SOW Polishing Skid Technical Specification.pdf

Technical Specification

Makeup Water Polishing Skid

REV DATE DESCRIPTION

PAGE or

PARA.

AUTHOR REVIEWER APPROVER

PSNS&IMF

CODE

0 7-10-2019 Original T. Nelson I. Swain B. Payne 2380.5

1 11-5-2021

Rev Original Not used for construction

Specification updated to reflect

Revision A of DWG 2301-3958

ALL T. Nelson K. Kettmann B. Payne 2380.5

2 3-5-2022

Addition of Intermodal Container and Cargo Trailer to Specification

Added Figures 1 and 2 and Table 1

ALL T. Nelson M. King B. Payne 2380.5

3 4-28-2023

Removal of Intermodal Container and Cargo Trailer from Specification

General refresh and minor edits

ALL T.Nelson M. King B. Payne 2380.5

Rev. 3, 4-28-23

MAKEUP WATER POLISHING SKID TECHNICAL SPECIFICATION

TABLE OF CONTENTS

1. SCOPE

1.1. Scope

2. APPLICABLE DOCUMENTS

2.1. General

2.2. Government Documents

2.3. Non-Government Publications

2.4. Order of Precedence

3. REQUIREMENTS

3.1. General Description of System

3.2. Cleanliness

3.3. Design

3.4. Construction

3.5. Safety and Environmental

3.6. Process Piping System

3.7. Skid Base and Frame

3.8. Electrical and Instrumentation

3.9. Lifting and Handling

3.10. Identification

3.11. Turnover 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 Makeup Water Polishing Skid Project Requirements

Attachment 1 – Cleanliness and Welding Standard Operating Procedure (CWSOP) for Pure Water Equipment

Attachment 2 – PSNS & IMF Drawing 2301-3958 Makeup Water Polishing Skid

1. SCOPE

1.1. Scope.

The purchase description set forth below describes the minimum requirements of the

Government for one makeup water polishing skid package. The wetted surfaces of the makeup water polishing skid shall comply with strict requirements for internal system cleanliness and materials and undergo “white glove” inspections by PSNS & IMF to ensure cleanliness requirements are satisfied. Detailed cleanliness controls are per Attachment 1. The stainless steel skid shall be outfitted with piping, tubing, and electrical systems per Attachment 2. It is the Government’s intent that a single primary contractor be awarded this contract and be responsible for the provision of equipment, and the accomplishment of all work detailed by this specification.

2. APPLICABLE DOCUMENTS

2.1. General.

Sections 3 and 4 of this specification invoke documents listed in this section. This section does not include documents cited in other sections of this specification. This section does not list documents recommended for additional information or as examples. While every effort has been made to ensure the completeness of this list, document users are cautioned that they must meet all specified requirements of documents cited in sections 3 and 4 of this specification, whether or not they are listed.

2.2. Government Documents.

2.2.1. Government Publications Specific to Makeup Water Polishing Skid. The following other Government documents, drawings, and publications 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.

ATTACHMENTS

Attachment 1 -------------------------------- Cleanliness and Welding Standard Operating

Procedure (CWSOP) for Pure Water Equipment, Revision 1

Attachment 2 -------------------------------- PSNS&IMF Drawing 2301-3958 Revision A, Makeup Water Polishing Skid

2.2.2. 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

(2019)

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

Disposal Data for Hazardous Materials

Furnished to Government Activities (2018)

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

DEPARTMENT OF DEFENSE STANDARDS

MIL-STD-130 ------------------------------ Identification Marking of U.S. Military Property

(2012)

MIL-STD-2035 ----------------------------- Nondestructive Testing Acceptance Criteria

(1995)

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

COMBINED FEDERAL REGULATIONS

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

Standards

40 CFR 82 ----------------------------------- Protection of Stratospheric Ozone

(Copies available online at http://www.gpo.gov/fdsys)

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) http://quicksearch.dla.mil/ http://quicksearch.dla.mil/ http://www.gpo.gov/fdsys

ASME B31.3 -------------------------------- Process Piping (2022)

ASME B30.26 ------------------------------ Rigging Hardware (2015; R2020)

