N6449820R4001.docx

N6449820R4001

Section A - Solicitation/Contract Form

MINIMUM AND MAXIMUM QUANTITIES

The Government is contemplating the award of a single contract.

The quantities of supplies specified are estimates only.

The Naval Surface Warfare Center, Philadelphia Division (NSWCPD) is the ordering activity authorized to issue delivery orders. Orders will be placed in writing only.

As referred to in paragraph (b) of FAR 52.216-22, “Indefinite Quantity” of this solicitation, the contract minimum is all CLINs 0001 to 0009 and the maximum quantity is the total of all CLINs. The minimum quantity will be met by issuance of delivery order 0001.

This solicitation is a 100% Small Business Set-Aside.

Section B - Supplies or Services and Prices

COST AND PRICING DATA

In accordance with 252.215-7010, please submit Other than Certified Cost or Pricing Data with proposal submission in order to support the proposal.

FIRST ARTICLE - DESIGN REPORT

FFP

In accordance with Contract Data Requirements List (CDRL) A001 and Contract Specifications FOB: Destination

PSC CD: 4810

NET AMT

FIRST ARTICLE - TEST PLAN

IAW CDRL A002 and Contract Specifications

NET AMT

ASSEMBLY DRAWINGS

IAW CDRL A003 and Contract Specifications

NET AMT

DETAIL DRAWINGS

IAW CDRL A004 and Contract Specifications

NET AMT

WIRING LIST AND DIAGRAM

IAW CDRL A005 and Contract Specifications

NET AMT

FIRST ARTICLE - TEST REPORT

IAW CDRL A006 and Contract Specifications

NET AMT

FIRST ARTICLE - TESTING & TESTED VALVES

This CLIN is for the testing and delivery of three (3) valves IAW the Contract Specifications.

NET AMT

ENGINEERING DATA PACKAGE

IAW CDRL A007 and Contract Specifications

NET AMT

TECHNICAL MANUAL

IAW CDRL A008 and Contract Specifications

NET AMT

MOPV PRODUCTION YEAR ONE

Date of contract award through 12 months thereafter.

NOTE: The requirements in DFARS 252.211-7003, Item Identification and Valuation, are applicable for this line item. The contractor shall provide DoD unique identification or a DoD recognized unique identification equivalent.

MAX

NET AMT

STEPLADDER PRICING

MOPV PRODUCTION YEAR TWO

To be ordered from 13 months to 24 months thereafter.

NOTE: The requirements in DFARS 252.211-7003, Item Identification and Valuation, are applicable for this line item. The contractor shall provide DoD unique identification or a DoD recognized unique identification equivalent.

MAX

MOPV PRODUCTION YEAR THREE

To be ordered from 25 months to 36 months thereafter.

NOTE: The requirements in DFARS 252.211-7003, Item Identification and Valuation, are applicable for this line item. The contractor shall provide DoD unique identification or a DoD recognized unique identification equivalent.

MAX

MOPV PRODUCTION YEAR FOUR

To be ordered from 37 months to 48 months thereafter.

NOTE: The requirements in DFARS 252.211-7003, Item Identification and Valuation, are applicable for this line item. The contractor shall provide DoD unique identification or a DoD recognized unique identification equivalent.

MAX

MOPV PRODUCTION YEAR FIVE

To be ordered from 49 months to 60 months thereafter.

MAX

Contract Data Requirements List (CDRLs)

Technical data IAW CDRLs A009 and A010 contained herein. Not Separately Priced (NSP). See Section C.

NET AMT

Section C - Descriptions and Specifications

TECHNICAL SPECIFICATION

TECHNICAL SPECIFICATION

FOR

MOTOR-OPERATED PILOT VALVE

Table of Contents

TECHNICAL SPECIFICATION FOR MOTOR-OPERATED PILOT VALVES (MOPVS)

1. SCOPE

1.1. PURPOSE

This specification defines the requirements applicable to the design and construction of the motor-operated pilot valve (MOPV) for use aboard US Navy ships. This document contains the specific performance, functional, maintenance and programmatic requirements for the MOPV.

References to the “MOPV” or the “valve” within this specification refer to the entire valve assembly, actuator, and any auxiliary devices supplied by the Contractor.

1.2. BACKGROUND

The MOPV is intended to replace the existing solenoid-operated pilot valves (SOPVs) which are installed in Aqueous Film Forming Foam (AFFF) and Washdown Counter Measure (WDCM) Systems.

The MOPV will provide two control functions, as a 4-port master MOPV and a 3-port service MOPV. The 4-port master MOPV will be used to initiate AFFF concentrate flow and firemain flow for mixing and disbursement to AFFF systems aboard ship. The 3-port MOPV serves as the local disbursement valve for either firemain flow or the AFFF mixture. The MOPV specified herein shall be a 4-port valve with capability to function as a 3-port valve. See Section 3.3.21 and the figure cited therein for the Port and Flow configurations and the Open/Close designations.

