FA8533-11-R-32637 Amend 0001 Package.pdf

AMENDMENT OF SOLICITATION/MODIFICATION OF CONTRACT 1. CONTRACT ID CODE Page 1

2. AMENDMENT/MODIFICATION NO.

FA8533-11-R-32637-0001

3. EFFECTIVE DATE

27 JAN 2012

4. REQUISITION/PURCHASE REQ. NO. 5. PROJECT NO (If applicable)

6. ISSUED BY CODE

WR ALC GRVKBB, MAJOR PROGRAMS

460 RICHARD RAY BLVD STE 200

BLDG 301 CP 478 222 1902

ROBINS AFB GA 31098-1813

BUYER: Patricia L. Farrell/GRVKBB Lauren.Farrell@robins.af.mil Phone: (478) 222- 1906 Fax: (478) 222-1854 No Collect Calls

7. ADMINISTERED BY (If other than item 6) CODEFA8533

8. NAME AND ADDRESS OF CONTRACTOR (No., street, county, State and ZIP Code)

CODE

X

9A. AMENDMENT OF SOLICITATION NO.

FA853311R32637

9B. DATED (SEE ITEM 11)

13-JAN-2012

10A. MODIFICATION OF CONTRACT/ORDER NO.

10B. DATED (SEE ITEM 13)

11. THIS ITEM ONLY APPLIES TO AMENDMENTS OF SOLICITATIONS

The above numbered solicitation is amended as set forth in item 14. The hour and date specified for receipt of Offers is extended, is not extended. Offers must acknowledge receipt of this amendment prior to the hour and date specified in the solicitation or as amended, by one of the following methods. ( a ) By completing Items 8 and 15, and returning copies of the amendment; ( b ) By acknowledging receipt of this amendment on each copy of the offer submitted; or ( c ) By separate letter or telegram which includes a reference to the solicitation and amendment numbers. FAILURE OF YOUR ACKNOWLEDGMENT TO BE RECEIVED AT THE PLACE DESIGNATED FOR THE RECEIPT OF OFFERS PRIOR TO THE HOUR AND DATE SPECIFIED MAY RESULT IN REJECTION OF YOUR OFFER. If by virtue of this amendment you desire to change an offer already submitted, such change may be made by telegram or letter, provided each telegram or letter makes reference to the solicitation and this amendment, and is received prior to the opening hour and date specified.

12. ACCOUNTING AND APPROPRIATION DATA (If required)

13. THIS APPLIES ONLY TO MODIFICATIONS OF CONTRACTS/ORDERS

IT MODIFIES THE CONTRACT/ORDER NO. AS DESCRIBED IN ITEM 14.

A. THIS CHANGE ORDER IS ISSUED PURSUANT TO: (Specify authority) THE CHANGES SET FORTH IN ITEM 14 ARE MADE IN THE CONTRACT ORDER NO. IN ITEM 10A.

B. THE ABOVE NUMBERED CONTRACT/ORDER IS MODIFIED TO REFLECT THE ADMINISTRATIVE CHANGES (such as changes in paying office, appropriation date, etc.) SET FORTH IN ITEM 14, PURSUANT TO AUTHORITY OF FAR 43.103(b).

C. THIS SUPPLEMENTAL AGREEMENT IS ENTERED INTO PURSUANT TO AUTHORITY OF:

D. OTHER (Specify type of modification and authority)

E. IMPORTANT: Contractor is not, is required to sign this document and return copies to the issuing office.

14. DESCRIPTION OF AMENDMENT/MODIFICATION (Organized by UCF section headings, including solicitation/contract subject matter where feasible.)

ROUTINE

15A. NAME AND TITLE OF SIGNER (Type or print)

15B. CONTRACTOR/OFFEROR

BY ________________________________________________________

(Signature of person authorized to sign)

15C. DATE SIGNED

16A. NAME AND TITLE OF CONTRACTING OFFICER (Type or print)

16B. UNITED STATES OF AMERICA

BY ____________________________________________________

(Signature of Contracting Officer)

16C. DATE SIGNED

FACILITY CODE

NSN 7540-01-152-8070

PREVIOUS EDITION UNUSABLE

30-105 STANDARD FORM 30 (REV. 10-83)

PRESCRIBED BY GSA

FAR (48 CFR) 53.243

X

X X

Except as provided herein, all terms and conditions of the document referenced in Item 9A or 10A, as heretofore changed, remains unchanged and in full force and effect.

Amendment/Modification FA8533-11-R-32637-0001

Continuation of block 14. DESCRIPTION OF AMENDMENT/MODIFICATION

1. The purpose of Amendment 0001 is to incorporate the attached Purchase Description PD10WRGBGBEC13, Revision B, dated 26 January 2012, TRAILER MOUNTED MULTI-AIRCRAFT SERVICING PLATFORM, into RFP FA8533-11-R-32637. Specifically, the PD Revision B serves to delete paragraph 3.8.1.15.1.

2. There are no other changes to the RFP as a result of Amendment 0001.

PD10WRGBGBEC13

Rev B

CAGE 98752

26 January 2012

PURCHASE DESCRIPTION (PD)

TRAILER MOUNTED MULTI-AIRCRAFT SERVICING PLATFORM

Fuels Operational Readiness Capability Equipment (FORCE)

1. SCOPE. This purchase description describes the design and test requirements for the procurement of FORCE multi-aircraft servicing platforms (A/E32R-20).

2 APPLICABLE DOCUMENTS

2.1 General. The documents listed in this section are specified in sections 3, 4, or 5 of this specification. This section does not include documents cited in other sections of this specification 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, 4, or 5 of this specification, whether or not they are listed.

2.2 Government documents.

2.2.1 Specifications, standards, and handbooks. The following specifications, standards, and handbooks of the exact revision listed below form a part of this document to the extent specified herein.