ASME BTH-1 ------------------------------ Design of Below-the-Hook Lifting Devices

(2020)

ASME BPE---------------------------------- Bioprocessing Equipment (2022)

ASME BPVC Section V ------------------ Nondestructive Examination (2021)

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

Division 1 (2021)

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

(2021)

(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 (2022)

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

Austenitic and Ferritic/Austenitic Stainless Steel

Sanitary Tubing (2015; R2019)

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

Steel Pipes (2022)

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

Passivation of Stainless Steel Parts, Equipment, and Systems (2017)

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

Treatments for Stainless Steel Parts (2017)

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

Stainless Steels Using Electropolishing (2002;

R2018)

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

(2018) https://www.asme.org/

ASTM E709 --------------------------------- Standard Guide for Magnetic Particle Testing

(2021)

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

AMERICAN WELDING SOCIETY

AWS A3.0 ----------------------------------- Standard Welding Terms and Definitions (2020)

AWS D1.6 ----------------------------------- Structural Welding Code – Stainless Steel (2017)

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

NATIONAL ELECTRICAL MANUFACTURERS ASSOCIATION

NEMA Z535.4 ------------------------------ Product Safety Signs and Labels (2011; R2017)

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 (2023)

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

U.S. GENERAL SERVICES ADMINISTRATION

CID A-A-59326E -------------------------- Coupling Halves, Quick-Disconnect, Cam-

Locking (2021)

2.4. Order of Precedence.

Unless otherwise noted herein or in the contract, in the event of a conflict between the text of this document and the references cited herein, the text of this document takes precedence.

Nothing in this document, however, supersedes applicable laws and regulations unless a specific exemption has been obtained.

http://www.astm.org/ https://www.aws.org/ http://www.nema.org/ http://www.nfpa.org/

3. REQUIREMENTS

3.1. General Description of System.

3.1.1. This specification covers the minimum Government requirements for a “Turn-Key” makeup water polishing skid. The makeup water polishing skid shall be fabricated in accordance with the engineered drawings, applicable documents identified in section 2, and requirements cited in sections 3 and 4 of this document.

3.2. Cleanliness.

3.2.1. Equipment Cleanliness. The demineralizer and all wetted components of the makeup water polishing skid piping system shall be cleaned, certified Type I clean, and maintained

Type I clean as detailed in Attachment 1. The compressed air system supplying pneumatic valves may be considered as commercial clean per Attachment 1. Tubing and fittings downstream of check valves CV1 and CV2 may be considered as commercial clean per

Attachment 1. The contractor shall designate a cleanliness quality assurance manager per paragraph 4.1.2.

3.2.2. Cleaning. The wetted surfaces of the makeup water polishing skid shall be cleaned free of all residual water, scale, rust, oil, loose particles, flux, and any other foreign material per Attachment 1. Individual hardware components shall be cleaned prior to welding and following surface finishing operations, such as polishing and passivation.

Hardware shall be verified clean after welding and prior to final assembly. After cleaning, hardware shall be maintained in a clean state with foreign material exclusion caps and covers. See Attachment 1 for additional cleanliness and inspection requirements.

3.2.3. PSNS & IMF Cleanliness Inspections. Polishing skid wetted surfaces designated as

Type I clean shall comply with strict requirements for internal system cleanliness and materials and undergo “white glove” inspections by PSNS & IMF to ensure cleanliness requirements per Attachment 1 are satisfied.

3.3. Design.

3.3.1. Design Services. A drawing detailing the general layout for the makeup water polishing skid is provided in Attachment 2. All dimensions in Attachment 2 shall be field coordinated, verified, and modified as needed. Dimensions listed in paragraph 3.3.4 shall not be exceeded. The drawing does not include fabrication details or wall thicknesses for the demineralizer or the skid base and frame. The contractor shall provide the following design services.

3.3.1.1. Demineralizer Design. The contractor shall design the demineralizer pressure vessel in accordance with the latest edition of ASME BPVC Section VIII. Additionally, the contractor shall design lifting lugs on the vessel per section 3.9. General layout of the demineralizer is included in Attachment 2. Modifications to the demineralizer layout

(excluding minor dimensional changes) must be approved in writing by PSNS & IMF.