1.3. LIABILITIES

The Contractor shall accept responsibility and liability for the effect on the baseline design of all design changes instituted, recommended, and approved. The Contractor shall evaluate all changes and modifications to the basic design to ensure that the strength, performance, service life, safety, interchangeability, maintainability, reliability and operation of the entire valve and components are not compromised as a result of the modification or change. In the event that this evaluation reveals compromise in any of the above, the Contractor shall immediately inform Naval Surface Warfare Center, Philadelphia Division (NSWCPD) in writing of the results of the evaluation and shall provide a recommendation, including schedule for the work needed to recover from the compromised condition.

1.4. SUBMITTALS

All Contractor submittals, including technical deliverables, shall be to NSWCPD as defined in the delivery order or herein. All Contractor requests for interpretation or clarification of any delivery order specification, requests for repair welding authorizations (when required) and requests for acceptance of a nonconforming condition shall be submitted to the Procurement Contracting Officer. The minimum required deliverables are defined in the applicable sections of this specification. Deliverables required by this and other specifications shall be submitted to NSWCPD for approval. The submittals shall identify the delivery order number and CDRL item number for which the data is submitted. To this purpose the following definitions apply:

(a) US Navy - United States Navy

(b) Contractor – Manufacturer, Corporation or Agency accepting a contract to develop or provide the material described herein.

(c) Government – All official agencies of the US Government

(d) NAVSEA – Naval Sea Systems Command

(e) NSWCPD – Naval Surface Warfare Center, Philadelphia Division

2. APPLICABLE DOCUMENTS

2.1. SPECIFICATIONS, STANDARDS, AND PUBLICATIONS

The following documents form a part of this specification to the extent specified herein. However, all revisions or effective dates of specifications referenced within the Technical Specification, shall take precedence over any newly released revisions, including effective issue dates defined in Section 2.2.

2.2. EFFECTIVE DATE

Unless otherwise specified herein, the revision of the applicable Government or commercial specification cited herein shall be the revision in effect at the time of contract award. The ASSIST database at http://assist.daps.dla.mil is the official source for all Defense Standardization Program documents and contains the most current information. The ASSIST database should be used as a guide for determining which issue of specifications, standards, handbooks, and amendments to these documents is in effect. Where a specification is cancelled and a replacement is identified in the cancellation notice, the last revision prior to cancellation shall be used until US Navy approval is obtained that the replacement specifications, with any necessary supplemental requirements or modifications, is adequate.

2.3. USE OF LATER REVISIONS OF MATERIAL SPECIFICATIONS

Except in cases where a specific revision of a specification is invoked by this procurement specification or other contractual document, the Contractor may elect to use material procured to later revisions than the effective revision of the material specification. This election is allowed provided that the material form, mechanical properties and composition of the material will not be altered, and that neither the number nor the scope of any required destructive or nondestructive tests or other inspections will be reduced or the acceptance criteria degraded.

Material specifications are defined as those specifications that identify the requirements for mechanical properties, material composition, testing, and inspection of the materials used in construction for the component. This includes specifications for metals in all forms, lubricants, non-metallics, such as gaskets and O-rings, and fasteners.

In the event that the Contractor elects to use material procured to a later revision of a specification, the applicable material certification packages, whether provided with the component hardware or retained on record at the Contractor’s facility, must be supplemented by appropriate documentation. This documentation must clearly identify the substitution that was made, identify the affected individual piece part number(s), and provide the following certification: “The Contractor hereby certifies that the material provided is in the same form and meets the same mechanical property and material composition requirements as would have been the case had the material been procured to the effective revision of the specification with any invoked additional ordering requirements. Furthermore, neither the number nor the scope of any required destructive or non-destructive tests or other inspections were reduced, or the acceptance criteria degraded, by this substitution.”

3. REQUIREMENTS

3.1. DESIGN QUALIFICATION TESTING

Equipment furnished under this specification shall be products, which have satisfactorily completed the tests specified herein. Onboard repair parts and stocked spare parts ordered for valves built to this specification shall be subject to the same requirements and tests (drawings, quality control, non-destructive tests, etc.) as the original equipment.

3.2. MATERIAL

The MOPV is subject to the preference for domestic specialty metals. The MOPV shall be designed and manufactured to exclude the use of lapped surfaces to prevent scoring from grit. The valve internals shall be fabricated from a corrosion resistant material. The valve body shall be fabricated from a material that is compatible with the valve internals and connecting copper-nickel pipe. Compatible materials are defined as those that do not result in galvanic corrosion or premature wear of the materials due to differences in physical or chemical properties.