FEDERAL STANDARDS

FED-STD-595C/26173 Gray

COMMERCIAL ITEM DESCRIPTIONS

A-A-393 Extinguisher, Fire, Dry Chemical (Hand Portable) A-A-50696 Reels, Static Discharge, Grounding, 50 and 75 Foot Cable

Lengths A-A-55804A Rods, Ground with attachments

A-A-52464B Coupler, drawbar, ring: light duty, 60,000 lb GVW; offset (taper shank), 60,000 lb GVW; and heavy duty 120,000 lb

GVW

A-A-59326B Coupling Halves, Quick Disconnect, Cam-Locking Type A-A-59377A Coupling Assembly, Quick Disconnect, Sexless Type

DEPARTMENT OF DEFENSE SPECIFICATIONS

INCH POUND

MIL-DTL-5624U Turbine Fuel, Aviation, Grades Jet A-1, JP-4, JP-5, JPTS and JP-5/JP-8 ST

MIL-DTL-83133F Turbine Fuels, Aviation, Kerosene Types, NATO F-34 (JP-8), NATO F-35, and JP-8+100 MIL-H-6615G Hose Assemblies, Rubber, Fuel and Water, with

Reattachable Couplings, Low Temperature MIL-PRF-85285D Coating: Polyurethane, Aircraft and Support Equipment

DEPARTMENT OF DEFENSE STANDARDS

MIL-STD-276A Impregnation of Porous Metal Castings and Powered Metal

Components MIL-STD-461C Requirements for the Control of Electromagnetic

Interference Emissions and Susceptibility MIL-STD-810G Environmental Test Methods and Engineering Guidelines MIL-STD-882D Standard Practice for System Safety MIL-STD-889B Dissimilar Metals

DEPARTMENT OF DEFENSE HANDBOOKS

MIL-HDBK-808 Finish, Protective and Codes for Finishing Schemes for

Ground and Ground Support Equipment MIL-HDBK-1791 Internal Aerial Delivery in Fixed Wing Aircraft

MS 24484 Adapter, Pressure Fuel Servicing, Nominal 2.5 Inch Diameter

(Copies of these documents, except for MIL-HDBK-1791 C-17 Appendix, are available online at http://assistdaps.dla.mil/quicksearch/ or from the Standardization Document Order Desk, 700 Robbins Avenue, Building 4D, Philadelphia, PA 19111-5094. A copy of MIL-HDBK-1791 C-17 Appendix can be obtained from the Procuring Contracting Officer (PCO) or requested by contacting Air Transportability Test Loading Agency (ATTLA) at 937-255-6296.)

LAWS AND REGULATIONS

Code of Federal Regulations (CFR)

Title 49: Transportation

(The CFR is for sale on a subscription basis by the Superintendent of Documents, U.S.

Government Printing Office, Washington, DC 20402.)

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

AMERICAN PETROLEUM INSTITUTE (API)

API/IP STD 1529 Aviation fueling hose

API RP 2003 Protection against ignitions arising out of Static, Lightning, and Stray Currents

API 510 Pressure Vessel Inspection Cod: Maintenance Inspection, Rating, Repair and Alteration-Eight Edition.

API/IP SPEC 1583 Specification and Qualification Procedures for Aviation Fuel Filter Monitors With Absorbent Type Elements

(Copies are available from the American Petroleum Institute, 1220 L Street, NW, Washington DC 20005.)

AMERICAN SOCIETY OF MECHANICAL ENGINEERS (ASME)

ASME Boiler and Pressure Vessel Code

Section IX Welding Qualifications

(Copies are available from the American Society of Mechanical Engineers, United Engineering Center, 345 East 47th Street, New York NY 10017.)

AMERICAN WELDING SOCIETY (AWS)

D1.1/D1.1M:2006 Structural Welding Code–Steel–20th Edition

D1.2/D1.2M:2003 Structural Welding Code–Aluminum–Fourth Edition

(Application for copies should be addressed to American Welding Society, 550 N.W.

LeJeune Road, Miami FL 33126.))

NATIONAL FIRE PROTECTION ASSOCIATION (NFPA)

NFPA 407 Aircraft Fuel Servicing

(Copies are available from the National Fire Protection Association, Batterymarch Park, Quincy MA 02269.)

SOCIETY OF AUTOMOTIVE ENGINEERS (SAE)

SAE J447 Prevention of Corrosion of Motor Vehicle body and Chassis Components

SAE J534 Lubrication Fittings SAE JISO 3411 Human Physical Dimensions

SAE J925 Minimum Service Access Dimensions for Off-Road Machines

SAE ARP 1247 General Requirements for Aerospace Ground Support Equipment Motorized and Nonmotorized

SAE AS 5877 Nozzle, Pressure Fuel Servicing, Locking, Type D-1, D-1R, D-2, and D-2R, Nominal 2-1/2 Inch Diameter

SAE AS 8090 Equipment, Towed Aerospace Ground, Mobility

(Copies are available from the Society of Automotive Engineers, 400 Commonwealth Dr.

Warrendale PA 15096.)

Kovatch Corp.

A/S 32 R-11 Fuel Servicing Truck

(Application for additional information should be addressed to Kovatch Corp, One Industrial Complex, Nesquehoning, PA 18240-1499)

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.

3. REQUIREMENTS

3.1 First article. When specified (see 6.2), a sample shall be subjected to first article inspection in accordance with 4.2.

3.2 Servicing platform description. FORCE multi-aircraft servicing platforms are used to interface between one or two receiver aircraft, and FORCE pumping and filtration modules in a bare base deployed environment. The servicing platform shall be trailer mounted and shall control fuel pressure, provide positive flow control, and meter fuel during aircraft refueling. Outside sources will provide the needed pressure to power the servicing platform operations.

