Attachment 1_MFR UV BWTS BDRD.docx

633/19-155 14 May 2020

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This baseline design requirements document has been prepared by the Naval Surface Warfare Center, Carderock Division (NSWCCD) and only applies to procurement in Solicitation N00167-20-R-0020.

This document is not an approved defense specification and is not published on Acquisition Streamlining and Standardization Information System (ASSIST) database at https://quicksearch.dla.mil/.

BASELINE DESIGN REQUIREMENTS DOCUMENT

ULTRAVIOLET BALLAST WATER TREATMENT SYSTEM FOR SURFACE VESSELS

1. SCOPE

1.1 Scope. This Baseline Design Requirements Document (BDRD) covers the requirements for ballast water treatment system(s) (BWTS) installed aboard Navy surface vessels. This document does not cover compensated fuel ballast water or rapid ballast water tanks.

1.2 Numerical quantities. Numerical quantities are expressed in metric (SI) units followed by U.S. customary units in parentheses. The SI and U.S. customary equivalents of the units are approximated to a practical number of significant figures.

2. APPLICABLE DOCUMENTS

2.1 General. The documents listed in this section are specified in sections 3 and 4 of this BDRD. This section does not include documents cited in other sections of this BDRD or 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 BDRD, whether or not they are listed.

2.2 Government documents.

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

COMMERCIAL ITEM DESCRIPTIONS (CIDs)

DEPARTMENT OF DEFENSE SPECIFICATIONS

DEPARTMENT OF DEFENSE STANDARDS

Electronic Equipment

(Copies of the CIDs, military standards and handbook are available online at https://assist.daps.dla.mil/quicksearch/ or https://assist.daps.dla.mil; copies of the DoD manual is available online at http://www.esd.whs.mil/DD/)

2.2.2 Other Government documents, drawings, and publications. 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.

NAVAL SEA SYSTEMS COMMAND (NAVSEA) PUBLICATIONS

(Copies of this document are available online via Technical Data Management Information System (TDMIS) at https://mercury.tdmis.navy.mil.)

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.

ASTM INTERNATIONAL

ASTM F1166 - Standard Practice for Human Engineering Design for Marine Systems, Equipment, and Facilities

(Copies of these documents are available from ASTM International, 100 Barr Harbor Dr., P.O. Box C700, West Conshohocken, PA 19428-2959 or online at www.astm.org.)

INSTITUTE OF ELECTRICAL AND ELECTRONIC ENGINEERS (IEEE)

IEEE 45 - Recommended Practice for Electric Installations on Shipboard

(Copies of these documents are available from the Institute of Electrical and Electronics Engineers, Inc., 445 Hoes Lane, P.O. Box 1331, Piscataway, NJ 08855-1331 or online at www.ieee.org.)

NATIONAL ELECTRICAL MANUFACTURERS ASSOCIATION (NEMA)

NEMA 250 - Enclosures for Electrical Equipment (1000 V Maximum)

(Copies of this document are available from the National Electrical Manufacturers Association, 1300 North 17th Street, Suite 1847, Rosslyn, VA 22209 or online at www.nema.org.)

SOCIETY OF PROTECTIVE COATINGS (SSPC)

SP 10/NACE No. 2 - Near-White Blast Cleaning

(Copies of this document are available from the SPPC, 800 Trumbull Drive, Pittsburgh, PA 15205, USA or online at http://www.sspc.org.)

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.

3. REQUIREMENTS

3.1 Description. The BWTS, which consists of skid-mounted components, shall be automatic and ready for operation with the vessel’s physical, electrical, electronic, and other architecture. The BWTS shall receive and treat ballast water inline during uptake (ballast) and discharge (deballast). The BWTS does not include ballast water pumps and associated piping that transfer ballast water into or out of the ballast water tanks.

3.1.1 UV BWTS description. The BWTS shall use a two-stage process: filtration and ultraviolet (UV) treatment. During uptake (ballast) operations, the ballast water shall be treated by filtration followed by UV treatment. During discharge (deballast) operations, the filter is bypassed and the ballast water receives a second dose of UV treatment before being discharged overboard. The BWTS shall also provide an automatic method of cleaning the filter and UV reactor(s).

