Attachment 0030 - Pump Reliability and Mobility PQT Plan WSDS-v16.docx

Water Storage and Distribution System (WSDS)

Phase I Production Qualification Test (PQT) Pump Reliability and Mobility Test Plan

VERSION 16.0

9 February 2021

1. Scope. The purpose of this test plan is to describe the tests to be conducted on the 125 and the 350 GPM pumps being proposed by offerors of the Water Storage and Distribution System (WSDS). The tests will provide the Government evaluation board with data needed to evaluate the reliability of these pumps. The pump samples provided for these tests shall be the same make and model of those proposed for the WSDS system. In addition to the pump samples, the contractor shall provide a Certificate of Conformance (CoC) for each type indicating that the pumps can meet the requirements of ATPD 2425.

2. System Description. The Water Storage Distribution System (WSDS) provides the large capacity capability that is tailorable in receiving, storing, and issuing bulk water to all water systems in the Army inventory. The WSDS is the Army’s primary large potable water bag farm storage. The WSDS can be set up to enable split operations and multiple configurations. The WSDS is comprised of collapsible storage tanks, engine driven centrifugal water pumps, meters, hoses, fittings and nozzles. The system also has hypochlorination units that automatically chlorinates water to Army standards.

3. Test Requirements and Conditions.

a) The contractor shall provide two each samples of each pump being offered (125 and 350 GPM).

b) The test shall be held at the U.S. Army Aberdeen Test Center (ATC) at Aberdeen Proving Ground (APG), MD. ATC will accommodate all Government personnel that are required to attend as well as all contractor personnel with the requisite expertise needed to assist with the operation and maintenance the pumps in accordance with this test plan.

c) The contractor shall provide a sufficient quantity of anticipated components to maintain the pumps as required and to support the service intervals for the test duration.

d) The contractor shall provide an onsite technical support representative throughout the test duration. The representative shall troubleshoot, maintain and correct all failures.

e) The Government shall provide all supporting materials and equipment required for operating the pumps including but not limited to: material handling equipment, petroleum, oil, lubricants, hose assemblies, fittings, flowmeters, and personnel protective equipment.

f) The Government shall operate the pumps and record all data.

g) All testing shall be conducted at ambient temperature and atmospheric pressure. All performance data shall be corrected to a water temperature of 60°F and standard sea level conditions of 29.92 inches of mercury (barometric pressure).

4. Test Procedures:

a) Pump Mobility Test: Prior to starting reliability testing, the 350 GPM pump assembly shall be towed by M1083 Series “Family of Medium Tactical Vehicles” over primary (improved/paved) roads at average speed of 20 miles per hour (mph) for 50 miles, and over secondary (unimproved/unpaved) roads at average speed of 10 mph for 50 miles. Terrains are defined in Appendix A.

b) Operational Check Test: A one hour operational check test will be performed on the 350 GPM pump both before and after the 350 GPM pump mobility test. A one hour operational check test will be performed on the 125 GPM pump prior to starting reliability testing.

c) Set-up: For the 125 GPM pumps, each pump assembly will be setup to operate in a standalone closed loop with a water tank or large basin as the water source. For the 350 GPM pumps, both pump assemblies will be setup to operate in series with each other. The first pump in the series will be operated in manual mode and the second pump in automatic mode for approximately half of the hours. For the remaining portion of the test, the operating modes of each 350 GPM pump will be swapped so that the first pump in the series will be operated in automatic mode and the second pump in manual. A calibrated flowmeter will be installed in the discharge line of each pump assembly. Calibrated suction and pressure gauges will also be installed. Each pump assembly will be operated at rated flow capacity and pressure. Note: The Government may not be able to segregate the set-up of multiple contractor’s equipment from each other.

d) Contractor Shakedown Period: Prior to starting the reliability test, the contractor shall be allowed to operate the pumps in 3(b) for up to eight hours to identify issues present with the test set-up or to correct infant mortality failures.

e) Reliability Test: The 125 and 350 GPM pump assemblies are each required to demonstrate a Mean Time Between Essential Function Failure (MTBEFF) of 535 hours as a point estimate. Essential Function Failures (EFFs) are defined in the Failure Definition and Scoring Criteria (FDSC), Attachment 0009. The test duration for each pump configuration will be 1070 hours with two allowable failures. The 1070 hours is cumulative between the two each samples provided for each configuration.

f) The Government will use the tables below (modified to allow note taking) as a record during the test.

Table 1. Operational Check Test Results

Operational Check Test - 125 GPM Pump

Produces 125 GPM at 50 ft. Total Head (22 psi)

Pre Mobility Operational Check Test - 350 GPM Pump

Produces 350 GPM at 275 ft. Total Head (108 psi)

Mobility Test

Completes 100 miles

Post Mobility Operational Check Test – 350 GPM Pump

Produces 350 GPM at 275 ft. Total Head

Table 2. Reliability Test Results

Reliability Test

125 GPM Pump

350 GPM Pump

Appendix A: Terrain Definitions

a. Primary Roads: Primary roads are high quality paved, secondary pavement, and rough pavement surfaces with RMS values varying between 0.1 inches to 0.3 inches. They consist of two or more lane, all weather, maintained hard surface (paved) roads with good driving visibility designed for heavy, high density traffic. These roads have lanes with a minimum width of nine feet (2.75 meters), road crown to 2 degrees and all bridges will support the maximum Gross Combination Weight Rating (GCWR). Secondary pavement can include significantly degraded (potholes, alligator cracking, freeze/thaw breakup) concrete, macadam concrete, or asphalt pavements. Rough pavement is two lane roads with degraded shoulders, and marginal subgrades which produce long wavelength swells and additional degradation of the surface. Grades can vary from 0% up through 6%.

b. Secondary Roads: Secondary roads are loose surface, loose surface with washboard and potholes, and surfaces with RMS values varying between 0.3 inches to 1.0 inches. Generally, washboard occurs in drier operational areas, whereas pothole gravel roads occur in wet operational areas. These roads are one or more lanes, all weather, occasionally maintained with varying surfaces (e.g., large rock, crushed rock, or gravel) intended for medium-weight, low-density traffic. Bridges on these roads cannot guarantee supporting the maximum GCWR. Grades can vary from 0% up through 15%. Rough degraded pavement accounts for 2% of secondary roads. Loose surface roads accounts for 8% of the secondary roads. Wash boarded and potholed surfaces makes up 8% due to weather and traffic deteriorating loose surfaces. Belgian Block makes up 2% of secondary roads.

c. Trails: Trails are one lane, unimproved, seldom maintained loose surface roads intended for low density traffic with Belgium Block RMS values varying between 1.0 inches and 3.4 inches. Typically trails have no defined road width, large obstacles (rubble, boulder, logs, and stumps), cross ditches, washouts, steep slopes, and no bridging/culverts. Naturally occurring grades can vary from 0% up through 40%.

d. Cross Country: Cross country is terrain not subject to repeated traffic with RMS values varying between 1.5 inches and 4.8 inches. Cross-country terrain can consist of tank trails with crushed rock or having large exposed obstacles (rocks, boulders, etc.), but there are no roads, routes, well-worn trails, or man-made improvements. This includes, but is not limited to, flat desert, marshes, vegetated plains, jungle, dense forest, mountains, and urban rubble. Naturally occurring grades can vary from 0% up through 60%.