BEAR Water Freeze Protection Purchase Description (PD) - DRAFT.pdf

Comments, suggestions, or questions on this document should be addressed to:

AFLCMC/ROZEC, 236 Milledgeville Street, Suite F30, Robins AFB GA 31098-1813. Delete the following sentence if this is to be a PD: Since contact information can change, you may want to verify the currency of this address information using the ASSIST Online database at https://assist.dla.mil.

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DISTRIBUTION STATEMENT A. Approved for public release.

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{PD_NUMBER}

CAGE 98752

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PURCHASE DESCRIPTION

BEAR WATER SYSTEM FREEZE PROTECTION

1. SCOPE

1.1 Scope. This Purchase Description (PD) describes six modular and scalable Freeze Protection Modules (FPM) for the Basic Expeditionary Airfield Resources (BEAR) water system components.

2. APPLICABLE DOCUMENTS

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

FEDERAL SPECIFICATIONS

TT-C-490H Chemical Conversion Coatings and Pretreatments for Metallic Substrates (Base for Organic Coatings)

DEPARTMENT OF DEFENSE SPECIFICATIONS

MIL-DTL-5541F NOT 1 Chemical Conversion Coatings on Aluminum and Aluminum Alloys

MIL-A-8625F(2) NOT 1 Anodic Coatings for Aluminum and Aluminum Alloys MIL-DTL-53022F(1) Primer, Epoxy Coating, Corrosion Inhibiting Lead and

Chromate Free MIL-DTL-53030D(1) NOT 1 Primer Coating, Epoxy, Water Reducible, Lead and

Chromate Free DRAFT

MIL-DTL-81706B(1) NOT 1 Chemical Conversion Materials for Coating Aluminum and Aluminum Alloys

MIL-PRF-85285F Coating: Polyurethane, Aircraft and Support Equipment

DEPARTMENT OF DEFENSE STANDARDS

MIL-STD-130N(1) NOT 1 Identification Marking of U.S. Military Property MIL-STD-461G Requirements for the Control of Electromagnetic

Interference Characteristics of Subsystems and Equipment

MIL-STD-810H(1) Environmental Engineering Considerations and Laboratory Tests

MIL-STD-882E NOT 1 System Safety MIL-STD-889D Galvanic Compatibility of Electrically Conductive

Materials MIL-STD-1472H Human Engineering

(Copies of these documents are available online at https://quicksearch.dla.mil/.)

TECHNICAL ORDERS

40W4-21-11 Basic Expeditionary Airfield Resources (BEAR) Water System (DISTRO C)

40W4-20-1 Reverse Osmosis Water Purification Unit (ROWPU)

(DISTRO C)

35E7-3-4-1 Heater, 130K Multi-Fueled, Portable, Duct Type

(DISTRO A)

35E4-164-1 Hygiene System (DISTRO B) 50D1-4-1 Self – Help Laundry (DISTRO C) 35E4-248-1 BEAR Portable Electric Kitchen, Type 1 (DISTRO C) AF TTP 3-32.34V1 Civil Engineer Bare Base Development AF TTP 3-32.34V4 Contingency Water System AF TTP 3-32.34V5 Contingency Electrical Power Production and

Distribution Systems 40H3-7-1 Heater, Water 400,000 BTU (WH-400) PN 111244

(DISTRO A)

35E7-4-27-1 Heater, Water, Liquid Fuel M-80, NSN: 4520-01-162-

0385 (DISTRO A)

DRAFT

https://quicksearch.dla.mil/

CODE OF FEDERAL REGULATIONS (CFR)

40CFR82 Protection of Stratospheric Ozone

(Copies of this document are available online at http://www.ecfr.gov/.)

2.3 Non-Government publications. The following documents of the exact revision listed below form a part of this document to the extent specified herein.

International Organization for Standardization (ISO)

668 Containers, Series 1 Freight, Classification, Dimensions, and Ratings

1161 Containers, Series 1 Freight, Corner Fittings, Specifications

6346 Freight Containers, Coding, Identification and Marking

10012 Measurement Management Systems - Requirements for

Measurement Processes and Measuring Equipment-First Edition.

1496-1 Containers, Series 1 Freight, Specification and Testing, Part 1: General Cargo Containers for General Purposes

(Applications for copies should be addressed to ISO, Case postale 56, 1211 Geneva 20, Switzerland, Fax +41 22 734 10 79.)

AEROSPACE INDUSTRIES ASSOCIATION (AIA) / NATIONAL AEROSPACE

STANDARD (NAS)

NASM24667 Screw, Cap, Socket Head, Flat Countersunk, 82°, Alloy Steel, UNC-3A

(Application for copies should be addressed to Aerospace Industries of Association of America, Inc., 1000 Wilson Blvd., Arlington VA 22209, http://www.aia-aerospace.org/.)

AMERICAN SOCIETY OF MECHANICAL ENGINEERS (ASME) INTERNATIONAL

B18.3-2012 Socket Cap, Shoulder, Set Screws, and Hex Keys (Inch Series)

(Application for copies should be addressed to ASME International, Two Park Ave., New York NY 10016, http://www.asme.org/.)

DRAFT

http://www.ecfr.gov/ http://www.aia-aerospace.org/ http://www.asme.org/

ASTM INTERNATIONAL (ASTM)

F835-20 Standard Specification for Alloy Steel Socket Button and Flat Countersunk Head Cap Screws

F1136/F1136M-11 Standard Specification for Zinc/Aluminum Corrosion Protective Coatings for Fasteners

(Application for copies should be addressed to ASTM International, 100 Barr Harbor Drive, PO Box C700, West Conshohocken PA 19428-2959, http://www.astm.org/.)

NACE INTERNATIONAL

SSPC-SP10/NACE No.2 Near-White Metal Blast Cleaning SSPC-Vis 1 Guide and Reference Photographs for Steel Surfaces

Prepared by Dry Abrasive Blast Cleaning

(Applications for copies should be addressed to NACE International, 15835 Park Ten Pl, Houston TX 77084, http://www.nace.org/.)

NATIONAL FIRE PROTECTION ASSOCIATION (NFPA)

NFPA 70 National Electrical Code, 2020

(Application for copies should be addressed to NFPA, 1 Batterymarch Park, Quincy MA 02169, http://www.nfpa.org/.)