3.3.1.2. Skid Base and Frame. The contractor shall perform structural analysis, specify wall thickness of structural members, and specify joint design and weld thickness for the skid base and frame. General layout of the skid base and frame are included in

Attachment 2. Modifications to skid base and frame layout (excluding minor dimensional changes) must be approved in writing by PSNS & IMF.

3.3.2. Equipment Design. The equipment shall be new and unused. The equipment shall include all components, parts, and features necessary to meet the performance requirements specified herein. All parts subject to wear, breakage or distortion shall be accessible for adjustment, replacement, and repair. The equipment shall be of the manufacturer's current field proven design, representative of equipment whose design, capacity and performance characteristics, having been proven through actual field application, are substantially the same as those required of the equipment specified herein. The structure shall withstand all forces encountered during operation of the makeup water polishing skid to its maximum rating and capacity without distortion.

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

3.3.4. Size Limitations. The size of the makeup water polishing skid shall meet the dimensional requirements as listed in Attachment 2, with overall dimensions not to exceed

82’’ length, 72’’ width, and 80’’ in height.

3.3.5. Flow Rate and Pressure. Components shall be sized according to the pressure and flow design criteria as listed in Attachment 2.

3.3.6. Controls. All electrical and mechanical controls shall be located convenient to the operator's work station(s).

3.3.7. New Developments. The contractor shall identify any new developments that would improve the efficiency, accuracy or productivity of the equipment or would decrease its operating costs. The contractor shall notify the Contracting Officer and technical POC in order that the new developments may, at the Government's option, be included in the equipment. Reports of such developments shall be addressed to the Contracting Officer.

3.3.8. Interchangeability. All parts subject to replacement shall be manufactured to definite dimensions and tolerances. Replacement parts shall be interchangeable without requiring modification. Replacement parts are those that are subject to wear or failure. Tooling and accessories normally supplied as standard items shall also be considered replacement parts.

Foreign-sourced replacement parts shall be interchangeable with domestically supplied components or be readily available from a domestic source.

3.3.9. Maintainability. The equipment shall be designed and constructed to permit maintenance personnel to service the equipment easily and effectively using a minimal number of tools. The contractor shall provide any special tools required to service the unit.

3.4. Construction.

3.4.1. Restrictions on Use of Material and Certain Tools. Apply the following restrictions to prevent the inclusion or embedding of ferrous materials in the inner surface of the demineralizer pressure vessel and associated piping and tubing system:

3.4.1.1. Grinding and Polishing Tools. All grinding and polishing tools coming in contact with stainless steel shall be for use on stainless steel only and shall not have been previously used on any non-stainless steel surfaces. Grinding tools shall be aluminum oxide or silicon carbide. Brushes shall be stainless steel wire only. 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). Carbon, low alloy, or tool steels may be used only under criteria detailed in

Attachment 1.

3.4.1.2. Rolling and Forming Machinery. The inner surfaces of the demineralizer 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 demineralizer, 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 demineralizer pressure vessel or piping and tubing components.

3.4.2. 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.

3.4.3. 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.

3.4.4. Threads. All threaded parts, either US or SI, used on the makeup water polishing skid and its related attachments and accessories 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.

3.4.5. Surfaces. All 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 have smooth finish and be devoid of surface defects.

3.4.6. Welding, Brazing, or Soldering. Welding, brazing, or soldering shall be employed only where specified in the original design. None of these operations shall be employed as a repair measure for any defective part.

3.4.6.1. Soldering. Solder connections shall show evidence of good bonding in metal-to-metal contact. Cold solder joints, incomplete joining of solder and metal, excess or insufficient solder or damaged insulation shall be considered reason for rejection of the equipment.

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

3.4.6.1.2. Flux and Cleaning Agents. Flux for soldering shall be rosin or rosin and alcohol. No acid, acid salts or acid core solder shall be used in preparation for soldering of electrical connections.

3.4.6.2. Welding. Weld requirements for the demineralizer and piping and tubing system are listed in Attachment 1. Weld requirements for the skid base and frame are listed in section 3.7.3.