3.2 First article. Not required.

3.3 Material requirements. The materials shall be compatible with the operational and environmental requirements specified in this section. Materials selected for construction are the responsibility of the supplier. The materials shall be selected to achieve the intended service life (see 6.1) and the intended service, and of sufficient durability to meet all the performance requirements as specified herein.

3.3.1 Wetted materials. All piping, valves, and associated components shall meet MIL-STD-777. The maximum general corrosion rate or pitting corrosion rate shall be limited to 0.05 mm (2 mils) per year for those internal surfaces and materials used to contain, carry, or transport ballast water. Aluminum and aluminum alloys shall not be used for water-wetted applications.

3.3.2 Dissimilar metals. Dissimilar metals shall not be used in intimate contact with each other unless protected against galvanic corrosion. Sacrificial anodes are permitted.

3.3.3 Plastics and rubbers. Plastic materials (e.g., polyvinyl chloride [PVC], chlorinated polyvinyl chloride [CPVC], polybutadienes [PB], polyethylene [PE], and acrylonitrile-butadiene-styrene [ABS]) that generate toxic gases when combusted shall not be used in any external components. Wetted components such as filters are not considered external components.

3.3.4 Hazardous and “prohibited” materials. When evaluated in accordance with Naval Sea Systems Command publications, NAVSEA Hazardous Material Avoidance Process (T9070-AL-DPC-020/077-2), the materials and operational processes used for the BWTS shall pose no serious or high risk to the health of personnel or the environment when used for its intended purposes. The BWTS shall not contain any materials categorized as “prohibited” as specified in T9070-AL-DPC-020/077-2. The supplier shall identify and provide Safety Data Sheets for all materials categorized as “restricted” or “tracked” as specified in T9070-AL-DPC-020/077-2.

3.3.5 Electrical cable and cord materials. All electrical cable and cord materials used in the BWTS shall meet MIL-DTL-24643.

3.3.6 Recycled, recovered, or environmentally preferable materials. Recycled, recovered, or environmentally preferable materials should be used to the maximum extent practicable, provided that the material meets or exceeds the operational and maintenance requirements, and promotes economically advantageous life cycle costs.

3.3.7 Painting. Non-working surfaces, normally painted, shall be finished as follows:

3.3.7.1 Surface preparation prior to painting in accordance with SSPC-SP 10/NACE No. 2.

3.3.7.2 Coating options:

a. Single coat of MIL-PRF-23236 Type VII Class 5/18, 0.5 - 0.8 mm (20 - 30 mils) dry film thickness; or

b. Two coats – one coat MIL-PRF-23236, Type VII, class 5, 0.1 – 0.2 mm (4 - 8 mils) plus one coat MIL-PRF-23236, Type VII, class 5, 0.25 – 0.30 mm (10 - 12 mils) dry film thickness per coat; or

c. Two coats epoxy paint formula 151 and one coat of formula 150 in accordance with MIL-DTL-24441, MIL-DTL-24441/20, and MIL-DTL-24441/21; average 0.08 mm (3 mils) dry film thickness per coat.

3.4 Environmental requirements. The BWTS shall be capable of meeting the following operational constraints and shipboard environmental requirements.

3.4.1 Shock. The BWTS shall meet Grade B shock acceptance requirements of MIL-DTL-901 when tested as specified in 4.4.2.1. Class I equipment shall meet hull-mounted testing requirements and Class II equipment shall meet deck-mounted testing requirements.

3.4.2 Environmental vibration. The BWTS shall meet the requirements of MILSTD-167-1, Type I, environmental vibration.

3.4.3 Internally excited vibration. The BWTS rotating machinery shall meet the requirements of MIL-STD-167-1, Type II, internally excited vibration.

3.4.4 Airborne noise. The BWTS shall meet the airborne noise requirements of MIL-STD-1474 for Grade E and shall not exceed acceptance criteria for any operational condition.

3.4.5 Structureborne noise. The BWTS shall meet the generated structureborne noise requirements of MIL-STD-740-2 and shall not exceed acceptance criteria for any operational condition.

3.4.6 Electromagnetic interference and compatibility. The BWTS shall meet the applicable electromagnetic emissions and susceptibility requirements of MIL-STD-461 for surface ship, below deck, metallic hull installations.