SAE INTERNATIONAL

AMS-STD-595A Colors Used in Government Procurement J429-2014 Mechanical and Material Requirements for Externally

Threaded Fasteners J995-2017 Mechanical and Material Requirements for Steel Nuts

(Application for copies should be addressed to SAE International Customer Service, 400 Commonwealth Drive, Warrendale PA 15096, http://www.sae.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 (except for related specification sheets), the text of this document takes precedence. Nothing in this document, however, supersedes applicable laws and regulations unless a specific exemption has been obtained.

DRAFT

http://www.astm.org/ http://www.nace.org/ http://www.nfpa.org/ http://www.sae.org/

3. REQUIREMENTS

3.1 Preproduction. When Specified (see 6.2), a sample kit or component shall be subjected to preproduction inspection in accordance with 4.2.

3.2 Description and general layout. The Basic Expeditionary Airfield Resources (BEAR) Water System is modular and scalable in 550 personnel support increments up to 3,300 personnel to meet a variety of user deployment needs. The BEAR Water System can draw water from a natural source, purify, store, and distribute the water while maintaining sufficient pressure, quantity, and quality for an entire base. Depending on the selected modular configuration, the water system can supply 30 gallons of water per person per day (gpppd) for a 1100-person camp and maintain enough storage capacity to sustain the camp for four days with no new water introduction. The BEAR Water System consists of a series of surface laid piping, pumping, fluid control, and water storage equipment that comprise distinct subsystems as shown in Figure 1.

Figure 1: BEAR Water System Overview.

See Appendix I for BEAR Water System Major Component Details.

An overview of the following subsystems is provided in 3.2.1 through 3.2.5.

• Water Source Run

• Water Production

• Initial 550 Water Distribution (550I)

• Follow-On 550 Water Distribution (550F)

• Industrial Operations/Flightline Water Extension (IDS)

The following facility systems descriptions are provided in 3.2.6.

• Hygiene

• Kitchen

• Laundry

3.2.1 Water Source Run. The Source Run Subsystem (SRS) is a modular raw water distribution subsystem used to provide raw water from a source (pond, lake, stream, sea, or ocean) up to 6,300 feet to the water production subsystem. The SRS consists of a series of surface laid piping, plumbing, fluid control, and water storage equipment. These components include a 4 in. strainer and float assembly, 400 GPM diesel pump assembly, 20,000-gallon collapsible fabric tank, hoses, ball valves, and flaking boxes. Figure 2 provides an overview of the Water Source Run.

Figure 2: Water Source Run Subsystem.

3.2.2 Water Production. The Water Production Subsystem (WPS) generates potable water for distribution to user facilities within the BEAR water system. The WPS has the capability to receive from the SRS or draw directly from a source. Water purification is accomplished by two 1500 gallons per hour Reverse Osmosis Water Purification Units (ROWPUs). Raw water input is distributed through a 125 gallon per minute diesel pump for storage in a 20,000-gallon storage tank then distributed through a series of hoses and fittings to interface with the ROWPUs. The potable water generated by the ROWPUs is distributed through another series of surface laid hoses and fittings configured to interface with a 20,000-gallon potable water storage tank. Byproducts from the water purification process, brine water and wastewater, are distributed to a 20,000-gallon storage tank. The brine/wastewater storage tank is interfaced to a 35 gallon per minute electric pump for distribution to a waste area. The WPS consists of 2 each, 1500-gallon per hour ROWPUs and associated equipment. The equipment includes three 20,000-gallon bladders (Raw, waste, and potable water), 125 gallon per minute diesel pumps, electric pumps, various size hoses, valve assemblies, and associated fittings. Figure 3 provides an overview of the

WPS.

Figure 3: Water Production Subsystem.

3.2.3 Water Distribution Initial. The 550 Initial Subsystem (550I) is the primary potable water distribution system and contains the required surface laid components to distribute water on the Base to locations for laundry, hygiene, and kitchen to support a population of 550 personnel. The potable water input is distributed to three 20,000-gallon collapsible fabric tanks for storage, in a tank farm configuration. Water is distributed to a variable speed dual pumping station. The pumping station consists of two pumps configured in parallel.

Output from the pumping station is applied to a distribution line that is looped and connected to form a pressurized feed line. The system can support up to a 6,000 feet distribution loop with a supply rating of 300 gallons per minute at 45 psi. User facilities are branched from the feed line. The 550I consists of adapters, 125 gallon per minute diesel pump, three 20,000-gallon collapsible fabric tanks, a dual pump station, four 3,000-gallon collapsible fabric tanks, four Bladder Water Level Controllers, two Sewage Ejector Systems, one Macerator Pump Lift Station, one Dual Pump Lift Station, one 25,000-gallon wastewater tank with mixing system, hoses and ball valves. Figure 4 provides an overview of the 550I subsystem.

Figure 4: 550 Initial Subsystem.

3.2.4 Water Distribution Follow-On. The 550 Follow-On (550F) Subsystem provides for expansion and builds upon the 550I to support a population of 1100. The 550 Follow-On system is identical to the 550I, but does not provide a dual pump station, dual pump sewage lift station or 25,000-gallon wastewater collection tank. The 550F cannot be used independently. The 550F provides three 20,000-gallon collapsible fabric tanks, four 3,000-gallon collapsible fabric tanks, four Bladder Water Level Controllers, two Sewage Ejector Systems, one Sewage Ejector Lift Station, one Macerator Pump Station, hoses and ball valves. Figure 5 provides an overview of the 550F Subsystem.

Figure 5: 550 Follow-On Subsystem.

3.2.5 Industrial Operations/Flightline Water Extension. The Industrial Operations Water Extension Subsystem provides surface laid potable water extension from the 550I, 550F, or Water Production subsystem by connection to any three-inch pressurized feed line. The system provides potable water to isolated user facilities up to 2,500 feet away. The Industrial Operations Water Extension Subsystem provides two bladder water level controllers, two 3,000-gallon collapsible fabric tanks, one 35 GPM electric pump, hoses, reducers, tee assemblies, ball valves, and check valves. Figure 6 provides an overview of the Flightline Water Extension.