3.4.7. Corrosion Control.

3.4.7.1. 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.

3.4.7.2. 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.

3.4.7.3. Painting. No painting of stainless steel components of the makeup water polishing skid demineralizer, piping system, or skid base and frame is allowed unless specifically approved in writing by PSNS & IMF. 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 to the surfaces covered 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, used in the construction of the equipment shall be provided.

3.4.8. Workmanship. Workmanship of the makeup water polishing skid shall meet all requirements specified herein and shall be of a quality equal to that prevailing among manufacturers producing equipment of the type covered by this purchase description.

3.4.9. Materials. The contractor is responsible for providing all material to fabricate and assemble the makeup water polishing skid as a complete and functioning unit. Attachment

2 provides multiple material lists, but does not include all materials required for construction. Additional materials to be provided by the contractor may include, but are not limited to, miscellaneous fasteners, mounting kits, conduit and conduit fittings, labels, weld wire, special tooling, foreign material exclusion (FME) covers, cleaning solvents and materials, and gases for welding, drying, and pressure testing. Wetted materials in the

Type I clean system shall undergo receipt inspection prior to installation per paragraph

4.3.1.2.

3.5. Safety and Environmental.

3.5.1. Occupational Safety and Health Administration (OSHA) Approved Certification.

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

NEC and National Fire Protection Association requirements. Approval must be as specified under the “Approval” and “Acceptance” criteria in the OSHA regulations Subpart

“O”, Machinery and Machine Guarding paragraph 1910.212 and Subpart “S” Electrical, paragraphs 1910.303 and paragraph 1910.399. After equipment delivery and installation, and prior to testing, the contractor must provide an OSHA compliance certification report.

Failure to provide this compliance certification report will delay acceptance of the equipment, and could result in rejection for failure to comply with the terms of the contract.

This report documents the results of all tests performed, provides an assessment of the equipment performance for compliance with the contract requirements, and forms a basis for recommending a safety certification. The report, test and evaluation must be a composite of those inspection requirements specified in the contract. The report must be prepared in an orderly manner to clearly and accurately set forth the collected data and conclusion resulting from these inspection requirements. Opinions and subjective conclusions must be clearly identified. A report is required as part of the turnover package.

Safety requirements for the turnover package are listed in paragraph 3.11.4.

3.5.2. OSHA Approved Certification. The 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 prior to shipment to final destination. An

NRTL field evaluation label, complete with reference number, shall be affixed to the electrical equipment.

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

3.5.4. 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.

3.5.5. 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.

3.5.5.1. 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 3.5.5.2. A mercury exclusion certificate per

Attachment 1 shall be provided prior to shipment.

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

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

3.5.5.3. State Regulations. The makeup water polishing skid shall comply with hazardous material regulations of the states of California and Washington in addition to federal regulations.

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

3.6. Process Piping System.

3.6.1. Outfitting. The makeup water polishing skid process piping system shall be outfitted in accordance with Attachment 2. Cleanliness requirements are listed in section 3.2 and

Attachment 1.

3.6.2. Demineralizer Design. Pressure vessel design, fabrication and inspection shall be in accordance with the ASME Boiler and Pressure Vessel Code, Section VIII, Division 1, for unfired pressure vessel (latest edition). The demineralizer pressure vessel shall be manufactured by a company possessing an ASME “U” stamp. The contractor shall deliver a copy of ASME data sheet, signed by an ASME inspector. Design pressure and temperature shall be 145 psig and 120 degrees Fahrenheit. The demineralizer shall meet all fabrication requirements listed in Attachment 2 including, but not limited to dimensions, surface finish, corrosion allowance, hydrostatic testing, marking, and inclusion of as-built drawings.

3.6.3. Materials.

3.6.3.1. Type I Clean Material. All components contacting the process fluid shall be compliant with the material requirements of Attachment 1. Documentation of Type I clean material is required per paragraph 3.11.5.

3.6.3.2. Piping, Tubing, and Flanges. Pure water piping and tubing shall comply with

ASME B31.3, Chapter X, for High Purity Piping. Size and location of piping, tubing, and mechanical joints shall be as shown in Attachment 2. Flange joints shall be butt weld or slip on flange joints. Bolted flanges shall be class 150 per ASME B16.5. Tri-clamp flanges (hygienic clamps) shall comply with ASME BPE. Piping shall comply with

ASTM A312. Metallic tubing shall comply with ASTM A270.