3.2.1. CORROSION RESISTANCE

Materials used in the construction of the valve body, valve internals, and associated equipment shall be corrosion resistant materials suitable for use in seawater environments and AFFF/seawater solution. Coatings shall not be credited for providing corrosion resistance.

3.2.2. UNIT PAINTING

3.2.2.1. VALVE BODY AND INTERNALS

The valve body and valve internals of the MOPV shall not be painted or coated.

3.2.2.2. ACTUATOR

The actuator shall be painted as follows:

a. If the actuator is made of corrosion resistant materials, as listed in Section 3.2.3, for the specified ambient conditions, no painting is required.

b. If the actuator is not made of corrosion resistant materials listed in Section 3.2.3, the actuator casing shall be thoroughly cleaned and painted in accordance with MIL-DTL-24441D. Anodizing aluminum in accordance with MIL-A-8625, Type II, Class 1, non-dyed, and sealed per Class 1 shall be acceptable. The final color shall be gray, color number 16187 (MECHANIC GRAY NAVY STANDARD) in accordance with AMS-STD-595A, or shall be approved by NSWCPD. A gray powder coat applied using material confirming to MIL-PRF-24712 may be used and shall be approved by NSWCPD.

3.2.3. ACCEPTABLE MATERIALS

The following section provides examples of acceptable materials for use in the MOPV. This list is not exclusive and only serves as a foundation for applicable materials. All materials used that are not listed or specified in this document shall be approved by NSWCPD.

3.2.3.1. VALVE BODY

(a) 70/30 CuNi alloy in accordance with ASTM-B122, ASTM-B369, MIL-C-15726F with Amendment 1, MIL-C-24679, or equivalent.

(b) 90/10 CuNi alloy in accordance with ASTM-B122, MIL-C-15726F with Amendment 1, MIL-C-24679, or equivalent.

(c) Bronze in accordance with ASTM-B61, ASTM-B62, ASTM-B584, MIL-B-24480A, or equivalent.

(d) Nickel-Copper-Aluminum in accordance with QQ-N-286G.

3.2.3.2. VALVE INTERNALS

(a) 6Al-4V ELI Titanium in accordance with MIL-T-81556A with Amendment 1, or equivalent.

(b) Nickel-Cobalt alloy in accordance with MIL-C-24689B, MIL-C-24252D or ASTM-B168, or equivalent.

(c) Monel in accordance with MIL-N-24106, MIL-N-24549, ASTM-B127, or equivalent.

(d) Nickel-Plated Bronze in accordance with ASTM-B689, or equivalent.

(e) Nickel-Copper-Aluminum in accordance with QQ-N-286G.

3.2.3.3. ELASTOMERIC POLYMER BASED COMPONENTS: SEALS, SEATS, O-RINGS, ETC.

(a) Nitrile Butadiene Rubber (NBR or Buna-N) in accordance with applicable SAE-AMS3200, or equivalent, or Hydrogenated NBR (HNBR or Therban).

(b) Ethylene Propylene Diene Monomer (EPDM) in accordance with ASTM-D4637, SAE-AMS3249, SAE-AMS3260, or equivalent.

(c) Polytetrafluoroethylene (PTFE) in accordance with MIL-P-24396A, SAE-AMS3666, or equivalent.

(d) If one of the above materials or equivalent is not selected, contractor shall provide the product, chemical composition, and compatibility with other components and all system fluids, including test fluids.

3.2.4. HAZARDOUS MATERIALS

Hazardous materials shall not be used unless suitable substitutes are not available. The contractor shall specifically identify to and obtain approval from NSWCPD for any hazardous material which the contractor determines is necessary. Rationale for use of the hazardous material shall be provided.

Materials that are capable of producing hazardous gases or other harmful effects under conditions encountered in naval shipboard service, and maintenance and repair shall not be used unless specifically approved by NSWCPD.

A hazardous material review shall be performed and shall be addressed in the Design Report.

3.2.5. DETRIMENTAL MATERIALS

The following materials shall not be used.

(a) Magnesium alloy

(b) Cast Iron

(c) Cadmium plating

(d) Aluminum and zinc castings

(e) Mercury

(f) Lead

(g) Beryllium

3.2.6. NOXIOUS FUMES

Instruments, equipment, fittings, paint, insulation, adhesives or other items containing material compounds that would give off noxious fumes at the ambient temperatures as specified in Section 3.3.6, or at any temperature below 200°F, shall not be installed or applied. For paint and adhesives, the requirement applies after drying or curing is complete.

3.2.7. LUBRICANTS AND COMPOUNDS

All lubricants and compounds for valve assembly, maintenance, and repair shall be specified on the valve drawing. This requirement does not apply to lubricants and compounds used only in the manufacturing process.