Figure 6: Industrial Operations Water Extension Subsystem.

3.2.6 Facilities. The facilities systems include the expandable BICON Hygiene System, Kitchen and Laundry. The following systems are designed to interface with the BEAR water subsystems providing water and wastewater service.

3.2.6.1 Hygiene. The Hygiene System includes four expandable BICON shelters; consisting of two latrine BICON shelters and two shower BICON shelters. The Hygiene System utilizes various hoses, pipes, fittings, electrical pumps, and a AWH400 Fuel-burning water heater. Figure 7 provides an overview of the Hygiene system.

Figure 7: BICON Hygiene System.

3.2.6.2 Kitchen. The BEAR Type I Portable Electric Kitchen (PEK) provides mess services to support up to 550 people. The PEK system includes complexed shelters, a complete meal preparation serving area, and a dining area. The PEK system utilizes various hoses, pipes, fittings, electrical pumps, a water bladder, and a grease trap for water distribution and waste collection. Figure 8 provides an overview of the PEK system.

Figure 8: Portable Electric Kitchen System.

Water System

1. Hose Assembly, 1” x 125’ to Coffee Urn (4036-609)

2. Hose Assembly, 1” x 50’; Hand Sink (4036-607)

3. Hose Assembly, 1” x 15’; Kettle (4036-605)

4. Hose Assembly, 2” x 25’; Bypass Hose (4036-608)

5. 2” Bypass Tee (1201990)

6. Hose Assembly, 2” x 5’; Bladder (3088-060)

7. Bladder (User-Furnished)

8. Hose Assembly, 1-1/2” x 25’; Supply Pump (4036-610)

9. Supply Pump (1201808)

10. Hose Assembly, 1-1/2” x 5’; Supply Tee (3088-061)

11. 1-1/2” Supply Tee (1201691)

12. Hose Assembly, 1-1/2” x 5”; Supply Manifold (3088-061)

13. Supply Manifold (1201896)

14. Hose Assembly, 1” x 15’; Vegetable Sink (4036-605)

15. Hose Assembly, 1” x 15’; Three-Well Sink (4036-605)

16. Hose Assembly, 1” x 50’; Ice Machine (4036-607)

Wastewater System

17. Hose Assembly, 1-1/2” x 25’ (4036-601)

18. Waste Pump 1 of 2 (1202362)

19. Hose Assembly, 2” x 50’ (4036-602)

20. Hose Assembly, 2” x 25’ (4036-604)

21. Hose Assembly, 1-1/2” x 15’ (4036-603)

22. Waste Pump 2 of 2 (1202362)

23. 3/8” Condensate Hose

24. Grease Trap (1202351)

25. Hose Assembly, 3” x 25’ (4036-606)

17 17 19,20 18 25 24

3.2.6.3 Laundry. The Self-Help Laundry is an expeditionary self-service laundry mat housed within a single 32ft by 20ft shelter. The laundry includes five top loading washers, a water system with a 3,000-gallon water tank, water heater, supply pump, and drain pump.

Figure 9: Self-Help Laundry.

3.3 BEAR Water Freeze Protection Overview. The Basic Expeditionary Airfield Resources (BEAR) Water Freeze Protection Modules (FPM) shall provide users with the equipment necessary to protect the BEAR water subsystem components from freezing. The BEAR FPM:

• Shall provide freeze protection of BEAR water system components in ambient temperature ranges from 32℉ to -25℉ (objective goal of -65℉).

• Shall provide the ability to automatically detect and provide visually indication of failed components or abnormal operational conditions, and may include interface for remote monitoring functionality.

• Shall have redundant capabilities and/or methods to overcome individual component failures.

• Shall provide the ability to return frozen system components to normal operating state.

• Shall provide the ability to penetrate ice layers for liquid water drawn from water source.

Any alternate technical approaches to requirements listed in this document shall be reviewed for approval by the procuring government activity.

The FPM shall be compatible with BEAR water distribution system without modification.

Relocation of system components is acceptable; however, any additive component must interface with the current system. The FPM shall use items currently in the BEAR configuration to the maximum extent.

The FPM shall be modular and scalable in design to protect the water system pumping, piping, storage equipment; applicable fittings; and other system components. The modules shall be constructed of interchangeable pieces to maximize configuration flexibility. The modules shall be capable of indefinite scalability through the connection of additional modules. FPM shall not be functionally dependent upon any other FPM. The contractor shall maximize usage of commercial-off-the-shelf components and strive to minimize overall system weight without adversely affecting performance.

The FPM shall be designed and constructed to be transported, stored, assembled, disassembled, and operated at remote and austere locations in accordance with 3.7.

The FPMs shall provide modified layouts within Technical Manuals for the relocation of BEAR Laundry and Kitchen equipment. These layout modifications are detailed in section 3.

3.3.1 Module 1, Water Source Run Freeze Protection. FPM 1 shall provide protection through the identified component requirements in accordance with section 3.4. The module shall provide operators with the ability to penetrate ice layers for drafting water from a natural source and prevent inlet hose from freezing between operational cycles. All electrical components required to support freeze protection of the BEAR water system components shall be provided with the respective modules and support interfacing with the standard BEAR electrical distribution system as described in 3.4.2.

3.3.1.1 Freeze Protection for Water Source Run. FPM 1 shall provide heating and insulation for the 20k bladder to maintain water temperature above 50℉. The module shall provide insulated wrap with integrated heating to protect 1000 feet of 6-inch hose, 250 feet of 4-inch hose and associated valves and fittings. The module shall provide one 32ft. X 20ft. heated and insulated shelter to provide protection for the 400 GPM diesel pump, the shelter shall provide means to route motor exhaust out of shelter. Requirements for this module are described in Figure FPM1, and Table FPM1.

Figure FPM1: SRS Freeze Protection Module

Table FPM1: SRS Freeze Protection Module, Water System Components

3.3.2 Module 2, Water Production Freeze Protection. FPM 2 shall provide protection through the identified component requirements in accordance with section 3.4. The module shall provide operators with the ability to penetrate ice layers for drafting water from a natural source and prevent inlet hose from freezing between operational cycles. All electrical components required to support freeze protection of the BEAR water system components shall be provided with the respective modules and support interfacing with the standard BEAR electrical distribution system as described in 3.4.2.