3.6.3.3. Substitute Material. Any changes or substitutions to Type I clean material in

Attachment 2 shall be submitted to PSNS & IMF for approval prior to installation on the makeup water polishing skid. PSNS & IMF will approve changes and substitutions that meet Attachment 1 cleanliness and detrimental material requirements and provide the same form, fit, and function. Substitution of non-Type I clean items in the material list in

Attachment 2 is acceptable only if substitutions provide the same form, fit, and function.

3.6.3.4. Process System Surface Finish. Wetted surfaces of stainless steel hardware shall be received from the manufacturer as 32 micro-inches USA Ra or smoother unless otherwise noted in Attachment 2. Hardware in the process system includes, but is not limited to, piping, tubing, valves, filters, and instrumentation.

3.6.3.5. Demineralizer Material and Surface Finish. The demineralizer shall be constructed of 316L stainless steel, polished, passivated, and rinsed per the following:

3.6.3.5.1. Material. Stainless steel used in construction of demineralizer shall comply with ASTM A240/A240M or equivalent specification. Piping materials installed on the vessel shall comply with paragraph 3.6.3.2.

3.6.3.5.2. Procedures. The contractor shall request approval of final polishing and cleaning procedure. The procedure shall include, but is not limited to, electropolishing, alkaline cleaning, passivation, final rinse, and a list of all chemicals used.

3.6.3.5.3. Final Surface Finish. Wetted stainless steel surfaces of the demineralizer pressure vessel shall be 20 micro-inches USA Ra or smoother. Finished weld surfaces shall be 32 micro-inches USA Ra or smoother. Welding shall be completed prior to electropolishing and passivation.

3.6.3.5.4. Electropolishing. Electro polishing shall be performed per ASTM B912.

3.6.3.5.5. Passivation. Passivation shall be performed per ASTM A380 or ASTM A967 prior to final precision cleaning.

3.6.3.5.6. 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. Conductivity instrumentation shall be calibrated. After completion of final rinse, drain equipment and then use filtered compressed air or nitrogen to dry the system.

3.6.3.6. Crevice Free. 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. Skid Base and Frame.

3.7.1. Outfitting. The makeup water polishing skid base and frame shall be fabricated in accordance with Attachment 2 and the specifications cited herein.

3.7.2. Skid Base and Frame Materials. The skid base and frame shall be constructed of

304/304L stainless steel with a mill finish. Sheet metal shall have a 2B finish or smoother.

Stainless steel skid components shall comply with the specifications listed in the material tables in Attachment 2. Alternate materials and specifications may be substituted with written approval from PSNS & IMF engineering.

3.7.3. Welding. Skid base and frame structural welds and visual inspections shall be in accordance with AWS D1.6 and the specifications cited herein.

3.7.3.1. Welder Qualification. All welders must be qualified in accordance with AWS

D1.6 (Stainless Steel Structural Welding Code). Records of qualifications shall be submitted to PSNS & IMF prior to start of construction.

3.7.3.2. WPQR and WPS Review and Approval. The Welding Procedure Qualification

Record (WPQR) and the Welding Procedure Specification (WPS) shall be submitted for review and approval. PSNS & IMF approval is not required for any Standard Welding

Procedure Specification (SWPS) that is approved by AWS. The WPQR, WPS, and

SWPS are defined in AWS A3.0, Standard Welding Terms and Definitions.

3.7.3.3. Joint Design. Joints designs shall be in accordance with AWS D1.6. Join intersection/mating structural members (1/4’’ thickness or greater) with a 3/16’’ minimum weld thickness for fillet, bevel, and flare bevel joints. Butt joints shall have complete joint penetration.

3.7.3.4. Continuous Weld. Welded portions of the skid base 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’’.

3.7.3.5. 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.

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

3.8. Electrical and Instrumentation.

3.8.1. Electrical System. The equipment shall conform to NFPA 70. The equipment’s electrical system shall be tolerant of voltage fluctuation of ± 10 percent. Additional electrical system details and requirements are included in Attachment 2.