3.3. DESIGN

The design requirements are defined below. The Contractor shall not deviate from the requirements unless modifications are approved by NSWCPD.

3.3.1. IDLE PERIODS

The MOPV shall operate satisfactorily after an idle period of one year without any prior maintenance or repair. “Idle period” shall be defined as meaning one year with or without pressurized conditions on the MOPV.

3.3.2. DESIGN LIFE

The MOPV design life shall be 10,000 actuation cycles (one cycle is defined as one full actuation stroke, and one return actuation stroke) occurring at irregular intervals over a period of 50 years with a minimum of servicing. The valve shall be designed to withstand the design temperatures and pressures specified in Sections 3.3.5.2, 3.3.6, and 3.3.7. The valve shall comply with the requirements of Section 3 and shall pass the tests of Section 4. Where wear or erosion is unavoidable, the parts subjected to such wear or erosion shall be of the best materials available for the purpose in order to reduce these detrimental effects to a minimum. The design life of such materials shall be identified in the drawings and manuals. A compact valve design is preferred and shall meet reliability requirements, as well as requirements defining accessibility for repair or replacement and resistance to wear or corrosion. The requirements set forth shall not be construed or interpreted as a warranty requirement, nor shall it otherwise affect the manufacturer's warranty.

3.3.3. MAINTENANCE AND OPERATION

The time between maintenance activities that require the valve to be disassembled shall be no less than 60 months (5 years); this includes any indicator lights (if provided). The number of cycles between maintenance activities that require the valve to be disassembled shall be no less than 1000 cycles; this includes any indicator lights (if provided).

3.3.4. RELIABILITY

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. Contractors are encouraged to advise NSWCPD of any findings related to the requirements or lack of requirements in this specification, whereby improvement of equipment reliability can be achieved.

3.3.5. FLUID MEDIUM

The fluid medium for this valve is seawater or an AFFF/seawater solution. The MOPV shall operate without seat leakage when exposed to incoming seawater containing contaminants, including inorganic and organic debris such as salt, sand, grit, barnacles, etc.

3.3.5.1. FLOW RATE

The MOPV shall provide a minimum flow rate of 1.5 gallons per minute of seawater at a supply pressure of 150 psig.

3.3.5.2. FLUID TEMPERATURE

Operating seawater temperature:

3.3.5.3. ENTRAINED PARTICLES

Particle sizes (e.g., sand) of up to 0.093 inches entrained in the respective fluid shall not damage or inhibit operation of any component in the MOPV.

3.3.5.4. MARINE GROWTH

The MOPV shall be resistant to the effects of marine growth and fouling.

3.3.6. ENVIRONMENTAL CONDITIONS

Environmental conditions experienced by the MOPV shall be as listed below:

(a) Ambient Temperature: The MOPV shall operate under temperatures nominally at 70°F, but varying between 32°F and 150°F

(b) Humidity: The MOPV shall operate under humidity varying between 0% and 100%, with the expectation of condensation forming in and on the MOPV.

(c) Spray: The MOPV shall be designed and tested to provide ingress protection of enclosure type, spraytight, in accordance with Section 4.10 and Table II of MIL-STD-108E with Notice 2. .

3.3.7. PRESSURE CONDITIONS

The valve shall operate at 50 to 250 psig.

Pressure boundary design and test pressure shall be as listed below:

(a) Casing design pressure: 250 psig

(b) Casing test pressure: 375 psig

The maximum pressure drop across the pilot valve shall not exceed 7.4 psid at a flow rate through the valve of 1.5 gpm when tested as described in Section 4.3.1.1(b).

3.3.8. POWER

3.3.8.1. SHIP SUPPLIED AC

The MOPV shall operate with 120 VAC single phase power in accordance with MIL-STD-1399 Section 300B. The MOPV shall not use or be provided with an energy storage device (e.g., battery, capacitor, etc).

3.3.8.2. CURRENT DRAW

The maximum steady state current draw of the valve operator shall not exceed three (3) amps. The maximum surge current draw shall not exceed 12 amps.

3.3.9. VALVE ACTUATOR

3.3.9.1. ACTUATION TORQUE

The actuator for the MOPV shall provide, at a minimum, a torque sufficient to cycle the valve at end of life (10,000 actuation cycles), with fouled and worn internals.

3.3.9.2. ACTUATION COMPLETION RATE

The valve shall successfully complete all 1,000 actuation cycles with no loss of functionality and no leakage during the Dirty Water Life Cycle Testing in Section 4.3.1.1 (d).

