Solid-state components shall not be adversely affected when subjected to power line transients and surges typically experienced in industrial environments. Series and parallel connections of solid-state devices without forced sharing circuitry for voltage and current, respectively, is not permitted. Solid-state devices shall be capable of handling the electrical load imposed by operation of the equipment to its maximum capability.

3.9.1.2. Electrical Enclosures. Electrical components of the equipment shall be contained in enclosures of drip-proof construction and of minimum size consistent with good design practices and ventilation of components, meeting the requirements of NEMA 250 Type

4X. The electrical control panel shall be type 304 stainless steel.

3.9.1.3. Electrical Connection. Electrical power to unit shall utilize either a lugged wire connection or mechanical connection for stranded bare copper wire of size 3/0 AWG

Type W. Cable entry point should accommodate a four (4) conductor cable of this size.

Outside diameter of this cable is 2.070 inches nominally.

3.9.2. Measuring and Indicating Device Graduations. All measuring and indicating devices on the water heater and skid platform shall be graduated in the inch/pound or both inch/pound and metric.

3.9.3. Instrument Programming. Programming of controllers or other applicable instruments shall be performed directly on the controller interface (e.g. by push-buttons). Instrumentation that requires programming via laptop connection, handheld meter, smartphone application, or by wireless signal, including but not limited to Bluetooth and Wi-Fi, is prohibited. A PLC control system may be used, if necessary for heater function, and shall be included in the design submittal of paragraph 3.12.1.

3.9.4. Calibrated Instrumentation. All measurement instrumentation shall be calibrated to accuracy specified by manufacturer. Measurement instruments shall have a sticker or tag affixed with calibration date. Calibration certificates shall be included in the deliverables package in section 3.13. All measurement instrumentation shall be submitted for approval prior to installation. PSNS & IMF review is necessary to verify instrument is within the existing Navy METCAL system, which allows calibration by PSNS metrology.

3.9.5. Conduit. Conduit shall be watertight and be rated for outdoor use in a marine environment. Conduit shall be PVC coated RGS type.

3.10. Lifting and Handling.

3.10.1. The heater shall be designed and constructed for lifting via forklift and pallet jack.

3.10.2. THE REMAINDER OF THIS SECTION WAS DELETED IN REV 2.

3.11. Equipment Labeling.

3.11.1. Marking on Instruments, Control Panels, and Plates. All words on instruments, control panels, and plates shall be in the English language. Characters shall be engraved, etched, embossed, or stamped in boldface on a contrasting background. All plates shall be corrosion resistant.

3.11.2. Identification Plate. A corrosion resistant identification plate shall be securely and conspicuously placed on the heater assembly. It may be the manufacturer's standard, but, as a minimum, it shall contain the following information:

Heater for Pure Water

Manufacturer's name

Manufacturer's model designation

Manufacturer's serial number

Contract Number or Order Number

Date of manufacture

Tare Weight

3.12. Pre-Construction Submittals.

3.12.1. Design Submittals. Provide a design submittal for one (1) heater per paragraph

3.4.1.4.

3.12.2. Product Data. Provide submittal of product data (e.g. technical datasheets and brochures) for wetted materials for PSNS & IMF review and approval to verify material composition and configuration is in compliance with this specification. Product data must be submitted prior to material procurement as specified in paragraph 3.4.12, and is separate from wetted material receipt inspection prior to final assembly per paragraph 4.3.1.2.

3.12.3. Polishing and Cleaning Procedures. Provide submittals for final polishing and passivation procedures per paragraph 3.7.4.2.

3.12.4. DELETED (REV. 2)

3.13. Deliverables Package.

3.13.1. Deliverable Requirements. This section provides requirements for deliverable items provided for each heat skid. For documentation and manuals, contractor shall provide two (2) hard copies and one (1) searchable electronic copy with each heater and skid platform assembly. Electronic copies shall be provided via compact disc (CD).

3.13.2. Operating and Maintenance (O&M) Manuals. O&M Manuals shall contain technical information, specifications, instructions for the operation, maintenance of the heater assembly and recommended spare parts list. All copies of technical data shall be legible and written in the English language. Data shall enable an average journeyman mechanic to operate, program, maintain, and repair the equipment. Technical Data shall contain at a minimum:

3.13.2.1. Complete data package with original manufacturer’s technical data and O&M manuals for vendor provided equipment.