3.3 Materials. All components and all materials shall be selected based on the defined purpose for the specified service life at the environmental extremes stated herein.

Materials shall be qualified under the applicable specification. Proprietary materials or processes shall not be used. Components shall not be used outside their published ratings. All components and materials that normally come into contact with the fuel during operation (including gaskets, fittings, valves, adhesives) shall not degrade or be affected by fuel. The servicing platform shall be fabricated from strong, durable and lightweight materials to the maximum extent possible to reduce overall unit weight. The servicing platform shall be fabricated from compatible materials, inherently corrosion-resistant or treated to provide protection against the various forms of corrosion and deterioration that may be encountered.

3.3.1 Prohibited materials. Magnesium alloys, wood products, polyvinyl chloride (with the exception of wiring harness), polyester, room temperature vulcanizing (yielding acetic acid), or asbestos shall not be used in any component or assembly of this servicing platform.

3.3.2 Metals. All metallic non-aluminum fuel-handling components shall be corrosion resistant and fuel resistant. All aluminum fuel-handling components shall be anodized or chemically conversion coated without deleterious effects on the function, performance, or availability of these components. Copper-based materials shall not come in direct contact with fuel, except when approved by program management office. Dissimilar metals shall not be used in intimate contact with each other unless protected against galvanic corrosion. Dissimilar metals and means of protection are defined in MIL-STD-889.

3.3.3 Impregnation of castings. All aluminum castings shall be impregnated in accordance with MIL-STD-276 or 100% hydrostatically tested.

3.3.4 Dissimilar metals. Dissimilar metals, as defined in MIL-STD-889, shall not be in contact with each other. Metal plating or metal spraying of dissimilar base metals to provide electromotively compatible abutting surfaces is acceptable. The use of dissimilar metals separated by suitable insulating material is permitted, except in systems where bridging of insulation materials by an electrically conductive fluid can occur. Sealants or gel type gasket materials shall be used between faying surfaces and butt joints.

3.3.5 Elastomers. Elastomeric materials used shall be compatible with fuels conforming to ASTM D910, CID A-A-52557, MIL-PRF-5624, ASTM-D-1655, and MIL-DTL- 83133.

3.3.6 Protective treatment. Materials used in the construction of the servicing platform trailer assembly shall be protected against deterioration due to climatic or environmental conditions likely to occur during service usage. However, that protection shall not prevent compliance with the performance requirements of this specification. The manufacturer shall not use any protective coating that will crack, chip, or scale with use, age, or extremes of climatic and environmental conditions. Guidance is provided in

MIL-HDBK-808.

3.4 Recycled materials. Recovered materials shall be used for fabrication of this aircraft servicing platform to the maximum extent practicable without affecting the intended use.

Used or rebuilt parts shall not be defined as recovered materials.

3.5 Design. The servicing platform shall conform to all Federal laws and regulations applicable for this type equipment in effect on date of issue of solicitation and meet the requirements of National Fire Protection Association (NFPA) 407, except for providing interlocks between trailer brakes and nozzle storage, and the design requirements of SAE ARP 1247. The servicing platform shall be designed according to the following:

a. All components may be readily removed, serviced, and operated wearing Mission Oriented Protective Posture (MOPP) level IV gear or arctic-weather gloves.

b. Rapid installation, maintenance, and repair of equipment.

c. The servicing platform shall be trailer mounted.

d. Servicing platform and trailer shall not exceed 106 inches in width, 108 inches in height, 176 inches in length, and 4,500 lbs.

e. Shall have a combined fueling capability of 900 GPM through two 2½-inch, 60-ft API/IP STD 1529 Type C, Grade 2 semi-collapsible servicing hoses (450 GPM through each hose).

f. When using only one servicing hose, the maximum flow rate shall be controlled to 600 GPM with universal nozzle pressure not to exceed 50 ± 5 psig.

g. Shall be equipped with two sections of 120-foot, 3-inch collapsible hose to be used during wide-body aircraft cold refueling operations. The hose shall be stored on reels, which shall be attached to the servicing platform.

h. Pressures at the single-point nozzles shall not exceed 50 ± 5 psig.

i. Parts shall not work loose while in service and shall be inherently capable of withstanding the stresses, jars, vibrations, and other conditions incident to shipping, storage, installation, and service.

j. Prohibit parts extending past the frame of the trailer in order to prevent accidental damage.

k. Pins, brackets, collars, dust covers, dust plugs, and components that are detachable in normal operation shall be attached to the assembly by wire lanyards, or chains, to prevent loss. “Dog tag” style beaded chains shall not be provided.

3.5.1 Controls. The range of control positions of any device shall not obstruct the range of control positions of another device.

3.5.2 Servicing provisions. Special tools shall not be required to access drains, lubrication, or service checkpoints. The design shall minimize the number of parts to be dissembled and reassembled and to minimize the different types of hand tools required for maintenance.

3.5.3 Fool-proofing. Components shall be designed, by shape or by mounting pattern, to prevent improper installation.

3.5.4 Foreign object damage (FOD). Any metal cap, plug, pin, or plate that must be removed for inspection, service, or operation shall be retained by wire rope lanyard or chain to prevent it from becoming separated from the aircraft-servicing platform. “Dog tag” style beaded chains shall not be provided.

3.5.5 Bonding. All metal components shall be bonded in accordance with the guidelines of API RP 2003. A braid, with less than 10 ohms resistance, shall be attached to all system drains as a bonding point for the drain bucket.

3.5.6 Prevention of static electricity. Nonmetallic components shall be certified to a resistance of 10 ohms or less to ground.

3.5.7 Lubrication. Lubrication fittings shall conform to SAE J534. Grease seals shall include pressure relief devices to prevent damage. Extended lubrication fittings may be used to overcome accessibility problems. A lubrication data plate shall identify all lubrication fittings on the servicing platform, with the type and grade of lubricant required for all operational temperatures.