3.8.1.1. 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.

3.8.1.2. 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 4 or 4X.

3.8.2. Measuring and Indicating Device Graduations. All measuring and indicating devices on the makeup water polishing skid shall be graduated in the inch/pound or both inch/pound and metric. Flow measurement shall be in gallons and gallons per minute.

3.8.3. Wireless Instrumentation. Instrumentation capable of emitting or receiving wireless signal, including but not limited to Bluetooth and Wi-Fi, is prohibited.

3.8.4. Calibrated Instrumentation. All instrumentation shall be calibrated to accuracy specified by manufacturer. Calibration certificates shall be included in the turnover package in paragraph 3.11.2.

3.9. Lifting and Handling.

3.9.1. Lift While Empty. The demineralizer is not designed to be lifted while full of water.

3.9.2. Demineralizer Lifting Pads. The demineralizer shall have two (2) lifting pads installed at locations shown in Attachment 2. Lifting pads shall be fabricated from a minimum of 1/2” thick stainless steel plate. Lifting pads shall be welded to upper shell of the demineralizer. Welding shall comply with applicable AWS Standards.

3.9.3. Lift Points. The equipment shall be readily liftable via lift points meeting the requirements of this section to allow lifting by crane during equipment off-loading, installation, operation, and removal. Lift points shall be located, designed, and marked per the following to ensure the equipment is readily liftable when it arrives. Lift points shall be located, designed, and marked to ensure the equipment is readily liftable when it arrives.

Lift points shall accommodate ASME B30.26 common rigging gear (e.g., shackles, wire rope pendants/grommets, etc.). Lift point allowable strength shall be based on ASME

BTH-1, Category B, Service Class 0.

3.9.3.1. Continuous Weld. The lifting pads portion of the attachments shall be continuously welded. Skip welds of load bearing members are not allowed on the lifting attachments.

3.9.3.2. Weld Quality. All welding and weld inspection of the lifting pads shall be in accordance with AWS D1.6. These welds shall meet the Workmanship requirements of

AWS D1.6 and shall be full-sized as specified by the design engineer. These welds shall be free of defects such as undercut, porosity, weld spatter, and cracks.

3.9.3.3. Lift Point Location. When possible, to maximize stability, locate lift point(s) symmetrically around, and above, the Center of Gravity (CG), on the same horizontal plane. This helps ensure equal length slings converging to a common point will lift the equipment visually level. Locate the lift points such that the routing of rigging gear is clear of obstructions. This is to avoid damaging equipment, chaffing, etc. Lift point supporting structures shall be designed to sustain the various loads imparted by the lifting arrangement. Lift points for three- or four-point lifts shall be sized such that any two points carry the entire load based on worse case load distribution with respect to center of gravity. For padeyes, align their primary planes toward the CG so that the slings do not pull out of plane by more than 5°. Exceptions may be acceptable if they are designed to account for the resultant out-of-plane loading, but as a minimum, padeyes shall be designed for an out-of-plane pull of ±5°.

3.9.4. Working Load Limit (WLL). The minimum lift point WLL shall be based on the entire weight of the equipment plus 10%. Unless otherwise specified by the design engineer, account for additional loads induced by 45° sling angles with respect to horizontal. Align padeyes so their primary planes are toward the CG so that the slings do not pull out of plane by more than 5°. Exceptions may be acceptable if they are designed to account for the resultant out-of-plane loading, but as a minimum, padeyes shall be designed for an out-of-plane pull of ±5°. The use of spreaders, lift beams, or strongbacks is not preferred. If spreaders, lift beams, or strongbacks are required, a lift sketch detailing the required spread, capacity and orientation of that gear shall be submitted. Multi-point lift points shall be sized depending on the number and type of lifts.

3.9.4.1. Three-point asymmetrical lift points – Padeyes are not located on the same horizontal plane and not symmetric about the load’s CG. The WLL for all three padeyes shall be based off the pick point that sees the highest loading.

3.9.4.2. Three-point symmetrical lifts – Padeyes are located on the same horizontal plane and symmetric about the load’s CG. Padeyes shall be sized based off of three legs equally carrying the entire load.

