N00167-16-R-0011_Incinerator_Released.pdf

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RATING PAGE OF PAGES

7. ISSUED BY

(Date)

IMPORTANT - Award will be made on this Form, or on Standard Form 26, or by other authorized official written notice.

Previous Edition is Unusable 33-134 STANDARD FORM 33 (REV. 9-97)

Prescribed by GSA

FAR (48 CFR) 53.214(c)

DO-C9 1 64

(If other than Item 7)

15A. NAME 16. NAME AND TITLE OF PERSON AUTHORIZED TO

AND

ADDRESS

SIGN OFFER (Type or print)

OF

OFFEROR

AMENDMENT NO. DATE

15B. TELEPHONE NO (Include area code) 17. SIGNATURE15C. CHECK IF REMITTANCE ADDRESS

IS DIFFERENT FROM ABOVE - ENTER

SUCH ADDRESS IN SCHEDULE.

18. OFFER DATE

1. THIS CONTRACT IS A RATED ORDER

UNDER DPAS (15 CFR 700)

2. CONTRACT NO.

N00167 8. ADDRESS OFFER TO

See Item 7

9. Sealed offers in original and 3 copies for furnishing the supplies or services in the Schedule will be received at the place specified in Item 8, or if handcarried, in the depository located in

CAUTION - LATE Submissions, Modifications, and Withdrawals: See Section L, Provision No. 52.214-7 or 52.215-1. All offers are subject to all terms and conditions contained in this solicitation.

10. FOR INFORMATION

CALL:

A. NAME (NO COLLECT CALLS)

EGBERT GOODMAN 301-227-1224

11. TABLE OF CONTENTS

SOLICITATION/ CONTRACT FORM

SUPPLIES OR SERVICES AND PRICES/ COSTS

2 - 4

X I CONTRACT CLAUSES

DESCRIPTION/ SPECS./ WORK STATEMENT X

PACKAGING AND MARKING

5 - 27

J LIST OF ATTACHMENTS

INSPECTION AND ACCEPTANCE

DELIVERIES OR PERFORMANCE

30 - 33 K

REPRESENTATIONS, CERTIFICATIONS AND

OTHER STATEMENTS OF OFFERORS

CONTRACT ADMINISTRATION DATA 34 - 37 X

SPECIAL CONTRACT REQUIREMENTS

OFFER (Must be fully completed by offeror) 38 X M

L INSTRS., CONDS., AND NOTICES TO OFFERORS

EVALUATION FACTORS FOR AWARD

NOTE: Item 12 does not apply if the solicitation includes the provisions at 52.214-16, Minimum Bid Acceptance Period.

is inserted by the offeror) from the date for receipt of offers specified above, to furnish any or all items upon which prices are offered at the price set opposite each item, delivered at the designated point(s), within the time specified in the schedule.

13. DISCOUNT FOR PROMPT PAYMENT

(See Section I, Clause No. 52.232-8)

14. ACKNOWLEDGMENT OF AMENDMENTS

(The offeror acknowledges receipt of amendments

AMENDMENT NO. DATE

to the SOLICITATION for offerors and related documents numbered and dated):

FACILITY

12. In compliance with the above, the undersigned agrees, if this offer is accepted within calendar days (60 calendar days unless a different period

SOLICITATION, OFFER AND AWARD

X

(X) SEC. DESCRIPTION (X) SEC. DESCRIPTION PAGE(S)

PART I - THE SCHEDULE

26. NAME OF CONTRACTING OFFICER (Type or print) 27. UNITED STATES OF AMERICA 28. AWARD DATE

EMAIL:TEL: (Signature of Contracting Officer)

CODE CODE

B. TELEPHONE (Include area code) C. E-MAIL ADDRESS

AWARD (To be completed by Government)

19. ACCEPTED AS TO ITEMS NUMBERED 20. AMOUNT 21. ACCOUNTING AND APPROPRIATION

22. AUTHORITY FOR USING OTHER THAN FULL AND OPEN COMPETITION:

10 U.S.C. 2304(c)( ) 41 U.S.C. 253(c)( ) (4 copies unless otherwise specified)

23. SUBMIT INVOICES TO ADDRESS SHOWN IN ITEM

24. ADMINISTERED BY (If other than Item 7) CODE 25. PAYMENT WILL BE MADE BY CODE

PART IV - REPRESENTATIO NS AND INSTRUCTIO NS

PART III - LIST O F DO CUMENTS, EXHIBITS AND O THER ATTACHMENTS

39 - 51

PART II - CO NTRACT CLAUSES

NAVAL SURFACE WARFARE CENTER CARDEROCK

CODE 0221, EGBERT GOODMAN

301-227-1224, EGBERT.GOODMAN@NAVY.MIL

9500 MACARTHUR BLVD

WEST BETHESDA MD 20817

301-227-1224

FAX:

TEL:

FAX:

TEL:

NOTE: In sealed bid solicitations "offer" and "offeror" mean "bid" and "bidder".