3.5.8 Threaded fasteners. Threaded fasteners shall include prevention for the loss of torque, while allowing for disassembly. Internal threads of aluminum components shall withstand not less than 20 fastener installation cycles to required torque. Adhesive-backed wiring supports shall not be used. The use of studs shall be minimized to prevent stripping of holes, except in low-pressure areas where bolt and nut arrangement cannot be readily applied. No less than three threads shall protrude from each nut fastener. Where studs are used, a suitable thread-locking agent shall be applied to prevent loosening. In high-pressure areas such as the discharge flange, studs are prohibited; bolts and nuts shall be used.

3.5.8.1 Permanent fasteners. Permanently fastened, overlapping surfaces shall be sealed.

Rivet selection shall be for a maximum joint strength. Rivet heading shall be consistent with published data for a matching application.

3.6 Welders and welding. All welders shall be certified to weld in accordance with AWS D1.1 and AWS D1.2. The contractor shall make available to the Government certifications for all welders being utilized on the servicing platform. Welding procedures and all welding on the servicing platform shall be in accordance with AWS D1.1 and AWS D1.2. The surface parts to be welded shall be free from rust, scale, paint, grease, and other foreign matter. Welds shall be of sufficient size and shape to develop the full strength of the welded parts. Welds shall transmit stress without cracking or permanent distortion when the parts connected by the welds are subjected to test, proof, and service loadings. Monitor vessels shall be welded in accordance with the ASME Boiler and Pressure Vessel Code.

3.7 Air transportability. The servicing platform shall be transportable on C-130, C-17 and C-5 aircraft. Design criteria can be found in MIL-HDBK-1791. In all air transport configurations, the servicing platform shall be capable of being restrained and withstanding, without loss of serviceability, 2.0 G up and 4.5 G down accelerations, and shall be capable of being restrained and withstanding, without loss of structural integrity,

3.0 G forward, 1.5 G aft, and 1.5 G lateral accelerations. The servicing platform shall be equipped with pressure relief devices or configured for air transport to prevent any part from becoming a projectile in the event of catastrophic loss of aircraft cabin pressure.

The servicing platform shall roll on and off the aircraft, negotiating the required maximum ramp angles without shoring.

3.7.1 Tie downs. The servicing platform shall be symmetrically restrained during air and ground transport. Tie down points shall be rated at a minimum of 25,000 pounds, marked for capacity, with a clear opening compatible with MIL-DTL-25959 and MIL-PRF-7260 tie down devices. Each end of each tie down device shall terminate at a tie down point and not pass through any other tie down point. There shall be no interference between tie down devices and the servicing platform. The axles may be used as tie down points;

however, no more than 50 percent of the restraint in any direction may be provided by the axles.

3.8 Construction.

3.8.1 Components.

3.8.1.1 Trailer. The servicing platform shall be mounted on a trailer. This trailer shall meet the requirements for SAE AS 8090, Type II, Group C trailers and the design requirements of SAE ARP 1247. Trailers shall have a suspension of torsion bar, leaf, or coil spring design, have a drawbar lunette coupler conforming to Commercial Item Description (CID) A-A-52464, Type II and shall include safety chains. The trailer shall have a minimum capacity of the weight of all installed components plus a factor of safety of 2 to 1 and shall be mounted on four wheels, two front and two rear, with pneumatic tires. The trailer shall be able to be towed by flight-line towing vehicles and a pintle hook shall be installed on the rear frame to allow additional units to be towed in tandem.

Provisions shall be included to allow the unit to be moved by forklift. Forklift tine openings shall be a minimum of 3 inches high and 10 inches wide. Parking brakes shall be furnished, shall apply to at least two wheels, and shall be capable of holding the servicing platform on a 20° slope. The servicing platform shall be designed and constructed in such a manner as to prevent any parts from overhanging the trailer frame.

3.8.1.2 Fire extinguisher. Two Type I, Class 2, Size 20 fire extinguishers shall be installed on the trailer, as specified in CID A-A-393. The extinguishers shall be accessible while standing on the ground and shall be protected from tire splash.

3.8.1.3 Major components. Major components include:

a. Six-inch female 4-ear camlock inlet with dust cap (CID A-A-59326). The inlet shall be provided with suitable valving for hose air elimination during initial charging of a fuel servicing circuit.

b. Two (2) 60ft hose assemblies consisting of API/IP STD 1529 Type C, Grade 2, 2 1/2 inch semi collapsible aircraft servicing hoses with a universal single point nozzle. The universal single point nozzle shall provide the capability of SAE AS 5877, D1 and D2 single point nozzles, within one nozzle configuration.

c. Two (2) hose assemblies consisting of 120 feet of MIL-H-6615, Type I, 3 inch collapsible hose.

d. Two 600 GPM rate of flow hydraulically operated control valves (3.8.1.15).

e. One 1000 GPM rate of flow hydraulically operated control valves.

f. Two flow meters (3.8.1.10).

g. Two surge suppressor(s) (3.8.1.16).

h. Two sampling connections (3.8.1.6).

i. Coupling with 100 mesh nozzle strainer.

j. Remote controls (3.8.1.9).

k. Two electrically powered (with manual back-up) low-profile hose reels (3.8.1.8).

l. 1000 GPM micronic filter (3.8.1.20).

m. Hose Evacuation Assembly (3.8.1.24).

n. Ball Valves

o. Two ground reels (3.8.1.5)

p. One sampling connection located downstream of the micronic filter (3.8.1.6).

NOTE: These components are mounted on an air-transportable, mobile trailer chassis.

Two 150-ft. static discharge ground reels are mounted on the frame of the chassis. Any design that renders the operation of the servicing platform as unduly difficult under field conditions is not acceptable. The servicing platform shall not exceed the listed maximum dimensions and weight requirements of paragraph 3.5d.