3.4.7 Operational temperatures (ambient air). The BWTS shall be able to operate and treat at a low and high ambient air temperature range of 0 to 52°C (32 to 125°F).

3.4.8 Operational temperatures (ballast water). The BWTS shall be able to operate and treat at a low and high ballast water temperatures range of -2 to 40°C (28 to 104°F).

3.4.9 Salinity. The BWTS shall be able to operate and treat in all salinity levels ranging from fresh (< 1 Practical Salinity Unit [PSU]), brackish (10-20 PSU), and marine water (28-36 PSU).

3.4.10 Ultraviolet Transmittance. The BWTS shall operate as specified herein when treating ballast water with UV transmittance (UVT) (see 6.3.28) levels as low as 70% UVT when operating at the full process rate.

3.4.11 Humidity. The BWTS shall withstand relative humidity environments up to 100 percent maximum with no resulting evidence of absorption of water, change in mechanical properties, corrosion, or other forms of deterioration.

3.4.12 Water spray. When in a non-operating state, the BWTS shall not be damaged nor shall subsequent operational performance be degraded as a result of all external system components being subjected to a water hose down test as specified in NEMA 250.

3.4.13 Dynamic inclination. The BWTS shall operate as specified herein and prevent loss of fluid when inclined under dynamic, rolling conditions at any angle of list up to and including 22.5° and, simultaneously, at any angle of trim (pitching) up to and including 7.5° by bow or stern.

3.4.14 Static inclination. The BWTS shall operate as specified herein and prevent loss of fluid when inclined under static conditions at any angle of list up to and including 15°.

3.5 Physical requirements.

3.5.1 Physical size. The supplier shall specify the BWTS access envelopes.

3.5.2 Weight. The supplier shall specify the dry and wet weight of the BWTS.

3.5.3 Modularity. BWTS components shall be modular skid-mounted to enable installation in separate ship compartments. The BWTS shall be equipped with all necessary connections (e.g., power, compressed air) to meet vessel function interface requirements (see 3.7.1). The modular skid-mounted components shall meet the space requirements in 3.8.3. The BWTS shall incorporate open architecture (see 6.3.20) to enable modularity in software and hardware/components.

3.6 Performance requirements.

3.6.1 Processing performance.

3.6.1.1 Process rate. The BWTS shall treat ballast water during ballast and deballast operations at the processing rates listed in Table I. The process rate determines the amount of ballast water that can be treated per unit time and represents the UV reactor effluent flow rate. During normal ballast operation (in the absence of filter self-cleaning), the BWTS shall maintain the process rate under challenging conditions including low UV Intensity (UVI) (see 6.3.27) and low UVT (see 3.4.10). During filter self-cleaning, the filter self-cleaning flow rate shall not exceed 15 percent of the process rate.

Table I. BWTS Process Rate

3.6.2 Effluent quality and removal.

3.6.2.1 Effluent discharge standards. When processing the ballast water stream, the BWTS shall produce an effluent meeting the ballast water discharge standards as defined in DoDM 4715.06. The BWTS standard and compact shall have demonstrated compliance by obtaining USCG Type Approval.

3.6.2.2 Material compatibility of effluent. The treated effluent shall be compatible with the vessel’s overboard discharge system. The supplier shall identify chemicals and corresponding quantities that can be expected to be introduced into the BWTS (see 3.3.4).

3.6.3 Filter self-cleaning. The filter self-cleaning mechanism shall be triggered automatically by differential pressure and/or time, and manually initiated by the operator via the control system. The filter self-cleaning cycle shall allow the BWTS to operate continuously. Filter self-cleaning waste stream shall be segregated from the treated flow stream to allow overboard discharge. The BWTS shall be capable of completely draining the filter to remove any standing water.

3.6.3.1 Booster pump. The BWTS shall be equipped with a booster pump to ensure sufficient pressure and flow are available for filter self-cleaning. An elapsed time meter shall be provided for each system pump.