3.3.9.3. STROKE TIME

Valve opening and closing (reset) time shall be such that the stroke of the MOPV is completed and the desired internal flow path is established within two seconds of receiving an actuation signal as demonstrated during the Functional Testing in Section 4.3.1.1 (b).

3.3.9.4. ACTUATOR CONTROL SIGNAL

The MOPV actuator shall open and close on a momentary single phase 120 VAC control signal. See Section 3.3.9.7 for more information.

3.3.9.5. LIMIT SWITCHES

The valve actuator shall include limit switches, which indicate the position of the valve. Connections to these limit switches shall be provided on the terminal board as specified in Section 3.3.9.6. Alternatively, a combination terminal board and limit switch external enclosure may be provided with the valve. Each limit switch shall be designed for a 440VAC, 15A signal. Limit switches shall provide open and close indication in an energized and de-energized state. Proper functionality of the limit switches shall be demonstrated during the Functional Testing in Section 4.3.1.1 (b). Contacts of “open position” limit switches shall be closed when the valve is in the fully open position. Contacts of “closed position” limit switches shall be closed when the valve is in the fully closed position. The valve shall be considered fully open or fully closed when a tolerance of ±5 degrees from the nominal electrical actuation stop point is established.

3.3.9.6. ACTUATOR TERMINAL BOARD

The MOPV actuator shall include terminal boards in accordance with A-A-59125/2 for connections identified in Section 3.3.9.7. Each terminal board provided shall be labeled consecutively. Each terminal shall be labeled to identify the function of that terminal. Wiring pairs shall not be split across multiple terminal boards. The MOPV shall include four ¾-14 NPT conduit connection ports to supply outside wiring to terminal boards. Ring lugs shall be used for all internal wiring connections. .

Figure 1 is a conceptual idea of a two terminal board configuration. See Section 3.3.9.7 for more information on MOPV actuation.

LSC1

LSC2

LSCC1

LSCC2

LSC3

LSCC3

PBC

LSO1

LSO2

LSOC1

LSOC2

LSO3

LSOC3

PWR IND

TB-2

TB-1

Terminal 1 Terminal 10

PBCC

120VAC

PBO

PBOC

120VAC

PWR IND

Figure 1: Conceptual MOPV Terminal Board Labeling (Two ten-terminal terminal boards shown for example only.)

3.3.9.7. MOPV CONTROLS AND OPERATION

The following inputs shall be provided: 120 VAC power for operation of the MOPV; an input for a momentary push button to open the valve; and an input for a momentary push button to close the valve. The following outputs shall be provided:

(a) A minimum of three (3) electrically isolated outputs for indication of fully open valve status rated for 1A at 440VAC;

(b) A minimum of three (3) electrically isolated outputs for indication of fully closed valve status rated for 1A at 440VAC; and

(c) One (1) output to indicate loss of 120 VAC power at the MOPV rated for 1A at 120VAC.

The MOPV shall actuate when single phase 120 VAC is applied to the open push button input and shall return to the standby position when single phase 120 VAC is applied to the close push button input. The minimum voltage required for the MOPV to change state (open to close or close to open) shall be equal to or greater than 90 volts AC. MOPV open and close command signal interfaces shall be immune to external shunt impedance of greater than or equal to 8.0 kohm at 60 Hz. Open and close push button operations shall be electrically isolated from each other. Contacts of “open position” limit switches shall be closed when the valve is in the fully open position. Contacts of “closed position” limit switches shall be closed when the valve is in the fully closed position. The valve shall be considered fully open or fully closed when a tolerance of ±5 degrees from the nominal electrical actuation stop point is established.

3.3.9.8. OVER-TEMPERATURE PROTECTION

The MOPV will be opened and closed by separate push buttons (not supplied by the MOPV contractor) that may be accidentally held closed or may fail in the closed position, resulting in extended current applied to the valve actuator. The valve actuator shall include features to protect against over-temperature damage caused by extended applied current.

3.3.10. COUPLING BETWEEN VALVE AND ACTUATOR

3.3.10.1. ELECTRO-MECHANICAL SYSTEM ALIGNMENT

There shall be no misalignment between the mechanical and electrical components of the MOPV during and upon completion of the 1,000 test cycles of the Dirty Water Life Cycle Testing, Section 4.3.1.1 (d).

3.3.10.2. MODE PRIORITY

In the event that the valve is operated manually due to a loss of power, restoration of power shall not change the manually selected position. When the MOPV is manually actuated, all internal switches shall change position automatically, such that the valve is correctly re-aligned upon restoration of power. The reliance on power to hold the MOPV in the desired position shall be prohibited.

3.3.10.3. VALVE AND ACTUATOR INTERCONNECTION

The MOPV valve and actuator shall provide simplicity in interconnection to allow replacement of either component with minimal time and effort. The interconnection design shall minimize the possibility of misalignment during assembly and re-assembly by maintenance personnel.