3.3.2.1 Freeze Protection for Water Production. FPM 2 shall provide one heated and insulated shelter with minimum dimensions of 50 ft. X 32ft. to provide protection for the ROWPUs, 3K water bladder, and electric pumps. FPM 2 shall provide dedicated freeze protection for the two diesel driven water pumps. Insulated hose wrap with integrated heating shall be provided for all exposed or unsheltered hoses and fittings. Requirements for this module are described in Figure FPM2, and Table FPM2.

Figure FPM2: WPS Freeze Protection Module.

Table FPM2: WPS Freeze Protection Module, Water System Components

3.3.3 Module 3, Water Distribution Initial Freeze Protection. FPM 3 for 550I with integration of Hygiene, Kitchen, and Laundry systems shall provide freeze protection through the identified component requirements in accordance with section 3.4. All electrical components required to support freeze protection of the BEAR water system components shall be provided with the respective modules and support interfacing with the standard BEAR electrical distribution system as described in 3.4.2.

3.3.3.1 Freeze Protection for 550I. FPM 3 shall provide freeze protection for the potable water distribution portion of the 550I that includes 3 each - 20K pillow type water bladders with accessory hoses and fittings, 1,000 ft. of 3-inch water hoses, 400 ft. of 4-inch hose, 400 ft. of 2-inch hose, a dual pump station, and a 125GPM diesel pump. FPM 3 shall include a 32ft. X 20ft.

heated and insulated shelter to house 3 each – 3K pillow type water bladders with bladder fill controller assemblies that provide water supply to the Hygiene, and Laundry systems.

FPM 3 shall provide freeze protection for the wastewater collection portion of the 550I that includes 1 each - 25K waste tank system, 1,000 ft. of 3 to 4-inch wastewater hose, 400 ft. of 1 ½ to 2-inch hose, a macerator pump lift station, and a dual pump lift station.

Requirements for this module are described in Figures FPM3, sheets 1 - 7, and Tables FPM3- 550I Water System, FPM3-550I Wastewater System, FPM3-PEK, FPM3-Laundry, FPM3- Hygiene.

Figure FPM3, 1 of 7: 550I Freeze Protection.

Figure FPM3, 2 of 7: 550I Freeze Protection Continued.

Figure FPM3, 3 of 7: 550I Freeze Protection Continued

Figure FPM3, 4 of 7: 550I Freeze Protection Continued

Table FPM3: 550I Freeze Protection Module, Water System Components

Table FPM3: 550I Freeze Protection Module, Wastewater System Components

3.3.3.2 Freeze Protection for Kitchen. FPM 3 shall include a 32ft. X 20ft. heated and insulated shelter to house 1 each – 3K pillow type water bladder, electric water pump, and grease trap assembly for the Kitchen system.

All pumps, equipment and hoses will be relocated within the kitchen shelter as illustrated in figure FPM3 Sheet 5, except for exposed water supply lines between shelters. The exposed lines are 1 ½ - inch X 15ft. water hose and 2ea 2-inch X 15ft. wastewater discharge hose. DRAFT

Figure FPM3, 5 of 7: PEK Freeze Protection, 550I Freeze Protection Continued.

Table FPM3-PEK: 550I Freeze Protection Module, PEK Components

3.3.3.3 Freeze Protection for Laundry. The Laundry System Water Source, 3k bladder, is housed in the shelter identified in 3.3.3.1. All pumps, equipment and hoses will be relocated within the laundry shelter as illustrated in figure FPM3 Sheet 6, except for the exposed water supply lines between shelters and the wastewater discharge that extends beyond the laundry shelter. The FPM 3 shall provide freeze protection for 40ft. of 1 ½-inch water supply lines, 40ft. of 2-inch wastewater lines.

Figure FPM3, 6 of 7: Self-Help Laundry Freeze Protection, 550I Freeze Protection Continued.

Table FPM3-Laundry: 550I Freeze Protection Module, Self-Help Laundry Components

3.3.3.4 Freeze Protection for Hygiene. The Hygiene Systems water source, 3K bladder, is housed in the shelter identified in 3.3.3.1. Requirements for this module are described in Figures FPM3 Sheet 7, and Table FPM3-Hygiene.

Figure FPM3, 7 of 7: BICON Hygiene Freeze Protection, 550I Freeze Protection Continued.

Table FPM3-Hygiene: 550I Freeze Protection Module, Hygiene Components

3.3.4 Module 4, Water Distribution Follow-On Freeze Protection. The FPM 4 for 550F with integration of Hygiene, and Laundry systems shall provide freeze protection through the identified component requirements in accordance with section 3.4. All electrical components required to support freeze protection of the BEAR water system components shall be provided with the respective modules and support interfacing with the standard BEAR electrical distribution system as described in 3.4.2.

3.3.4.1 Freeze Protection for 550F. The FPM 4 shall utilize freeze protection components consistent with FPM 3 without the requirement to provide protection for the dual pump station, dual pump lift station, 25K gallon waste tank system, and Kitchen system.

FPM 4 shall provide freeze protection for the potable water distribution portion of the 550F that includes 3 each - 20K pillow type water bladders with accessory hoses and fittings, 1,000 ft. of 3-inch water hoses, 400 ft. of 4-inch hoses, 400 ft. of 2-inch hoses, and a 125GPM diesel pump.

FPM 4 shall include a 32ft. X 20ft. heated and insulated shelter to house 3 each – 3K pillow type water bladders with bladder fill controller assemblies that provide water supply to the Hygiene and Laundry systems.

FPM 4 shall provide freeze protection for the wastewater collection portion of the 550F that includes 1,000 ft. of 3 to 4-inch wastewater hose, 400 ft. of 1 ½ to 2-inch hose, a macerator pump lift station.

Requirements for this module are described in Figures FPM4, sheets 1 - 6, and Tables FPM4- 550F Water System, FPM4-550F Wastewater System, FPM4-Laundry, FPM4-Hygiene.

Figure FPM4, 1 of 5: 550F Freeze Protection.