3.6.4 UV reactor cleaning. UV reactor shall be designed with an automatically cleaning process to prevent scaling/fouling of the UV lamp sleeves. The cleaning cycle may utilize a mechanical, chemical, or a combination of mechanical and chemical cleaning process. The mechanical cleaning cycle shall have automatic start to enable the system to start and finish the cleaning operation with no operator assistance and no interruption to ballasting and deballasting operations. Chemical cleaning cycle shall have semi-automatic start to require the operator to initiate the operation and automatically stop when the process finishes. The maximum duration of the chemical cleaning cycle shall not exceed 30 minutes per UV reactor; the cleaning cycle shall be capable of being terminated by the operator at any time and immediately return the system to the standby mode (see 3.6.6.2). The chemical cleaning cycle shall have a closed loop design to allow the cleaning liquid to be reused. Chemical cleaning agents shall not include hazardous or prohibited materials (see 3.3.4). The waste stream generated from the chemical cleaning process shall be segregated from the treated effluent and shall be collected for shoreside disposal. The BWTS shall be capable of completely draining the UV reactor to remove any standing water.

3.6.5 Discharged vapor/gas. The BWTS shall be designed to prevent the accumulation and discharge of gas/vapor under normal operating condition.

3.6.6 Control system. The control system shall incorporate a Programmable Logic Controller (PLC) or equivalent with a message display unit that provides a visible graphic interfaces to enable the control and monitoring of BWTS operations. The Human Machine Interface (HMI) is comprised of the control panel and connection between the HMI and PLC to enable the operator to control and monitor operations. The HMI design may vary depending on installation, available operation modes, and BWTS functionality. The control system shall perform the following functions: operation of monitors and controls, activation of warnings and alarms, automatic acquisition of data from BWTS components, visual display of system data, and prevention of unsafe operation. The BWTS shall provide a means to send signals/information to the vessel’s centralized control system to enable monitoring including the display of warnings and alarms. The communication of the systems used shall be cyber secure (see 3.6.6.1).

3.6.6.1 Security.

a. Cybersecurity. The BWTS shall meet requirements for a secured and encrypted control system in accordance with MIL-DTL-32613. The BWTS control system shall provide password protection to prevent access by unauthorized personnel.

b. Physical security. The control system shall be equipped with physical security controls including lockable enclosure. All programming ports (Ethernet jacks) shall be protected from unauthorized access by placing them within the secured control enclosures or a separately locked cover. The enclosures shall be provided with fasteners allowing use of lead wire or other suitable tamper evident seals and hasps suitable for use with locks in accordance with A-A-59486 or A-A-59487 for all access points.

3.6.6.2 Operational modes. The BWTS shall continuously monitor and automatically control the valves and sensors to enable the following modes of operation:

3.6.6.3 Fail-safe design. The design of the BWTS shall be such that failure of components or subassemblies will not result in unsafe operating conditions. In the design of fail-safe features, consideration shall be given to their effect on system reliability. Fail-safe features shall not cause undue complexity or excessive increase in size or weight. Fail-safe features shall at a minimum including the following:

c. Valve control. The PLC shall automatically control the opening and closing of the automatic valves required for operation in ballast and deballast modes, as well as during filter self-cleaning and UV reactor cleaning. All automatic valves shall be equipped with a valve position indicator.

3.6.6.4 Sensors and measuring instruments. All sensors and measuring instruments used in the BWTS shall be calibrated to the appropriate accuracy as required by the supplier. The BWTS shall be equipped with sensors and instruments necessary for automatic operation, fail-safe design and troubleshooting. If a sensor provides an erroneous signal, the BWTS shall trigger a warning or alarm based on the event. The BWTS shall, at a minimum, include the following sensors and measuring instruments:

a. Pressure and/or differential pressure sensor(s) to monitor and maintain a sufficient minimum pressure for UV reactor, filter cleaning, and across the entire BWTS.

b. Flow meter(s) to monitor and control the flow rate through the BWTS.

c. UVI sensor(s) to monitor and establish the treatment parameter (e.g., minimum UVI or UV dosage).

d. Temperature sensor(s) to monitor the temperature in the UV reactor(s) to prevent overheating of lamps.

e. Sensor(s) to ensure the BWTS has sufficient water inside the UV reactor.