3.13.2.2. Calibration certificates for all instrumentation.

3.13.2.3. Final As-built drawings (paper, electronic, and AUTOCAD) including detailed fabrication drawings for the heater and skid assembly.

3.13.2.4. Operating instructions including programming requirements, pre-operational checks, start up, shutdown, emergency shutdown, and energy control.

3.13.2.5. Maintenance and service instructions.

3.13.2.6. Paint specifications and safety data sheets.

3.13.3. Test Data Results. The Contractor shall submit a written report of all tests and results conducted at origin per paragraph 4.3.5. The test report shall be submitted within

10 working days after all tests are completed.

3.13.4. Occupational Safety and Health (OSHA) Certifications. A Nationally Recognized

Testing Laboratory (NRTL) field evaluation report shall be provided as certification of compliance with OSHA requirements for electrical equipment and components per paragraph 3.6.3

3.13.5. Record of All Wetted Materials. The contractor shall document the chemical composition of all installed materials in contact with system fluid. Contractor records shall be made available to the government prior to fabrication of heater assembly. A compiled record of all wetted materials shall be delivered to the government upon completion of operational testing. Record shall include, but is not limited to, product data per paragraph

3.12.2 and all documentation collected for wetted material receipt inspection per 4.3.1.2.

3.13.6. Inspection Records. A copy of all inspection records and certifications shall be provided to the government upon delivery of each heater assembly. This shall include all inspections performed during fabrication and acceptance inspections. These records shall be provided to the Government upon delivery of each heater.

3.13.7. Mercury Certification. The contractor certification shall provide a certificate that specifically includes statements that certify compliance with paragraph 3.6.7.

3.13.8. Spare Soft Goods. The contractor shall provide a full set of gaskets and seals with each heater and skid assembly per paragraph 3.7.3.3.

3.13.9. Warranty. The manufacturer or vendor shall provide a warranty for the heater assembly, control system, and skid platform as free from defects in materials and workmanship under normal use and service for a period of twelve (12) months from the date of delivery to PSNS & IMF. The vendor shall accept returns and make necessary repairs or provide replacement parts on behalf of the manufacturer in the case of defective products within the warranty period.

4. QUALITY ASSURANCE

4.1. Responsibility for Inspection.

4.1.1. Contractor Responsibility for Inspection and Testing. The contractor shall be responsible for performance or facilitation of all inspection requirements specified herein.

Except as otherwise specified in the contract or purchase order, the contractor may use any facility suitable for the performance of the inspection requirements specified herein, unless disapproved by the Government. Only supplies that totally conform to the specifications shall be offered for inspection and test. The contractor's test schedule shall allow consecutive inspection and test of the supplies offered. The Government reserves the right to charge the contractor for any Government re-inspection cost when supplies are not ready at the time requested by the contractor or when necessitated by prior rejection. The

Government reserves the right to perform any inspections set forth in the purchase description where such inspections are deemed necessary to assure supplies and services conform to prescribed requirements. The contractor shall provide all materials required for all inspection and testing, including de-ionized water.

4.1.2. Responsibility for Compliance. All items must satisfy the requirements of paragraphs 3 and 4.

4.1.3. Measuring and Testing Equipment and Inspection Personnel. The contractor shall provide and maintain gauges and other measuring and testing devices necessary to assure conformance with technical requirements. These devices shall be calibrated at established intervals against certified standards traceable to national standards. Any production tooling

(i.e. jigs, fixtures, templates and patterns) used as inspection media, shall also be proved for accuracy at established intervals. When required, the contractor's measuring and testing equipment shall be made available for use by the Government representative to determine conformance of product with contract requirements. If conditions warrant, the contractor's personnel shall be made available for operation of such devices and verification of their accuracy and condition.

4.1.3.1. The contractor’s inspector(s) shall perform inspections as required by this specification and shall be fully qualified per the applicable ASME and/or ASTM standards.

4.1.3.2. A contractor’s inspector(s) shall witness all tests,…