Figure FPM4, 2 of 5: 550F Freeze Protection Continued.

Figure FPM4, 3 of 5: 550F Freeze Protection Continued.

Table FPM4-550F Water System: 550F Freeze Protection Module, Water System Components.

Table FPM4-550F Wastewater System: 550F Freeze Protection Module, Wastewater System Components.

3.3.4.3 Freeze Protection for Laundry. Freeze protection requirements for the Laundry System can be found in 3.3.3.3. Requirements for this module are described in Figures FPM4, and Table FPM4-Laundry.

Figure FPM4, 4 of 6: Self-Help Laundry Freeze Protection, 550F Freeze Protection Continued.

Table FPM4-Laundry: 550F Freeze Protection Module, Self-Help Laundry Components

3.3.4.2 Freeze Protection for Hygiene. Freeze protection requirements for the Hygiene System can be found in 3.3.3.4. Requirements for this module are described in Figures FPM4, and Table FPM4-Hygiene.

Figure FPM4, 6 of 6: BICON Hygiene Freeze Protection, 550F Freeze Protection Continued.

Table FPM4-Hygiene: 550F Freeze Protection Module, Hygiene Components

3.3.5 Module 5, Industrial Operations/Flightline Water Extension Freeze Protection. FPM 5 for industrial operations shall provide protection for all components through a combination of components or methods described in section 3.4. All electrical components required to support freeze protection of the BEAR water system components shall be provided with the respective modules and support interfacing with the standard BEAR electrical distribution system as described in 3.4.2.

3.3.5.1 Freeze Protection for Industrial Ops/Flightline Extension. FPM 5 shall provide freeze protection for two 3,000-gallon pillow type bladders with bladder fill controllers, one 35GPM electric water pump, and 1,000 ft. of 2 – 3 in. diameter hose. Requirements for this module are described in Figure FPM5, and Table FPM5.

Figure FPM5: Industrial Operations Freeze Protection

Table FPM5: Industrial Operations Freeze Protection Module, Water System Components.

3.3.7 Module 6, Expansion Kit. FPM 6 shall universally extend freeze protection capabilities of the previously described modules. FPM 6 shall consist of an additional 1,000 feet of heated and insulated hose/pipe wrap, additional 20,000-gallon and 3,000-gallon bladder freeze protection equipment. The expansion kit shall consist of components previously developed to support freeze protection of Modules 1 through 5.

FPM 6 shall provide protection through a combination of components or methods described in section 3.4. All electrical components required to support freeze protection of the BEAR water system components shall be provided with the respective modules and support interfacing with the standard BEAR electrical distribution system as described in 3.4.2.

3.4 Performance. The BEAR Water Freeze Protection Modules shall provide freeze protection for the BEAR water subsystem components in an operating temperature range from 32℉ to -25℉ (objective goal of -65℉).

3.4.1 BEAR Water Freeze Protection Installation. The Water Freeze Protection Modules shall be designed to support quick and easy installation of all freeze protection components. The Modules shall be designed to support installation without major interruption to water system operation.

Installation of freeze protection material onto any 3-inch diameter hose, 100-feet in length, shall not exceed 5 minutes with two trained personnel, with gloved hands.

3.4.2 BEAR Water Freeze Protection Electrical Requirements. The Water Freeze protection modules’ electrical components shall be compatible and interface with the existing BEAR electric power system equipment to receive electrical power as required for module operation.

Electrical power for each module shall be derived from Government Furnished Equipment (GFE) Mobile Electric Power (MEP) generators (see Table 1) to provide tactical power at the point of use locations and secondarily be capable of interfacing with the BEAR Electrical Distribution system as described in AF TTP 3-32.34V5. GFE components listed in Table 2 shall be utilized in the design of module power system and identified and listed within the respective module’s baseline index as GFE. BEAR power generation and distribution is a nominal 120/208 VAC single or three phase 60 Hertz, additional details may be provided upon request. Any equipment required that is not listed in Table 2 shall be furnished with the respective module.

The freeze protection solution shall maximize energy efficient solutions. The contractor shall provide total power requirements for all freeze protection modules individually and a total requirement for FPM 1 through 6.

No single electrical component, device or single fed system shall draw more than 60 amps. All exposed electrical components shall be weatherproof and shall be UL listed for their intended use wherever possible. All electrical installations shall comply with NFPA 70. Military specification connectors shall be utilized for all electrical components; however, some commercial, three-prong, 120V connectors may be used with procuring activity’s approval.

MOBILE ELECTRIC POWER (MEP) GENERATORS, ADVANCED MEDIUM MOBILE

POWER SOURCES (AMMPS) FAMILY

1 PHASE

AMPERAGE

3 PHASE

AMPERAGE

Model NSN kW Remarks 120V 120V/240V 120V/208V 240V/416V

MEP-1030 6115-01-561-7329 5

120 VAC 1 ph, 120/240 VAC 1 ph, 120/208 VAC 3 ph @ 50/60 Hz

52 26 17 N/A

MEP-1030A 6115-01-679-2558 5

120 VAC 1 ph, 120/240 VAC 1 ph, 120/208 VAC 3 ph @ 50/60 Hz

52 26 17 N/A

MEP-1040 6115-01-561-7455 10

120 VAC 1 ph, 120/240 VAC 1 ph, 120/208 VAC 3 ph @ 50/60 Hz

104 52 35 N/A

MEP-1040A 6115-01-679-5145 10

120 VAC 1 ph, 120/240 VAC 1 ph, 120/208 VAC 3 ph @ 50/60 Hz

104 52 35 N/A

MEP-1050 6115-01-561-7634 15 120/208 VAC 3 ph, 240/416 VAC 3 ph @ 50/60 Hz N/A N/A 52 26

MEP-1050A 6115-01-679-5596 15 120/208 VAC 3 ph, 240/416 VAC 3 ph @ 50/60 Hz N/A N/A 52 26

MEP-1060 6115-01-561-7718 30 120/208 VAC 3 ph, 240/416 VAC 3 ph @ 50/60 Hz N/A N/A 104 52

MEP-1060A 6115-01-679-5442 30 120/208 VAC 3 ph, 240/416 VAC 3 ph @ 50/60 Hz N/A N/A 104 52