3.6.6.5 Alarms and warnings. Alarms shall indicate errors or failure of critical components. Alarms shall stop the ongoing process, activates a normal shutdown, and return the BWTS to standby mode. The BWTS shall remain in standby mode and shall not allow automatic operation until errors are corrected and alarms are acknowledged by the operator. Warnings shall allow the current operational process to continue. Warnings shall indicate notable changes in conditions, requests for actions or a problem that should be addressed. All warnings and alarms shall remain active until they are acknowledged by the operator and until the cause is corrected.

The BWTS shall provide audible and visual alarms and warnings on the BWTS main control panel and the vessel’s centralized control system. The BWTS shall have the means for logging data on all alarms and warnings triggered by the system. The supplier shall provide a full list of alarms and warning with descriptions and set points, as well as, a troubleshooting guide to explain the possible causes and the respective corrective actions. All BWTS alarms and warnings shall be capable of being tested using procedures as determined by the supplier.

3.6.6.6 Displays. All BWTS displays and control panels shall have measurements registered in SI and to the greatest extent as practicable, U.S. Customary units. The information displayed shall, at a minimum, include alarms and warnings, as well as the following key operating parameters: operational mode; ballast and deballast flow rates; total volume processed for the current operation; temperature and pressure sensor readings, UVI, reactor cleaning events, and filter self-cleaning events. The display data shall be capable of being transmitted to the vessel’s centralized control system.

3.6.6.7 Data acquisition and retrieval. The BWTS shall, at a minimum, save data values and allow retrieval of data to enable authorized personnel to monitor the BWTS status and operating parameters. Data retrieval shall be protected by physical security control and password (see 3.6.6.1). The control system shall be capable of saving data sets at a minimum interval of 10 seconds for at least 24 months. When operated beyond 24 months, the control system shall be capable of saving the most recent data sets recorded within the last 24 months of operation. All data entries shall include date and time for operation started and ended (year, month, day, hour, and minute in Greenwich Mean Time (GMT). Data values and resolution (i.e., number of significant figures) shall be representative of the measurement interval to allow the operator to discern the differences between the interval. Provisions shall be made to allow transfer of data from the control system PLC to an Ethernet port on a laptop computer with proper software control. The physical connection on the BWTS control panel for the laptop computer shall be protected with lockable control panel cover. The BWTS shall not be integrated with GPS.

Below is a list of the minimum set of status conditions and operating parameters that the system shall monitor, save, and allow data retrieval.

a. System operational mode including standby, startup, ballasting, deballasting, and manual.

b. Warning and alarm log data including a description of all warning and alarms.

c. Flow rate and volume of ballast and deballast operations.

d. Status of measured consumables (e.g., chemical cleaning fluid).

e. All sensor inputs including pressure, temperature, and UVI.

f. Pump and valve operations (e.g., on/off status, valve position)

g. UV reactor cleaning operation

h. Filter self-cleaning cycle.

Datasets shall be available in Comma Separated Value (CSV) format to place data in columns and arrange the rows in chronological order.

3.7 Shipboard interfaces.

3.7.1 Vessel functional interfaces. The BWTS functional interfaces with the systems of the intended vessel shall be compatible with the applicable shipboard electrical power, data, hydraulic, and pneumatic supply characteristics defined in Table II.

3.7.2 Vessel physical interfaces. The BWTS interfacing pipe connections shall be compatible with the mating shipboard interface connection defined in Table II. The BWTS shall provide a means for attachment to the vessel structure. The interfacing structural mounts shall be independent from the connecting shipboard pipes. The BWTS electrical and electronic subsystems and equipment, including chassis and frames of electrical equipment with conductive cases, shall provide a means for grounding the major metallic frames or assemblies to the vessel structure as specified in MIL-STD-1310.

3.8 Maintenance and storage.

3.8.1 BWTS maintenance. UV lamp sleeves shall have removable end covers to allow for inspection and replacement of lamps. Filters shall have a filter cover to allow for inspection and maintenance of the filter element. All Organization-level maintenance (see 6.3.20) and inspection tasks shall be performable without the use of special tools (see 6.3.25). The supplier shall provide handling equipment, such as hinges, pad eyes and other lifting devices, to service BWTS components. The equipment shall be able to handle the weight and size of the BWTS components and accommodate a range of anthropometric measurements and capability ranging from a 5th percentile woman to a 95th percentile man per ASTM F1166 or MIL-STD-1472. The supplier shall provide a list of special tools required for Intermediate-level (see 6.3.12) and Depot-level maintenance (see 6.3.7).