3.9.4.3. Four-point symmetrical/asymmetrical lifts – Padeyes shall be sized based off of two diagonal opposing legs carrying the load based on worse case load distribution with respect to CG.

3.9.5. Lifting Sketches. Provide all arrangement drawings, lift sketches, calculations required for the design and usage, and manufacture’s documentation of the lift points. All calculations required for the design of the lift points shall be stamped by a Professional

Engineer. When required, lift sketch labels shall be permanently and conspicuously located on the equipment and must be suitable to withstand outdoor, potentially corrosive, environments. Lift sketch labels shall include, at a minimum, the following:

3.9.5.1. The maximum weight of the equipment expressed in pounds.

3.9.5.2. The CG location(s).

3.9.5.3. The lift point locations and their capacity.

3.9.5.4. Recommended minimum sling lengths and capacities.

3.9.6. Load Test.

3.9.6.1. Load test lifting points to 125% (+5%, -0%) of the WLL and hold for at least two

(2) minutes. Acceptance criteria shall be: no bending, cracking, or permanent deformation of the lift points or associated structure. The contractor shall perform load tests plus a pre- and post-load visual damage check per applicable standards.

Documentation of satisfactory results shall be submitted prior to Government acceptance.

3.9.6.2. Alternative to a load test, a magnetic particle testing (MT) of the lift point welds per ASTM E709 is permitted. The acceptance criteria is section 6.2 of MIL-STD-2035A, or equivalent standard(s) as approved by the government, provided the testing is performed by a certified third party. Documentation of satisfactory results shall be submitted prior to Government acceptance.

3.9.7. Demineralizer Lifting Label Plate. Permanently label all lift points, or immediately adjacent to them, with the WLL, and test date. Label letters shall be 1/4 inch tall and applied by stencil or metal label plate. Each lifting pad shall be labeled as follows:

MAX WORKING LOAD = (ACTUAL MAX WORKING LOAD) LBS

PROOF TEST LOAD: (ACTUAL TEST LOAD) LBS

TEST DATE: (TEST DATE), TESTED BY: (COMPANY NAME)

LIFT ONLY WHEN VESSEL IS EMPTY

3.10. Identification.

3.10.1. Marking on Valves, Instruments, Control Panels, and Label Plates. All words on valves, filters, instruments, control panels, and label plates shall be in the English language.

Characters shall be engraved, etched, embossed, or stamped in boldface on a contrasting background. All label plates shall be corrosion resistant. Identification label plates on valves and field mounted instruments shall be lanyarded to the respective component.

Label plates for filters shall be bent to match radius of the filter and mounted to filter using adhesive. Component label plates shall include component identifier listed in Attachment

2.

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

Makeup Water Polishing Skid

Manufacturer's name

Manufacturer's model designation

Manufacturer's serial number

Contract Number or Order Number

Date of manufacture

Tare Weight

3.10.3. Identification Marking of Military Property. An Item Unique Identification

(IUID) Marking shall be provided in accordance with MIL-STD-130 and all applicable documents within the standard with Machine Readable Information (MRI) for item identification marking and automatic data capture. The application of Human Readable

Information (HRI) shall be used in combination with MRI and free text.

3.11. Turnover Package.

3.11.1. Two (2) hard copies and one (1) searchable electronic copy of the following technical data shall be provided with the makeup water polishing skid.

3.11.2. Operating and Maintenance (O&M) Manuals. O&M Manuals shall contain technical information, specifications, instructions for the operation, maintenance of the makeup water polishing skid 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:

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

b. Calibration certificates for all instrumentation.

c. Final As-built drawings (paper, electronic, and AUTOCAD), including detailed fabrication drawings for the demineralizer.

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

e. Maintenance and service instructions for the polishing skid, including preventive maintenance schedule and troubleshooting.

f. Paint specifications and safety data sheets.

3.11.3. Test Data Results Used for Evaluation of Equipment to Meet Specification

Requirements. The Contractor shall submit a written test report of all tests and results conducted at origin and destination. The test report shall be submitted within 10 working days after the tests are performed.