3.8.1.4 Hoses and fittings. The servicing platform shall be provided with two 2½ -inch 60-ft. API/IP STD 1529 Type C, Grade 2 semi collapsible servicing hoses connected to universal single point nozzles. Each servicing platform shall also be equipped with two 140-foot, MIL-H-6615, Type I, 3- inch collapsible hoses to be used for cold refueling wide body aircraft.

3.8.1.5 Static ground reels. Each servicing platform shall be provided with two, manually retracted, static grounding reels identical, except for capacity to those installed on the current (2004) model R12 as manufactured by Beta Systems. Two reels shall be installed side-by-side on the servicing platform. The reels shall have 150-ft. cables that are insulated with a corrosive resistant coating. Each reel shall have a welder-style grip clamp and a grounding plug. Reels shall be mounted vertically. Reels may also be mounted inverted. Resistance between reel base and the servicing platform frame shall not exceed 10 ohms.

3.8.1.6 Sampling connections. One sampling connection shall be provided downstream of the micronic filter. The sampling connection shall be located to provide adequate space for the connection of an in-line sampler such as the Millipore Corporation (Bedford MA, 01730) fluid sampling kit, Gammon Model GTP-1110 or equivalent for solids and water samples. The sampling device shall consist of the necessary corrosion-resistant piping, a one-quarter-turn ball valve, and a Snap Tite Inc., part number SVEAC4-4F (JF) quick disconnect or equivalent, with a Snap Tite Inc, part number AMPE-4 dry break coupler or equivalent, with a dust plug, for connection to the sampling kit.

3.8.1.7 Electrical components. All electrical components shall meet provisions of Class I, Division 2 locations as defined by the National Electrical Code.

3.8.1.8 Hose reels. The servicing platform shall be equipped with two electrically-powered/electrically conductive hose reels (with manual backup) capable of retracting 60 working feet (from the hose roller guide to the end of the nozzle) of 2½ inch non-collapsible servicing hose. The hose reels shall be designed as follows:

a. The hose rewind mechanisms must be properly geared, designed, and constructed to fully rewind the entire length of the 2½-inch servicing hoses (outside diameter plus wear or scuff protectors) while full of fuel.

b. The hose reels shall include a clutch-released drag brake that is adjustable from zero to 50 pounds of force to deploy the hose.

c. The hose reels shall include a manual rewind, with a removable crank handle that securely stores on the trailer assembly. The manual rewind system shall be geared for mechanical leverage, and shall be designed and constructed to fully rewind the entire length of the 2½-inch servicing hoses without undue effort from the operator.

d. The hose reel shall be electrically powered and capable of retracting a fully deployed, fuel-filled hose over a paved surface in not more than 60 seconds, against a 15-pound force drag brake setting.

e. The rewind control shall be placed so the operator can guide the hose with one hand while operating the control with the other. Serviceable rollers shall guide the hose during deployment or rewind.

f. The hose assemblies shall consist of 60 feet as API/IP STD 1529, Edition 5, Grade 2, Type C hose (see 3.8.1.4), including; non-reattachable corrosion-resistant metal couplings, as specified in API/IP STD 1529, Section 7; and a dry break coupling compatible with the SAE AS 5877 nozzle(s). Each servicing platform shall include two universal single point nozzles, which meet the requirements of SAE AS 5877 D-1 and D-2 single point nozzles in a single configuration and which shall be attached to the hoses with dry break adapters (see 3.8.1.4). The nozzles shall include a 40 mesh stainless steel strainer and an automatic vacuum breaker.

3.8.1.9 Remote controls. The servicing platform shall be provided with a remote control system. The control system includes deadman and emergency stop controls. It shall work in concert with other servicing platforms and the FORCE pump unit, PD10WRGBGBEC12, using wired communication links between the units. The system shall be configured with a manual override capability to bypass the remote control system. The controls shall be operable while wearing MOPP IV gloves or arctic mittens.

3.8.1.9.1 Remote control panel (RCP). Each servicing platform shall be provided with a remote control panel (RCP) that is shaded from the sunlight. Each RCP shall be rated NEMA 4X. The panel door shall have a viewing window, which allows the operator to see the position of the unit designator switches without opening the panel door. The RCP shall be equipped with a receiving unit that shall receive commands from the Hand-held Control Units (HCU) at a range of at least 200 feet. Communications between the servicing platforms and the FORCE pumping units are required at a minimum distance of 1,500 feet. Communications from each RCP to the FORCE pumping units shall be accomplished via a wired communications link. Control of the two local control valves shall be determined by logic resident in the Programmable Logic Controller (PLC). In addition, the servicing platform shall be equipped with a mushroom-type emergency stop switch located on the RCP. When the emergency stop system is activated, it shall adjust all FORCE pump units in the FORCE dispensing system from any engine throttle position to STOP. Upon activation, the emergency stop system must be reset on the RCP for each FORCE pump unit in the system to function again. The RCP shall incorporate a status light mounted on top of the panel such that the light is visible from at least 200 feet. The light shall provide information such as emergency stop activation, loss of communication, selected other malfunctions, and/or operating parameters, as practical, to an operator using the remote control. In addition, a light on the RCP shall illuminate when the emergency stop command is activated anywhere in the system.

3.8.1.9.2 Remote control panel communications. The wired communications link used in each RCP shall be on a “control by exception” basis to limit the drain on the batteries and to reduce control response time. Transmission from any RCP shall be received by all

FORCE pump units in the system layout. This shall provide an emergency stop signal from any RCP to stop all FORCE pump units in the system.