3.8.2 Flexible hoses. Flexible hoses may be used in elements that are assembled/disassembled on a regular basis for operation or maintenance. Flexible hoses shall be wire or synthetic fiber reinforced, be compatible with the fluid, and have a rated working pressure equal to or greater than the intended service in which they are used.

3.8.3 Parts and consumables. All BWTS parts and consumables requiring replacement per suppliers’ maintenance schedules or repair over the service life of the system (see 6.1) shall be capable of being disassembled to pass through a standard Navy doorways 66 centimeters (26 inches) wide by 168 centimeters (66 inches) high, reduced further by round corners on a 20 centimeter (8-inch) radius, and hatches 76 centimeters (30 inches) wide by 152 centimeters (60 inches) long, reduced further by round corners on a 19-centimeter (7.5-inch) radius.

3.8.4 Spares and repair parts. All BWTS components that are critical to meet the system performance requirements specified herein shall be provided with spares or repair parts as recommended by the supplier. Spares and repair parts shall meet the space requirements in 3.8.3. Spares and repair parts shall include items having long lead time and are prone to damage or failure. An item is considered a long lead item if it requires more than 30 days from placement of order to delivery of item.

TABLE II. Shipboard interfaces.

System interface Vessel interface (vessel side of the interface)

Physical: Connection specified in MIL-STD-777, Category D, Groups 1 and 3, Maximum system pressure 17 bar (250 psig), maximum system temperature 66°C (150°F)

Supply characteristics:

Normal temperature range: -2 to 35°C (28 to 95 °F)

Maximum temperature: 40°C (103 °F)

Physical: Connection specified in MIL-STD-777, Category L, Group 1, Maximum system pressure 10 bar (150 psig), maximum system temperature 93°C (200°F)

Physical: Connection specified MIL-STD-777, Category R, Group 3, Maximum system pressure 4 bar (50 psig), maximum system temperature 66°C (150°F)

Physical: Connection specified MIL-STD-777, Category R, Group 3, Maximum system pressure 4 bar (50 psig), maximum system temperature 66°C (150°F)

Physical: Connection specified MIL-STD-777, Category J, Group 4, Maximum system pressure 14 bar (200 psig), maximum system temperature 66°C (150°F)

Supply characteristics:

Low pressure air at 8.6 bar (125 psig), 100 cfm at a dew point of 40°C atm

Wet bulb temperature: 81 °F (27.2 °C) (assuming space temperature is 90 °F (32.2 °C) max.)

Hydrocarbon Contaminant: Max. 50 ppm by weight

Particulate Contaminant: Max. 5 microns

Physical: Conductor identification of control and signal cables specified in IEEE 45.

Supply characteristics:

Specified in MIL-STD-1399-300-1, Type I Power (440/115 Voltage Alternating Current (VAC), 60 Hertz, 3 phase).

Integration not required

The supplier shall specify the connection and network standards for data transmission

* The BWTS shall meet the user equipment interface requirements of MIL-STD-1399, Section 300, Part 1 for ungrounded (as related to the electric power system ground) equipment using Type I power. Grounding and bonding of the BWTS electrical and electronic subsystems and equipment, including chassis and frames of electrical equipment with conductive cases to the vessel’s substructure, shall meet the electrical safety and effective low-impedance radio frequency (RF) connection requirements in MIL-STD-1310. All electrical equipment shall meet MIL-DTL-917 and MIL-STD-108, except as specified in this section.

3.8.5 BWTS storage. All BWTS equipment shall be stored indoors at 5 to 52°C (41 to 125°F). If the system is stored for less than 12 months, the system shall be capable of being immediately put into service without affecting system performance. If the system is stored for an extended period of time (e.g., more than 24 months), the supplier shall provide a list of components that are expected to require replacement or need to be checked upon return to service.

3.8.6 BWTS long period shutdown. The supplier shall provide instructions to prepare the BWTS for long period shutdown. This includes periodic maintenance required during the shutdown period. The supplier shall also provide instructions to startup the BWTS after extended period of shutdown.