MEP-1070 6115-01-561-7788 60 120/208 VAC 3 ph, 240/416 VAC 3 ph @ 50/60 Hz N/A N/A 208 104

MEP-1070A 6115-01-679-4747 60 120/208 VAC 3 ph, 240/416 VAC 3 ph @ 50/60 Hz N/A N/A 208 104

Table 1

BEAR Electrical Distribution Equipment

Item NSN Input Connection Output Connection 25KW Power Distribution Panel

(PDP)

6110-01-244-3209 (P/N 8642307)

120/208V, 3PH, 60A, MS90558C32412P (1 EA) 120/208V, 3PH, 60A, MS90555C32412S (1 EA)

120V, 1PH, 15A , MS25199-1 (1 EA)

120V, 1PH, 20A, 8642377-1, NEMA L5-20R (4 EA)

60KW Power Distribution Panel

(PDP)

6110-01-237-4637 (P/N 8542414)

120/208V, 3PH, 200A, MS90558C52412P (1EA) 120/208V, 3PH, 60A, MS90555C32412S (4 EA)

Secondary Distribution Center (SDC)

6110-01-168-8077 (P/N 8335844)

4160V Load Breaks (3 Phase) or

120/208V, 3PH, 200A, MS90558C52412P (1EA)

120/208V, 3PH, 60A, MS90555C32412S (16 EA)

120V, 1PH, 15A , MS25199-1 (2 EA)

Cable, 200A, 25 ft 6150-00-178-9159 120/208V, 3PH, 200A, MS90556C52412P (1 EA) 120/208V, 3PH, 60A, MS90557C52412S (1 EA)

Cable, 60A, 50 ft 6150-00-255-8313 120/208V, 3PH, 60A, MS90556C32412P (1 EA) 120/208V, 3PH, 60A, MS90557C32412S (1 EA)

Cable, 60A, 100 ft 6150-00-255-8332 120/208V, 3PH, 60A, MS90556C32412P (1 EA) 120/208V, 3PH, 60A, MS90557C32412S (1 EA)

Table 2

3.4.3 BEAR Water System Configuration and Approved Layout Deviations/Alternate Technical Approaches. The BEAR Freeze Protection Modules may propose alternate approved layouts and/or approved alternate technical approaches that increase effectiveness of protection or accommodate recirculation. The baseline configuration of the BEAR water system shall not be modified, any deviations that require additional piping, valves, or other components shall be provided by the freeze protection kits/modules. Alternate layouts may include consolidation of components across FPMs into collective protection such as sheltering, to accommodate efficiency and or more robust protection.

3.4.4 BEAR Freeze Protection Equipment. The BEAR Freeze Protection Modules may contain equipment including but not limited to insulated valve boxes, electrical and fuel-powered pump insulation covers, bladder covers, immersion heaters, recirculation devices, insulated hose wrap, heat tape, shelters, etc. The freeze protection system shall utilize universal or common components across freeze protection kits/modules. Unique items shall be limited as much as possible.

3.4.4.1 Hose and Fittings Freeze Protection. The BEAR Water Subsystems contain various size hoses and fittings to support distribution of potable and combined grey and black wastewater by-products. The BEAR Freeze protection modules shall provide protection for hoses and fittings in ambient temperatures ranging from 32℉ to -25℉. The hose protection solution shall allow for easy install and removal with gloved hands, without breaking hose connections. The hose protection solution shall be made of materials that are UV resistant outer layer and resist splitting or cracking in arctic climates. The hose protection solution shall be designed to be installed on existing water/waste hoses and fasteners together via hook and loop strips along its entire length, or other expedient installation method. The hose protection solution shall be standardized to support various hose sizes to the maximum extent, i.e. 3 in. and 6 in. hoses utilize the same Part Number (P/N) for hose wrap insulation. Any proposed solution shall be approved by the procuring government activity. Wrap that identifies the requirement for heat trace shall conform with 3.4.4.2.

3.4.4.2 Heat Tape/ Heat Trace. The BEAR Freeze Protection Modules may utilize self-regulating, electrical heat tape or heat trace to increase system effectiveness. The heat tape/trace shall be terminated with male/female weatherproof plugs/receptacles so the units can be daisy chained to accommodate longer hose/pipe runs. Electrical power draw of the self-regulating heat tape shall not exceed 9 watts per foot. Electrical distribution system for heat tape/trace shall not exceed 120/208 volts, 60 amps per connection from BEAR electrical Power Distribution Panel (PDP). Heat trace may be integrated into insulated wraps or covers.

3.4.4.3 Water Bladder and Waste Tank Freeze Protection. The BEAR Water Subsystems contain 3K and 20K gallon pillow type bladders and a 25K gallon open top waste tank. The BEAR freeze protection modules shall provide insulation material or heated shelters to prevent contents of bladders or waste tanks from freezing and minimize energy loss. All covers shall allow easy access for normal operations, and water sampling. Usage of heat additive systems may be utilized to increase system effectiveness. Heat additive systems include but are not limited to heat pads, water boilers/heaters, heat trace, etc.

3.4.4.4 Electrical and Diesel Driven Pumps Freeze Protection. The BEAR Water Subsystems contain various size pumps to support water distribution or waste ejection. The BEAR freeze protection modules shall provide form fitting heated insulated blankets or boxes designed for each respective pump. Pumps may also be protected by use of a heated shelter listed and in accordance with 3.4.4.6.

3.4.4.5 Various Valve Freeze Protection. The BEAR Water Subsystems contain various valves to support water distribution or waste ejection. The BEAR freeze protection modules shall provide insulated and heated valve boxes for each valve not protected by a heated shelter. The design of the valve box shall allow easy access, and operation of valves as required.