3.8.1.9.3 Hand-held control unit (HCU). The RCP shall be equipped with three hand-held control units (HCU). The HCUs shall be capable of communicating with the RCP using both wired and radio frequency (RF) communications links. Choice of the mode of communication (wired or RF) shall be at the discretion of the operator. The RF communications link shall be of the spread spectrum, frequency hopping type using the

2.4 GHz frequency band. The HCUs shall be powered by either rechargeable batteries or long-life lithium batteries. If rechargeable batteries are used, a maximum of two HCUs shall be in use while the other one is charging in its respective charging station in the RCP. Three charging stations shall be available in each RCP. Each HCU shall be able to communicate with its associated RCP up to a distance of 200 feet. Each HCU shall be ergonomically designed and equipped with a red emergency stop button, a control valve selector switch with “Control Valve 1.” “Control Valve 2,” and “Both Control Valves” positions, and a “deadman” switch. The status of these items shall be transmitted to a receiving unit in the RCP. When the deadman switch is activated, it shall open the Servicing Platform control valve for the servicing hose it is programmed to operate. The deadman control shall incorporate a continuous operator input feature requiring the operator to momentarily release the deadman every two minutes. The HCU shall have a light that illuminates when the deadman is activated and blinks a warning 105 seconds after activation. When the emergency stop system is activated, it shall adjust all FORCE pump units in the FORCE dispensing system from any engine throttle position to STOP.

All functions shall occur within two seconds after depressed.

3.8.1.9.4 Remote control panel programmable logic controller (PLC). A programmable logic controller (PLC) shall be located in each RCP. The PLC shall be programmed to input emergency stop, control valve selection, and deadman position signals from the HCU along with local inputs. The PLC shall be programmed to control local devices, including two control valves and local status lights. The PLC shall also be programmed to communicate with the FORCE Pump Units to verify communication via periodic communications with the FORCE pump units. The PLC Input/Output (I/O) shall be initially sized to meet system requirements plus 50% spare inputs and outputs. The PLC shall be designed for expansion to allow the system to grow beyond initial design specifications. The PLC shall have removable terminals to allow for replacement of processor and I/O modules.

3.8.1.9.5 Remote control panel batteries. There shall be two rechargeable batteries located in each RCP. Each battery shall be capable of delivering power to operate the RCP for a minimum of 12 hours. A charging circuit shall be included for each battery, which shall allow the batteries to receive charging current from a fluid-driven generator or solar panel. A battery detection circuit shall indicate low battery condition for each battery via a front panel NEMA 4X guarded indicator light. A battery disconnection switch shall be made available to disconnect power when the RCP is not in use. The battery shall be an available battery in the DOD supply system.

3.8.1.10 Meters. The meters shall be bi-rotor, positive-displacement type with a display capable of displaying totalized flow and a rate of flow indicator in gallons per minute (GPM). The meters shall be interchangeable with the Kovatch (Commercial and Government Entity (CAGE) 59556) A/S 32 R-11 produced after 2004. The meters shall be located downstream of the surge suppressor on the servicing platform supporting each 60-ft. aircraft servicing hose. The meters shall be certified to be accurate within ± 0.1% for fuel flows between 80 and 900 GPM. The meters shall incorporate a display capable of displaying totalized flow and a rate of flow in gallons per minute. The meters shall also have a resetable and non-resetable totalizer. The resetable totalizer shall have an operator input feature (knob, button, or other such device) for resetting the counters to zero. The meters shall be readable from a 15-foot distance, day or night. The meters shall be compatible with current fuels Automatic Data Collection (ADC) equipment. If digital output meters are used, they shall be equipped with a pulse output card. The Syn- Tech Fuel Master 2525 Automated Data Collection/Fuel Dispensing System (ADC/FDS) P/N 002A0100 or equivalent is required.

3.8.1.11 Battery. The battery shall be maintenance free, sealed lead acid, starved electrolyte, gas recombination design or equivalent. The batteries shall have sufficient capacity at -25o F to provide a minimum of two starts.

3.8.1.12 Battery box. The battery box shall be fabricated from non-corrosive material such as polyvinyl or stainless steel with a hinged cover and latches for holding it in a closed position, and it shall include provisions for holding the cover in the open position.

The cover shall permit the enclosure to breathe. The batteries shall be rigidly retained in the container. Electrolyte checking and filling and battery removal and replacement shall be easily accomplished with the cover in the open position. There shall be a minimum of ¼ inch clearance between the uppermost extremity of the battery and the cover to prevent arcing and a minimum one-inch clearance between the battery terminals and the container sides to facilitate removal. Provisions shall be furnished for catching and discharging spilled electrolyte.

3.8.1.13 Fluid motor generator. The servicing platform shall have a fluid motor-driven alternator/generator electrical battery charging system that operates 900 GPM flow through the platform. The fluid motor generator shall not create more than a 10 psig pressure drop across the generator. The fluid motor generator shall be integrated with a solar-powered battery charger that shall charge the battery during extended non-operational periods.

3.8.1.14 Voltage regulator. The servicing platform shall have a voltage regulator that controls electrical flow from the fluid motor driven alternator/generator to the battery to prevent overcharging the battery.

3.8.1.15 Pressure control valves. The servicing platform shall incorporate three hydraulically-operated diaphragm control valves with positive indicators. Two shall regulate pressure through the servicing hoses to either 50 ± 5 psig (high pressure) or 30 ± 5 psig (low pressure) at the nozzle. Each control valve shall have a pressure selector switch to allow an operator to select the desired nozzle pressure for each individual servicing hose. If necessary, there shall be a third control valve to control the rate of flow through the micronic filter to a maximum of 1000 GPM.