3.3.11. INCORRECT ASSEMBLY

Individual valve parts shall be self-aligning and nonreversible, unless parts are reversible with no effect on the valve function or performance.

3.3.12. END CONNECTIONS

The MOPV shall be provided with 3/8-inch male union fittings that are capable of accommodating a 3/8-inch nut in accordance with MIL-F-1183.

3.3.13. VALVE MOUNTING

The MOPV shall operate when mounted in any orientation. Successful operation of the valve shall not rely on orientation or be impacted by gravity. The valve shall include a mounting device that is compatible with the existing mounting configuration aboard ship. Figure 2 depicts the existing mounting configuration with the critical dimensions.

Figure 2: MOPV Mounting Configuration (Units are in inches, Figure not to scale)

3.3.13.1. WEIGHT AND CENTER OF GRAVITY

The Contractor shall provide a calculated weight and center of gravity with the Design Report. The actual dry and wet weight and center of gravity shall be stated on the valve drawing. The MOPV wet weight shall not exceed 28 lbs.

3.3.14. SPACE ENVELOPE

3.3.14.1. REFERENCE FRAME

The MOPV shall have a fixed body reference frame with axis defined in relationship to specified dimensions as follows:

(a) Width along the x-axis

(b) Height along the y-axis

(c) Depth along the z-axis

The body reference frame is defined as follows and shown in Figure 3:

(a) The x-z plane shall be parallel to deck.

(b) The x-y plane shall be parallel to the local bulkhead where valve is mounted.

MOPV

Figure 3: Reference frame of MOPV with Line of Sight

3.3.14.2. SINGLE UNIT ENVELOPE

The MOPV space envelope shall be within the dimensions shown in Figure 4. The MOPV mounting plate is located at the transition between the “upper” and “lower” portions (3.50 inches from bottom) of the Figure 4 Front View. The end connections for the MOPV shall be within the space envelope depicted in Figure 4

Figure 4: MOPV Space Envelope (Units are in inches)

3.3.15. MAINTENANCE ENVELOPE

The maintenance envelope for minor adjustment or alignment of the MOPV shall fit in the space envelope shown in Figure 4. The removal of any/all covers must be done from the front and within the space envelope.

3.3.16. FASTENERS

Fasteners shall be as follows:

(a) Bolts shall be in accordance with ASME B18.2.1.

(b) Nuts shall be in accordance with ASME B18.2.2.

(c) Cap screws shall be in accordance with ASME B18.3.

(d) Studs shall be in accordance with MIL-DTL-1222J.

(e) All fasteners shall be made from corrosion resistant materials for the specified environment.

(f) Grades 410, 416/416Se, and 431 corrosion resistant steel fasteners shall not be used.

(g) Inspection of fasteners, threads, and threaded parts shall be in accordance with FED-STD-H28/20B with Notice 1, System 21 unless otherwise specified by the applicable fastener specification.

(h) As a minimum, fasteners joining valve parts that form the pressure boundary shall be torqued to maintain the leak tightness of the valve under all design pressures.

(i) Threaded fasteners of normal stock length and standard diameters shall be used unless approved by NSWCPD. Male threads on threaded fasteners, after being installed, shall protrude between one to five threads beyond the top of the nut or plastic-locking element. Washers shall not be used to reduce thread protrusion. The method of determining the required length of thread engagement shall be in accordance with FED-STD-H28A.

(j) Nickel-copper-aluminum (GRADE 500) fasteners shall be in accordance with MIL-DTL-1222J.

3.3.17. OPERATING ORIENTATION

The MOPV shall meet all performance requirements with the valve installed in any orientation.

3.3.18. BEARING SURFACES

Bearing surfaces of valve parts that contact with nuts and bolt heads shall be machined to a 63 μin roughness average.

3.3.19. LOCKING DEVICES

All threaded fasteners and threaded machine parts internal to the valve, actuator and moving parts shall be secured using locking devices, which are in accordance with SAE J2280. Staking, set screws, split lock washers, and snap-rings shall not be used. If self-locking fasteners are used, they shall be in accordance with MIL-F-8961A with Amendment 1.

3.3.20. POSITION INDICATOR

Visual indication of MOPV valve stem position shall be provided through a non-powered mechanical indicator. Position indication shall be visible to the normal eye at a distance of at least three (3) feet. Position indication shall be viewable from the line of sight shown in Figure 3. Viewing angle shall be a minimum of 40-degrees on either side of a perpendicular line to the face of the MOPV. Visual indications shall comply with Section 5 of MIL-STD-1472F with Notice 1. Compliance with the MOPV valve stem position requirements shall be assessed during the Functional Testing in Section 4.3.1.1 (b).