3.4.4.6 Shelters for Freeze Protection. To protect collective components from freezing, BEAR Water Subsystems’ operational layouts require heated shelters. Government-qualified shelters shall be used as the primary solution. However, alternative shelters may be recommended for approval if they offer superior performance, such as greater efficiency or improved snow load capacity. All shelters, whether soft or hard-sided, must be equipped with a cold-weather insulation package. Each shelter must be evaluated for its performance in the intended operating environment; it is recommended that this evaluation references the testing standard TOP 10-2-

175. The key performance requirement is the ability to maintain an internal temperature above 32°F with an external ambient temperature as low as –25°F. Shelters will be heated by the government-furnished (GFE) 130K BTU multi-fuel burning heater (NSN 4520-01-521-2076), and any alternative heating source such as inferred, radiant, alternative forced air, etc. must be approved. Shelters can be combined or complexed to fit the required footprint and shall be provided as an integral component of the freeze protection module.

BEAR qualified shelter systems:

Small Shelter System, NSN 8340-01-469-1876 (tan), Dimensions: L 32 ft. x W 20 ft. x H 10ft.

Medium Shelter System, NSN 5419-01-465-3019 (tan), Dimensions: 52 ft. x 30 ft. x 15 ft.

4K Dome Shelter System, NSN 5410-01-455-2004, Dimensions: 89 ft. x 70 ft. x 25 ft.

8K Dome Shelter System, NSN 5410-01-494-5130, Dimensions: 116 ft. x 69 ft. x 25 ft.

Large Area Maintenance Shelter, NSN 5410-01-533-7395, Dimensions: 129 ft. x 75 ft. x 31 ft.

3.4.4.7 Heat Pad. The BEAR Water Freeze Protection Modules may utilize self-regulating, electrical heating pads to increase system effectiveness. Heat pads may be used to provide freeze protection to various BEAR water system components including bladders, waste tanks, and pumps. Installation and usage instructions must be provided. Electrical distribution system for heat pads shall not exceed 120/208 volts, 60 amps per panel.

3.4.4.8 Water Boilers/Heaters. The BEAR Water Freeze Protection Modules may utilize the AWH400 (4520-01-566-6669) or M-80 (4520-01-162-0385) to increase system effectiveness.

Water Boilers/Heaters may be used to increase overall temperature of water in the BEAR water system. When used in shelters, exhaust adapters shall be provided to redirect exhaust outside of shelter.

3.4.4.9 Immersion Heaters. The BEAR Freeze Protection Modules may utilize immersion style heaters to improve freeze protection capabilities. Each immersion style heater shall be self-regulating, and properly sized for the bladder or storage tank, and clearly identified to prevent misuse.

3.4.4.10 Flow Control Devices, Pumps and/or Equipment. The BEAR Freeze Protection Modules may utilize water recirculation to increase effectiveness. The flow control devices and equipment shall be compatible with the current BEAR systems. The flow control devices, pumps and/or equipment shall be capable of operation without freezing in the desired operating environment.

The flow control devices, pumps and/or equipment shall be automatically actuated based on ambient air temperature set point.

3.5 Environmental conditions.

3.5.1 Operating temperature range. The BEAR Freeze Protection Modules shall prevent the BEAR Water subsystems from freezing in ambient temperatures ranging from 32℉ to -25℉ (objective goal of -65℉).

3.5.2 Storage temperature range. The BEAR Freeze Protection Modules shall be capable of being stored in ambient temperatures ranging from -65° F to 160° F.

3.5.3 Precipitation.

3.5.3.1 Rain. The BEAR Freeze Protection Modules shall be capable of storage and operation during rainfall of 5-inches per hour for three consecutive hours and 10-inches per hour for 10 consecutive minutes, with winds of up to 35 knots; and with 6-inches of rain per hour impinging on the BEAR Freeze Protection Modules at angles from vertical to 45° for 30 consecutive minutes.

3.5.3.2 Snow. The BEAR Freeze Protection Modules shall be capable of long-term storage and operation during accretion of wet snow up to 2-inches per hour for at least 12 hours on exposed horizontal surfaces.

3.5.3.3 Ice. The BEAR Freeze Protection Modules shall be capable of long-term storage and operation with ice accretion up to 1.5-inches on exposed horizontal surfaces.

3.5.4 Solar radiation. The BEAR Freeze Protection Modules shall not be adversely affected by full time exposure to solar radiation, such as those conditions encountered in desert environments and high altitudes.

3.5.5 Fungus. All materials used in the BEAR Freeze Protection Modules shall be fungus resistant or shall be suitably treated to resist fungus. Materials treated for fungus resistance shall retain their original electronic and physical properties, shall not present toxic hazards, and treatment shall last for the entire service life of the part. The BEAR Freeze Protection Modules shall be suitable for operation and storage in conditions encountered in a tropical environment.

3.5.6 Salt fog. The BEAR Freeze Protection Modules shall be capable of sustained use and storage in high temperature, high humidity, salt laden, sea-coast environments without damage or deterioration of performance. The BEAR Freeze Protection Modules shall also be capable of storage and operation in part-time (5%) exposure to a five percent salt solution, with fallout rate of 0.10 oz (3 ml) of per hour per each 12.40 sq. inch (80 sq. cm) of horizontal collecting area without damage or deterioration of performance.

3.5.7 Sand and dust. The BEAR Freeze Protection Modules shall be capable of sustained use and storage with exposure to 0.062 grams/cubic foot wind-blown sand (particle size 150-1000 microns) or dust (particle size less than 150 microns) at wind speeds up to 35 knots without damage or deterioration of performance.

3.5.8 Humidity. The BEAR Freeze Protection Modules shall be capable of operation and storage from 5 to 95% (±5%) relative humidity, including conditions where condensation takes place in the form of water and/or frost.

3.6 Weight and dimensions. The size and weight of the BEAR Water Freeze Protection Subsystems shall be as small as practicable consistent with the requirements specified herein.

Maximum size and weight shall not exceed TABLE I requirements for Surface transport configurations and TABLE II requirements for Air Transport configurations. The packaging container weight shall be included in the total weight of each subsystem UTC.

TABLE I. Maximum weight and dimensions for Surface Configurations.

TRICON Weight 14, 900 pounds.

BICON Weight 25,000 pounds.

20’ Container Weight 25,000 pounds.

TABLE II. Maximum weight and dimensions for Air Configurations.

463L/ISU-90 Weight 10,000 pounds.