3.11.4. Safety Report. The contractor shall submit an Occupational Safety and Health

Report as required per paragraph 3.5.1.

3.11.5. Record of All Wetted Materials. The Contractor is responsible for documenting compliance with material requirements of Attachment 1. Contractor records shall be made available to the government prior to final cleaning and Type I clean certification. A compiled record of all wetted materials shall be delivered to the government upon completion of project.

3.11.6. Inspection Records. A copy of all inspection records and certifications shall be provided to the government upon delivery of each makeup water polishing skid. This shall include all inspections performed during fabrication and acceptance inspections. Records pertaining to cleanliness are listed in section 4 of Attachment 1. These records shall be provided to the Government upon delivery of each completed makeup water polishing skid.

3.11.7. Mercury Certification. The contractor certification shall specifically include statements that certify compliance with paragraph 3.5.5.1 and 3.5.5.2.

3.11.8. NRTL Field Evaluation Report. The contractor shall submit an approved NRTL field evaluation report for the polishing skid per paragraph 3.5.2.

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 deionized water.

4.1.2. Cleanliness Quality Assurance Manager (QAM). The contractor shall designate a cleanliness QAM for ensuring the requirements of Attachment 1 are followed throughout construction. The QAM is responsible for establishing training, developing and/or reviewing commercial or manufacturer cleaning procedures for compliance with

Attachment 1, and providing oversight during construction of the Type I clean equipment.

4.1.3. Responsibility for Compliance. All items must meet all requirements of sections 3 and 4.

4.1.4. Measuring and Testing Equipment and Inspection Personnel. The contractor shall provide and maintain gauges and other measuring and testing devices necessary to assure that supplies conform to the technical requirements. In order to assure continued accuracy, these devices shall be calibrated at established intervals against certified standards traceable to national standards. If production tooling, such as jigs, fixtures, templates and patterns, is used as a media of inspection, such devices 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. In addition, if conditions warrant, contractor's personnel shall be made available for operation of such devices and verification of their accuracy and condition. All wetted surfaces of instrumentation shall comply with Attachment 1.

4.1.4.1. 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.

4.1.4.2. A contractor’s inspector(s) shall witness all tests, and sign the applicable test data sheet.

4.1.4.3. All required inspection reports shall be legibly signed in ink by the inspector. The signature shall consist of the inspector’s full name, title, company, and date.

4.2. Classification of Inspections.

4.2.1. The inspection requirements specified herein are classified as follows:

4.2.1.1. Facility inspection, initial receipt inspection, and construction kickoff (Origin) (see section 4.3.1).

4.2.1.2. Contract quality assurance inspection and factory acceptance testing (Origin) (see section 4.3).

4.2.1.3. Site acceptance and final examination/acceptance (Destination) (see section 4.5).

4.3. Factory Acceptance Testing and Examination (Origin).

Contract quality assurance inspection shall be applied at the contractor’s facility prior to being offered for acceptance under the contract. The equipment shall pass the examination, all tests, and the contract quality assurance inspection to be acceptable for shipment (see section 4.4). At the option of the Government, tests may be witnessed by technical representatives of the NAVSEA 04XI Plant Equipment Support Office (PESO) and receiving activity. The Contractor shall notify the Government Point of Contact of the scheduled date, time, and location of the tests.

4.3.1. Facility Inspection, Initial Receipt Inspection, and Construction Kickoff Meeting.

The contractor shall schedule inspection of facilities and materials to be used for fabrication, final cleaning, and cleanliness inspections of the makeup water polishing skid.

Contractor shall notify PSNS & IMF at least fifteen working days prior to the scheduled date of inspection. Inspection shall occur prior to contractor starting fabrication of makeup water polishing skid.

4.3.1.1. Facility Inspection. The facility inspection performed by PSNS & IMF shall be used to determine capability of contractor to establish and maintain a clean work area per

Attachment 1. Deficiencies discovered during this inspection shall be corrected prior to initiation of final cleaning per Attachment 1.

4.3.1.2. Initial Receipt Inspection. All hardware in the wetted portion of the Type I clean system shall undergo receipt inspection per Attachment 1 prior to fabrication.