3.9 Hydrostatic integrity. All portions of the BWTS designed to operate under pressure shall withstand a hydrostatic test pressure of 135 percent of the system design pressure as determined by the supplier using clean freshwater or seawater for a period of not less than 30 minutes. When pressure is applied and maintained for the specified period, there shall be no sign of leakage, material deformation or rupture, or other defects that harmfully affect the performance and serviceability of the BWTS.

3.10 Reliability, maintainability, and availability.

3.10.1 Operational availability (Ao). The Ao (see 6.3.21) of the BWTS shall be no less than 0.90 over one year of operations.

3.10.2 Mean-time-between-critical-failure (MTBCF). The MTBCF (see 6.3.15) of the system shall be no less than 600 hours.

3.10.3 Mean-time-between-failure (MTBF). The MTBF (see 6.3.16) of the system shall be no less than 225 hours at 80% confidence level when the system is operated at rated capacity.

3.10.4 Maintenance ratio. The BWTS shall have a maintenance ratio (see 6.3.13) of no greater than 0.03.

3.10.5 Mean-time-to-repair (MTTR). The MTTR (see 6.3.19) of any BWTS failure shall not exceed five man-hours, 95 percent of the time, at the organizational level by a U.S. Navy Hull Technician or Damage Controlman with no more than five hours of formal equipment training.

3.10.6 Maximum time-to-repair (MaxTTR). The MaxTTR (see 6.3.14) of any BWTS failure shall not exceed 12 man-hours. Failed components shall be able to be replaced or restored to an operable condition by a U.S. Navy Hull Technician or Damage Controlman with no more than five hours of formal equipment training.

3.10.7 Accessibility. All components of the BWTS shall be easily accessible for Organizational-level maintenance inspection and maintenance without the use of special tools. The BWTS shall be constructed and arranged so that all major system assemblies, attachments, and non-hull integrated consumable tanks are accessible for maintenance, repair, and replacement without requiring the removal of other major assemblies and temporary attachments. BWTS components that require to be serviced routinely or that is liable to wear and damage shall be readily accessible in the installed position(s).

3.11 Safety. The BWTS shall meet the system safety requirements of MIL-STD-882. The BWTS shall present no uncontrolled safety or health hazard to operating or maintenance personnel while the system is secured or during operation. Hazard mitigation measures, such as sensors and alarm settings, shall be provided such that the shipboard personnel will not be exposed to UV and other safety risks during operation, maintenance, and repair of the system. External moving parts, which are a potential hazard to personnel, shall be avoided wherever practicable. When their use is unavoidable, positive protection in the form of a guard shall be provided. Sharp corners and projections, which may cause injury to personnel or on which clothing may catch, shall be avoided. The following are some of the known safety criteria that apply to auxiliary machinery; others are contained in MIL-DTL-917.

3.12 Identification marking. All BWTS components shall have permanently affixed and legible markings as specified in MIL-DTL-15024, and at a minimum, identifying the supplier’s name, model and serial number, and inspection lot identification. Additionally, electrical enclosures shall include permanently affixed and legible markings identifying the voltage, frequency, maximum horsepower rating, and low noise, if applicable. All system piping shall be identified for its specific service (i.e., potable water) and direction.

3.12.1 Wire identification. For internal chassis wiring, any wire less than 12 inches in length, or wires connecting studs on a single part shall be marked for identification in the center unless such wires are laced or secured by sleeving into a wire bundle. All other internal wires of the equipment shall be marked for identification at both ends. Designations shall be marked on sleeve type wire markers over the wire insulation. Markings shall be applied in a permanent legible manner, resistant to water, oil and abrasion. Designations at each end of the wire shall consist of the part and terminal number, as assigned in the wire list or schematic diagram. Adhesive strip type markers designed for wrapping around wire shall not be used. Marking of internal chassis wiring or color-coding may be used as an aid in manufacture or maintenance. Internal wiring in a wire bundle terminating at a multi-pin connector does not require wire markers at the end of the wire that terminates at the connector.

3.13 Human factors. All human-machine interfaces, such as controls, displays, alerts and alarms, labeling, environment, and accessibility shall accommodate a range of anthropometric measurements and capability ranging from a 5th percentile woman to a 95th percentile man per ASTM F1166 or MIL-STD-1472.