3.3.21. FIRST ARTICLES

Contractor First Article Testing shall consist of producing three (3) First Article units (CLIN 0007), which shall be tested and approved by NSWCPD prior to the release for production and issuance of delivery orders under this Contract. The First Articles shall be subject to design evaluation, inspection, and testing as specified in Section 4.3. A test readiness review shall be conducted prior to initiation of First Article Testing. Table 1 shows the inspections/tests to be performed on each of the First Article units. The inspections/tests for each unit shall be performed in the order shown below:

Table 1. First Article Units and Inspections/Tests Performed on Each

3.3.22. 4-PORT VALVE

The selected port design (size and area) shall not restrict seawater flow, thus ensuring that the MOPV will satisfy operational flow requirements. The MOPV shall be a 4-port valve as specified below with alignments, including open and closed positions, as shown in Figure 5. No ports shall be located on the back side of the valve.

3.3.22.1. SUPPLY PORT

The MOPV shall be supplied with one (1) supply port. The supply port shall be located on the front side of the valve.

3.3.22.2. DRAIN PORT

The MOPV shall be supplied with one (1) drain port.

3.3.22.3. OUTLET PORT

The MOPV shall be supplied with two (2) outlet ports. The MOPV shall function as a 3-port valve when either outlet port is capped, as shown in Figure 5, which also shows the open and closed positions. The two outlet ports shall be located on opposite sides of the valve.

Figure 5: MOPV Port and Flow Configurations

3.3.23. FABRICATION

Fabrication shall be performed such that all parts manufactured to the same drawings shall be interchangeable and installable in the field with no added process steps.

3.3.23.1. WELDING AND INSPECTION

Welding and inspection shall be in accordance with the requirements defined in NAVSEA Technical Publication S9074-AR-GIB-010/278.

3.3.23.2. CASTINGS

Castings shall be free of adhering sand, hard spots, excessive shrinkage, cracks, or scale. Castings shall be smooth and well cleaned both inside and out, and all fins and roughness shall be removed. Unacceptable visual surface discontinuities, including cracks, tears, shrinkage, inclusions, gas holes, and other potentially harmful defects, shall be removed and their removal shall be verified by visual examination of the resultant surface. Castings shall not be repaired, plugged, impregnated, brazed, burned in or peened except as approved by NSWCPD.

3.3.24. GREASE FITTINGS

The MOPV shall not rely on grease for lubrication nor contain any grease fittings. Lubrication for assembly purposes is acceptable.

3.3.25. SHOCK

The MOPV shall be tested and conform to MIL‑S‑901D shock requirements. The MOPV shall be tested as Lightweight, Grade A, Class I, Type A.

3.3.26. VIBRATION

The MOPV shall be tested and conform to MIL-STD-167-1A, Type I vibration requirements. The MOPV shall be designed so that they will not be damaged or caused to malfunction either by internal excited vibrations, or by the environmental vibrations specified in MIL-STD-167-1A for the frequency range specified.

3.3.27. ELECTRO-MAGNETIC INTERFERENCE

The electromagnetic interference (EMI) tolerance of the MOPV shall be tested and conform to the requirements of CE101, CE102, CS101, CS106, CS114, CS116, RE101, RE102, RS101, and RS103 of MIL-STD-461F for Internal Installations on Surface Ships. For RS103, CS114, and CS116, tests shall also be conducted at 25 V/m applied across the full applicable frequencies range. The MOPV shall also comply with MIL-STD-464C paragraph 5.11, electrical bonding, as applicable.

3.3.28. TIGHTNESS

The MOPV shall be rated in accordance with the testing requirements of Section 4.3.1.3.

3.3.29. MANUAL OPERATION

3.3.29.1. MANUAL OPERATION MODE

A manual operation mode shall be provided for the MOPV in the event of electrical failure or signal loss. Manual operation mode shall provide the user with a means of mechanically changing the valve position. The preferred method for manual operation is via a lever or handwheel operator. Manual operation shall not require opening, disassembly, or temporary modification of the MOPV. The manual operator shall not employ any detachable/removable components.

3.3.29.2. DURATION AND TORQUE

The manual operator shall be designed to minimize the time it takes to fully stroke the valve in manual mode. Manual operation of the valve shall not exceed five (5) seconds to transition the valve from one position to the other when tested in accordance with Section 4.3.1.1 (f). The torque required to fully stroke a valve using a lever operator for manual operation as described in Section 3.3.29.1 shall not exceed 19.9 lb-in when testing in accordance with Section 4.3.1.1 (f).

Figure 6 – Example of Level Operator

3.3.29.3. ELECTRICAL SHOCKS

Personnel shall not be exposed to shock hazard from the MOPV while manually operating the MOPV.