3.7 Packaging, Marking and Transportability. The BEAR Water Freeze Protection Modules shall be designed to properly store and ship in ISU-90 containers for air transport OR TRICONS, BICONS and/or 20’ ISO containers for surface transport configurations. Packaging instructions for both container types shall be provided. Specific packaging configuration mode will be identified within delivery order contract terms.

The BEAR Water Freeze Protection Modules shall be air transportable mode on aircraft; or surface mode by truck, trailer, railcar, and ship and all shall be capable of withstanding the mechanical shock, vibration, temperature, humidity, and pressure characteristics of these modes of transportation.

3.7.1 Air Transport Mode. All Unit Type Codes (UTC) shall be configured for air transport in accordance with MIL-STD-1791. Air configured packaging for each Freeze Protection Module will fit 463L Pallet/ISU-90 containers.

ISU-90, NSN 8145-01-512-1201, in accordance with MIL-STD-1791

3.7.2 Surface Transport Mode. The Freeze Protection Modules shall be packed for multimodal transportation. For surface transportation configuration the sub-systems shall be packed in TRICONS, BICONs, or combination of both type containers.

TRICON, Type 5, NSN 8150-01-574-1682, in accordance with MIL-PRF-32402 BICON, Type 2, NSN 8150-01-586-4979, in accordance with MIL-PRF-32410 20’ ISO Container, NSN 8150-01-501-2741, in accordance with A-A 52032B

3.7.3 Preservation, packing and marking. The Freeze Protection Modules interior packages and shipping containers shall be preserved, packed and marked for shipping in accordance with the AFMC Form 158. The shipping containers shall be packed in accordance with the BEAR WSO Packing Plans and shall include watershed shrouding per the AFMC Form 158.

3.8 Maintainability and service life.

3.8.1 Maintainability. The BEAR Freeze Protection Modules shall be designed for maintainability in accordance with 5.9 through 5.9.22.9 of MIL-STD-1472; forces shall not exceed those specified for both males and females while wearing arctic clothing.

The BEAR Freeze Protection Modules shall be designed to use common tools to the maximum extent possible, if special tools are required, they shall be included in the respective subsystem/module components.

3.8.1.1 Preventive maintenance. The recommended routine preventive maintenance interval (PMI) shall be at least 500 operating hours. Preventive maintenance tasks, other than tasks required daily or before operation, shall not require more than 1 man-hours to complete while wearing arctic clothing. This shall be calculated by:

N i i T i

PMMHPMMH

where:

PMMHT is the total preventive maintenance man-hours, i is a multiple of the routine PMI (that is, i=1 for the routine PMI, i=2 for every other routine PMI, etc.), and

PMMHi is the preventive maintenance man-hours at the ith

PMI.

Routine servicing and inspections shall not require hand tools.

3.8.2 Service life. The BEAR Freeze Protection Modules shall be designed for a minimum service life of 10 years without a need for major overhaul or repair. Service life does not apply to wear items such as filters, electric motor brushes, fuses, hoses, cables, etc. The system design shall be suitable for a minimum of 25 years outside storage.

3.9 Human systems integration (HSI). The BEAR Freeze Protection Modules shall be designed in accordance with MIL-STD-1472 for ease of operation, inspection, and maintenance, including the use of arctic mittens.

3.10 Removed.

3.11 Safety.

3.11.1 System safety. The design of the BEAR Freeze Protection Modules shall not contain any system safety mishap risk categories greater than medium as defined in MIL-STD-882.

3.11.2 Hazardous materials. The design shall minimize, and control hazards associated with the inclusion or use of hazardous or toxic materials and the generation of toxic or noxious gases.

The BEAR Freeze Protection Modules shall not generate or use Class I or Class II Ozone Depleting Substances (ODS) during operation, maintenance, or disposal. Class I ODS and hazardous materials shall not be used in any system, component, or process. The BEAR Freeze Protection Modules shall not contain or use either hexavalent chromium or cadmium without written approval by the procuring activity. The Environmental Protection Agency maintains an online list of toxic chemicals and hazardous substances at http://www.epa.gov/emergencies/tools.htm. Class I and Class II ODS are defined in 40CFR82.

http://www.epa.gov/emergencies/tools.htm

3.11.3 Component protection. The BEAR Freeze Protection Modules shall be designed so that all electrical/mechanical output components are enclosed, and access is not required during normal operation. Further, the BEAR Freeze Protection Modules shall be designed to safely permit access to internal components that may be required during troubleshooting for failures or other special needs. All space in which work is performed during operation, service, and maintenance shall be free of hazardous protrusions, sharp edges, or other features which may cause injury to personnel. All rotating and reciprocating parts and all parts subject to high operational temperatures or subject to being electrically energized, that are of such nature or so located as to be hazardous to personnel, shall be guarded or insulated to eliminate the hazard without impairing the function of the parts. All wires, cables, tubes, and hoses shall be supported and protected to minimize chafing and abrasion and shall be located to provide adequate clearance from moving parts and high operational temperatures. Grommets shall be provided wherever wires, cables, tubes, or hoses pass through bulkheads, partitions, or structural members.

3.12 Protective coatings, finish, and corrosion control.

3.12.1 Protective coatings. Materials that deteriorate when exposed to sunlight, weather, or operational conditions normally encountered during the service life of the BEAR Freeze Protection Modules shall not be used or shall have means of protection against such deterioration that does not prevent compliance with the performance requirements specified herein.

The BEAR Freeze Protection Modules shall be constructed of corrosion resistant materials to the maximum extent possible. Surface treatments, pre-treatments and coatings shall be applied to all components that are not corrosion resistant. Surface treatments include electroplated coatings, thermal sprayed coatings, and hard anodize coatings. Surface pre-treatments include thin film anodize, conversion coatings, zinc phosphate, and other coatings used to enhance subsequent corrosion protective coating adhesion and performance. Corrosion protective coatings include corrosion inhibited epoxy primers and polyurethane topcoats. Corrosion protective coatings that chip, crack, or scale with age or extremes of climatic conditions or when exposed to heat shall not be used. Exposed surfaces of fasteners, handles, and fittings shall also be primed and painted.

Commercial items (see 6.3.1) used as components of the BEAR Freeze Protection Modules (but not the BEAR Freeze Protection Modules itself) may be prepared and coated in accordance with the manufacturer's standard practice,…