3.8.1.16 Surge suppressors. The servicing platform shall include two air-filled surge suppressors to control hydraulic shock. Each surge suppressor shall not exceed a 10-gallon capacity, and shall be diaphragm- or piston-operated type. The surge pressure control system shall function for steady state operating pressures of 50±5 psi or 30±5 psi at the discharge nozzle. The pressure control system shall limit the pressure surge at the aircraft to a maximum of 120 psi at the discharge nozzle with a 2 second aircraft valve closure speed. For the following length and diameter hoses, the pressure control system shall bleed off or recover to 25 psi within the specified time limits after release of the deadman control.

a. 60’ X 2 ½” hose: 10 seconds (desired), 30 seconds maximum.

b. 120’ X 3” hose: 30 seconds (desired), 90 seconds maximum.

3.8.1.17 Pressure regulating control pilots. The pressure-regulating control pilots shall regulate delivery pressure at the servicing hose nozzles to 50 ± 5 psig or 30 ± 5 psig as selected by the operator. The control pressure shall be capable of being reset manually by adjusting the spring tension of the control pilot.

3.8.1.18 Surge pressure pilots. The surge suppressors shall act in conjunction with the pressure regulating valves to reduce pressure surge.

3.8.1.19 Ground rod. CID A-A-55804A, type II, class B, 8-foot ground rod with a 6-foot cable shall be provided. The ground terminal shall be bolted to the base, forming an electrical continuity with a maximum resistance of 10 ohm. Provisions shall be incorporated for storing and retaining the ground rod with attached cable.

3.8.1.20 Micronic filter. Each servicing platform shall be equipped with a 1,000-GPM micronic filter.

3.8.1.21 Low point drain. To facilitate removal of all fuel from the plumbing, a 2-inch male camlock fitting shall be provided, at the lowest point, allowing an air operated diaphragm pump to be connected. The low point drain shall include a 2-inch spring-loaded ball valve that maintains the valve in the normally closed position.

3.8.1.22 Differential pressure gauge. A Gammon Technical Products GTP-534PBPH- 30A0 differential pressure gauge, or equivalent, meeting the requirements of API 1583 shall monitor the pressure drop across the filtration media during operation, register, and hold the highest pressure drop achieved during operation.

3.8.1.23 Additive injection connections. A total of eight quick-disconnect connections shall be provided for connecting additive supply lines. The connections (4 per side) shall be located downstream of each meter. Each additive’s quick-disconnect connections shall be located to provide adequate space for the connection of an additive supply line.

Each connection shall consist of the following

a. Corrosion-resistant piping

b. One-quarter-turn ball valve

c. A Snap Tite Inc, part number SVEAC4-4F (JF) quick disconnect or equivalent, with a Snap Tite Inc, part number AMPE-4 dry break coupler or equivalent, with a dust plug, for connection to the additive supply lines.

3.8.1.24 Hose evacuation and expansion/return tank assembly. The servicing platform shall incorporate a hose evacuation and expansion/return tank of sufficient size to evacuate all the fuel from the servicing hoses (to include 2 X 120-foot, 3-inch hose extensions) , capacity to allow for thermal expansion and relief, and the capability to return fuel collected to system during refueling operations. The assembly shall be installed on the servicing platform in a bypass loop configuration so as not to impact the primary flow of fuel across the servicing platform.

3.8.1.24.1 Tank and tank assembly. The tank shall have a 100-gallon capacity, and satisfy ASME Boiler/Pressure Vessel Code, Section IX. The tank assembly shall include all necessary piping, isolation valves (ball valves), and check valves allowing fuel pressure created by thermal expansion during non-operational periods to be collected in the tank assembly to prevent leaks and collect fuel from hose evacuation operations. The tank assembly shall incorporate a feature to return the tank contents back into the fuel flow during the next aircraft servicing operation. The tank assembly shall have a 2-inch male camlock fitting at the lowest point to allow for draining or the connection of an air operated diaphragm pump. The low-point drain shall include a 2-inch spring-loaded ball valve that maintains the valve in the normally closed position. The tank shall be equipped with a calibrated, easily visible from the operator’s panel position, sight gage for determining tank level quantities, a high level shutoff device with visual indicator and audible alarm at 75% capacity, and a pressure-vacuum vent. The high level device shall be installed on the inlet side of the tank; the low level device shall be installed on the discharge side of the tank.

3.8.1.24.2 Defuel evacuation assembly. The evacuation assembly shall consist of a 1/3 to 1/2 hp electric motor powered by the servicing platform electrical/battery system, and a positive displacement pump rated at 10 GPM. The motor and appurtenances shall satisfy the hazardous classification rating for the overall servicing platform. The evacuation assembly shall include all necessary piping, isolation valves (ball valves), check valves, and components to allow fuel to be evacuated from the servicing platform refueling hoses and transferred to the collection tank.

3.8.1.24.3 Return assembly. The return assembly shall consist of a siphon venturi (eductor) that shall draw fuel from the collection tank back into the system during refueling operations as required and re-introduce the fuel to the servicing platform up stream of the fuel quality monitor. This eductor shall be sized to allow the capacity of the collection tank to be re-introduced back to the system at a rate of not less than 10 GPM.

3.9 Reliability and maintainability.

3.9.1 Reliability. The servicing platform shall have a Mean Time Between Failures (MTBF) not less than 1500 hours at an 80% confidence level. The servicing platform shall have a reliability of not less than 0.9933 for a one-hour mission at an 80% confidence level. Guidance is provided in PD10WRGBGBEC11, Appendix A.

3.9.2 Maintainability. Maintainability shall be a consideration in the design of the servicing platform. Except for daily operational inspections, maintenance shall be performed by trained mechanics. Maintainability shall be a measure of the time required to accomplish defined tasks. The maintainability design objective shall include the following:

a. Service access clearances while wearing MOPP IV gear, arctic gloves and clothing, as specified in SAE J925.

b. No requirement to disconnect or remove components to gain access to other components.

c. A one-task time limit of eight hours for any item in the fueling system, such as an element change, or valve change.

d. A 15-minute time limit for one person to perform all daily inspection and service tasks, including, but not limited to; inspection for leaks.