3.14 Interchangeability. Identically identified components shall be functionally and physically interchangeable, without degradation of performance, reliability, or operating characteristics and without selective assembly or modification except for calibration and adjustment. Repair parts shall be interchangeable with, and identified identically to, the part they replace. Notwithstanding the above, parts balanced as complete assemblies shall not be exchanged without rebalancing the complete assembly.

3.15 Workmanship. All parts of the BWTS, before and after painting, shall be clean and free of sand, rust, dirt, pits, sprues, scale, and other harmful extraneous material that might detract from the intended operation, function, or appearance of the equipment. Fasteners shall be fully engaged and bolt heads and nuts shall be flat on washers or mating surface.

4. VERIFICATION

4.1 Classification of inspections. The inspection requirements specified herein are classified as follows:

4.1.1 First article inspection. A first article inspection shall be performed as specified herein on a minimum of one functional BWTS when a first article is required (see 3.2). This inspection shall consist of one or both of the following options:

4.1.2 Conformance inspection. A conformance inspection shall be performed on each production unit. Inspection shall include examinations and inspection as listed in Table III and as specified in 4.2 through 4.4.

4.2 Examination. The BWTS shall first be examined for compliance with the below requirements and shall encompass all visual examinations of the static test item to determine that physical requirements have been met. Tools (e.g., measurement devices and scales) may be used to assist this process. Noncompliance with any specified requirements or presence of one or more defects shall constitute cause for rejection.

TABLE III. Inspection requirements

X

X

X

X

X

X

X

X

X

TABLE III. Inspection requirements – Continued.

First article inspection

X

X

X

TABLE III. Inspection requirements – Continued.

First article inspection

NOTE:

1 Unless specified otherwise, the analysis shall rely on existing test data to demonstrate compliance.

4.3 Analyses.

4.3.1 Materials. Compliance with the material requirements in 3.3.1 through 3.3.7, and 3.6.2.2 shall be determined by inspection of supplier records providing proof or certification that materials conform to requirements. In addition, at the end of the operational and functional tests, the test unit shall be disassembled so components can be inspected for signs of corrosion, degradation or failure. A risk assessment, consistent with the NAVSEA Hazardous Material Avoidance Process, shall be conducted to ensure conformance to 3.3.4.

4.3.2 Ultraviolet Transmittance. Compliance with the UVT requirements in 3.4.10 shall be determined by inspection of supplier records providing proof or certification that the BWTS achieve the stated flow rates at the corresponding UVT levels.

4.3.3 System weight. Compliance with the weight restriction in 3.5.2 shall be verified by analysis based on quality objective evident that certifies the actual weight of the BWTS. .

4.3.4 Operational availability. Compliance with the Ao in 3.10.1 shall be verified by analysis providing objective quality evidence that certifies that the BWTS will achieve the stated Ao of 3.10.1. Shutdowns or interruptions resulting from failures external to the system, such as loss of vessel service air or electrical power, shall be exempted as a system failure.

4.3.5 MTBCF. Compliance with the MTBCF in 3.10.2 shall be verified by analysis using reliability prediction methods approved by the appropriate government authority. Shutdowns or interruptions resulting from failures external to the system, such as loss of vessel service air or electrical power, shall be exempted as a system failure.

4.3.6 Maintenance ratio. Compliance with the maintenance ratio in 3.10.4 shall be verified by analysis using test data obtained during operational testing. The scheduled and unscheduled maintenance shall be timed, accumulated, and converted to a maintenance ratio. Only scheduled maintenance in the supplier’s recommended maintenance schedule shall be permitted. Scheduled maintenance time includes time to perform periodic prescribed inspection and servicing of the system that includes replacement of consumables. Unscheduled maintenance time includes the time for fault isolation, disassembly, repair or replacement of faulty components, re-assembly, and replacement of consumables if necessary. Administrative or logistics delay times shall not be included in either the scheduled or unscheduled maintenance times. Shutdowns or interruptions resulting from failures external to the system, such as loss of vessel service air or electrical power, shall be exempted as a system failure.

4.3.7 MTTR and MaxTTR. Compliance with the MTTR in 3.10.5 and MaxTTR in 3.10.6 shall be verified by analysis using test data obtained for corrective…