3.3.29.4. POSITIVE STOP CONSTRUCTION

The MOPV shall have positive stop(s) to ensure that the valve is not opened or closed too far when manually operated.

3.3.30. FAILURE MODE

The valve shall fail in the as-is position under all operating modes. If the valve is unable to fail mid-stroke due to the design or manufacturing of the valve, the valve shall fail to the last commanded position.

3.3.31. ANTI-TAMPER DEVICES

Anti-tamper devices shall be provided to deter personnel from inadvertently operating the MOPV. The anti-tamper device shall be easily visible and physically attached to the MOPV.

3.3.32. LEAKAGE

3.3.32.1. ALLOWABLE LEAKAGE

The valve shall be designed and constructed to allow zero seawater/AFFF solution leakage along the valve stem and stem seal.

3.3.32.2. LEAKAGE FLOW ISOLATION

The valve shall be designed such that leakage resulting from malfunction or mechanical failure cannot reach electrical components of the MOPV.

3.4. BODY MARKING AND IDENTIFICATION PLATES

Valve bodies and on the valve identified plates shall have the pressure rating or Class and the Contractor’s name or trademark permanently marked or affixed to the valve body and valve identification plate. Marking shall be in accordance with MIL-STD-792F. The valve drawing shall identify the valve body marking and location on the valve body and valve identified plate.

The valve identification plate shall be in accordance with MIL-DTL-15024F, type A, B, C, D, or L. The valve drawing shall identify the identification plate information and location on the valve body. The identification plate shall include the following data:

(a) Contractor’s name or trademark.

(b) Contractor’s commercial and government entity (CAGE) code.

(c) Drawing number and revision.

(d) National Stock Number (NSN)

The ports shall be clearly identified with 1, 2, S (Supply), and D (Drain). The markings shall be impression stamped or cast with 0.25-inch-high gothic style characters in accordance with MIL-STD-130.

3.5. TOOLS

3.5.1. ORDINARY TOOLS

Ordinary tools are those, which are available in the Federal Supply Catalog (FSC). Special tools are defined as those tools not listed in the FSC. The MOPV shall not require special tools for installation and maintenance.

3.6. TECHNICAL DATA (A001-A009)

Technical data shall be prepared in accordance with ordering data included in the Contract and as specified herein. The Contractor shall submit all technical data to NSWCPD for approval.

The Contractor shall provide all logistic data in electronic format (Microsoft Word and pdf) at the time of transfer. If graphics are created in a computer file, a copy of the native format file shall be provided. The logistics support products required are described in the following Sections.

3.6.1. DESIGN REPORT (A001)

A design report with supporting calculations and a material list shall be submitted to NSWCPD for approval prior to valve manufacturing including first article manufacturing. .

3.6.2. PROCEDURES AND REPORTS (A002)

The Contractor shall forward all required procedures to NSWCPD for approval. The Contractor shall not perform tasks described in a procedure until the procedure has been approved by NSWCPD. All reports shall be submitted to NSWCPD for approval.. The required procedures shall be in accordance with Section 4.2.2 Test Plan (A002).

3.6.3. DRAWINGS (A003-A004)

The Contractor shall develop engineering drawings for the MOPV sufficient to fully and clearly delineate the design, construction and performance capabilities, and to permit Shipbuilder and Naval personnel, in conjunction with technical manuals, to install, operate, maintain, and repair the equipment. Drawings may be combined if specifically approved by NSWCPD. Drawings shall be in accordance with ASME Y14.100 and the requirements specified herein. Drawing size and basic format shall be in accordance with ASME Y14.1. Drawing identification shall be in accordance with Appendix D to ASME Y14.100. Revisions to drawings and associated documentation shall be in accordance with ASME Y14.35M. Dimensioning and tolerances shall use English units and be in accordance with ASME Y14.5.1. The MOPV component drawings shall include part lists, lists of materials, and material specifications in accordance with ASME Y 14.34M. These drawings shall include:

(a) Dimensions (including mounting pattern)

(b) Weight

(c) Electrical schematic

(d) Port configuration

(e) Materials of construction

(f) Center of gravity

(g) Required lubricants and compounds

3.6.3.1. ASSEMBLY DRAWING (A003)

The Contractor shall provide assembly drawings for the MOPV components in accordance with ASME Y14.24 and the requirements specified herein. Assembly drawings shall contain the information required for installation drawings and mechanical schematic diagrams as specified in ASME Y14.24. Tightening torques and thread lubrication requirements for threaded fasteners shall be shown on the assembly drawings.

3.6.3.2 DETAIL DRAWING (A004)

The Contractor shall provide detail drawings for the MOPV components in accordance with ASME Y14.24 and the…