3.10 Performance characteristics.

3.10.1 Environmental requirements.

3.10.1.1 Storage temperatures. The servicing platform shall not be damaged by storage in ambient temperatures ranging from -60° to +160°F for not less than 50 hours (4.5.8.1 and 4.5.8.2)

3.10.1.2 Operating temperatures. The servicing platform shall be capable of performing as specified herein in ambient temperatures between -40° and +140°F for not less than 50 hours (4.5.8.1 and 4.5.8.2).

3.10.1.3 Humidity. Operation or storage in any relative humidity up to and including 100% shall not damage the servicing platform including conditions where condensation takes place in the form of water and frost (4.5.8.3).

3.10.1.4 Sand and dust. The servicing platform shall not be damaged by operation or storage in atmospheres containing sand and dust particles as encountered in desert areas (4.5.8.4).

3.10.1.5 Rain. The servicing platform shall not be damaged by operation or storage in rainfall as encountered in any locale. The servicing platform shall not have areas that would trap and retain water from rainfalls (4.5.8.5).

3.10.1.6 Fungus. The servicing platform shall not be damaged by exposure to moist fungus growth such as encountered in tropical and subtropical climates (4.5.8.6).

3.10.1.7 Salt-fog. The servicing platform shall not be damaged by operation or storage in atmospheres containing salt-laden moisture such as encountered near bodies of salt water and in transportation on shipboard (4.5.8.7).

3.10.2 Hydrostatic pressure. The servicing platform shall be capable of meeting a hydrostatic pressure of 225 psig (4.5.3).

3.10.3 Mobility. The servicing platform shall be designed and constructed as a full trailer, with wheels and supported by its own suspension system and shall be capable of being towed at 35 mph over paved highways, 10 mph over gravel roads and sand, as specified in SAE AS 8090, type III, Group C, and 5 to 6 mph (not to exceed 8 mph) over rough terrain.

3.10.4 Flow. The servicing platform shall be capable of issuing fuel simultaneously through both 2½ inch API/IP STD 1529 servicing hoses at a combined flow rate of 900 GPM (450 GPM each) with individual nozzle pressures not to exceed 50 ± 5 psig. When using only one servicing hose, the flow rate shall be controlled to 600 GPM with nozzle pressure not to exceed 50 ± 5 psig.

3.10.5 Electromagnetic interference. The servicing platform shall be in accordance with the electromagnetic interference (EMI) requirements of MIL-STD-461E for Air Force ground equipment (4.5.5).

3.11 Human factors engineering. All system operations, servicing, and maintenance functions shall be configured to be accomplished by a range of personnel from a 5th percentile female to a 95th percentile male in accordance with human engineering design criteria of SAE JISO 3411.

3.12 Safety. A system safety program that complies with the requirements of MIL-STD- 882 shall be established. A System Safety Analysis (SSA) shall establish the risk levels associated with the fueling systems. A Subsystem Hazard Analysis (SSHA) shall include, in industry terms, a Failure Mode Effects and Criticality Analysis (FMECA).

The SSHA shall include pumping, controls systems, and include methods for controlling any identified hazard.

3.12.1 Safety considerations. The servicing platform shall not have exposed surfaces that exceed 750°F.

3.12.2 Inadvertent ignition. System shall be designed to preclude inadvertent ignition and to perform effectively, during or after exposure to the operational electromagnetic environment and while operating electronic controls in a fueling environment.

Equipment shall be intrinsically safe.

3.13 Diagrams. Schematic diagrams of the electrical and controls systems shall be provided. Each switch/component on the diagram shall be properly identified to correspond to the markings on like parts on the servicing platform.

3.14 Protective coatings. Materials that deteriorate when exposed to sunlight, weather, or operational conditions normally encountered during the service life of the item shall not be used or shall have means of protection against such deterioration that does not prevent compliance with the performance requirements specified herein. Protective coatings that chip, crack, or scale with age or extremes of climatic conditions or when exposed to heat shall not be used. Fasteners, handles, and fittings used in the assembly of the item shall also be primed and painted.

3.14.1 Surface preparation and pretreatment. Surface preparation and pretreatment shall be in accordance with the respective primer and topcoat specifications. Structures shall be cleaned and degreased and scuffed or blasted prior to priming; primer shall be applied before any oxidation or rusting occurs. Aluminum surfaces shall have MIL-DTL-81706, Type II, Class 1A, and MIL-DTL-5541, Type II, Class 1A, chemical conversion coating applied in accordance with the manufacturer’s directions prior to priming.

3.14.2 Primer. Raw metal edges, to include fastener and drain holes, shall be coated with primer before applying topcoat.

3.14.2.1 Ferrous surfaces. Ferrous structures and surfaces shall be primed with a water reducible zinc rich primer in accordance with MIL-PRF-26915, Type II, Class B; this shall be followed, within four hours, by a coat of MIL-DTL-0053030 intermediate primer in a wet-to-wet primer application. This two part primer system shall yield a dry-film thickness of 2.0-2.5 mils for the zinc primer and 0.9 to 1.1 mils for the intermediate primer. The two-primer system shall be allowed to dry and fully cure in accordance with the primer manufacturer's directions prior to top coating.

3.14.2.2 Aluminum and mixed aluminum and ferrous surfaces. Aluminum and mixed aluminum and ferrous structures and surfaces shall be primed with an epoxy primer, Type II, Class N of MIL-PRF-23377. This single part primer system shall yield a dry-film thickness of 0.6 to 0.8 mils.

3.14.2.3 Topcoat. Topcoat shall be polyurethane in accordance with Type I, Class H of MIL-PRF-85285. Neither Chemical Agent Resistant Coating (CARC) nor powder coating shall be used. Topcoat shall be applied to a dry film thickness of 1.6 to 2.4 mils in all instances, regardless of the primer system utilized.