SOLICITATION

6. REQUISITION/PURCHASE NO.5. DATE ISSUED

04 Mar 2016

4. TYPE OF SOLICITATION

SEALED BID (IFB)

NEGOTIATED (RFP)

[ X ]

3. SOLICITATION NO.

N00167-16-R-0011

Section B - Supplies or Services and Prices

ITEM NO SUPPLIES/SERVICES QUANTITY UNIT UNIT PRICE AMOUNT

0001 1 Each Shipboard Incinerator

Shipboard Incinerator built per the Specifications of the Statement of Work (SOW)

FOB: Destination

FFP

NET AMT

0002 1 Lot Contract Data Requirements List (CDRLs)

Deliverables DD 1423

0003 1 Lot Parts List for Incinerator (Option)

Recommended Parts List required for continuous Operation year 1. The

Contractor will provide a list of recommended spare parts and price for the Navy to maintain the unit in operational readiness.

0004 10 Days Installation Support (Option)

The Contractor will provide installation and commissioning support after the unit is delivered to the Naval Surface Warfare Center-Carderock Division (NSWCCD) per Section 4.4 of the Specification.

0005 24 Months Post Installation Support

The Contractor will provide Telephone Service Support Monday - Friday from

8:00 AM - 5:00 PM Eastern Standard Time (EST) to the Naval Surface Warfare

Center to keep the Incinerator operational. The Period of Performance (POP) is effective date of Award thru 24 months.

SECTION B

This solicitation will result in the award of a Firm-Fixed-Price (FFP), single award Contract for a Shipboard

Incinerator. Delivery of the unit shall be no more than five (5) months after Contract Award.

CLAUSES INCORPORATED BY FULL TEXT

HQ-B-2-0009 NOTE (CDRL)

NOTE A - Offeror shall complete the "Price Group" and "Estimated Total Price" blocks of each data item on the Contract Data Requirements List(s), attached hereto.

(End of Text)

HQ B-2-0022 CONTRACT SUMMARY FOR PAYMENT OFFICE (FIXED PRICE) (FEB 1997)

This entire contract is fixed price.

Section C - Descriptions and Specifications

SECTION C

SECTION C

1.SCOPE

1.1 NAMING CONVENTION USED

2.APPLICABLE DOCUMENTS

2.1 GENERAL

2.2 GOVERNMENT SPECIFICATIONS, STANDARDS, AND HANDBOOKS

2.2.1 Department of Defense

2.2.2 Other Government Documents, Drawings and Publications

2.3 COMMERCIAL SPECIFICATIONS

2.3.1 AMERICAN SOCIETY FOR TESTING AND MATERIALS (ASTM)

2.4 ORDER OF PRECEDENCE

3.DESIGN REQUIREMENTS

3.1 SHIP INTEGRATION

3.1.1 Ship Integration Requirements

3.2 COMPATIBILITY WITH SHIP’S SERVICES

3.3 WASTE STREAM PROCESSING CAPABILITY

3.3.1 Waste Stream Compositions

3.3.2 Waste Stream Incidental Items

3.4 WASTE FEED SYSTEM

3.4.1 Operating Personnel

3.4.2 Waste Segregation

3.4.3 Waste Sizing

3.4.4 Feed System Overloading

3.4.5 Feed System Cleaning

3.4.6 System Cleaning

3.4.7 Feed System Airlock

3.4.8 Feed System Liquid Handling

3.4.9 Feed System Interlocks

3.4.10 Feed System Ventilation

3.5 DESTRUCTION CHAMBER(S)

3.5.1 Process/Temperature Control

3.5.2 Operator Interface

3.5.3 Process Gas

3.5.4 Destruction Chamber Pressure

3.5.5 Combustion By-Product Management

3.6 EXHAUST GAS TREATMENT AND EMISSION REQUIREMENTS

3.6.1 Emission Requirements

3.6.2 Temperature Requirement

3.6.3 Exhaust Plume

3.6.4 Burning Embers, Sparks, and Fly Ash

3.7 CONTROL AND ALARM REQUIREMENTS

3.7.1 Process Monitoring

3.7.2 Alarms

3.7.3 Fail-Safe and Emergency Shut Down

3.8 GUARDS AND SAFETY INTERLOCKS

3.9 DOORS AND OTHER ACCESSES

3.10 SYSTEM STRENGTH

3.11 ELECTRICAL SYSTEMS

3.12 PIPING SYSTEMS

3.13 EQUIPMENT LIFE, RELIABILITY AND MAINTAINABILITY

3.13.1 Life Expectancy

3.13.2 Cleanliness

3.13.3 Reliability Requirements

3.13.4 Maintainability

3.13.5 U.S. Navy Ship Material Compatibility

3.13.6 Service Life

3.13.7 Paints and Coatings

3.14 HUMAN ENGINEERING

3.15 MANNING

3.16 TRAINING MATERIALS

3.17 MANUALS AND INTEGRATED LOGISTICS SUPPORT

3.18 CONSUMABLE MATERIALS

3.19 AIRBORNE NOISE

3.20 SHOCK AND VIBRATION

3.21 SAFETY

3.21.1 Emergency Requirements

3.21.2 Forbidden Materials

3.21.3 Surface Temperature

3.21.4 System Compartment Ambient Temperature

3.21.5 Considerations for Operability and Serviceability

4.DELIVERABLES

4.1 SYSTEM DESIGN DRAWINGS

4.2 SYSTEM DESIGN REPORT

4.2.1 Preventive Maintenance Times

4.2.2 Daily Operating Time

4.2.3 Acceptable Processing Rate

4.2.4 System Compliance Report and Presentation

4.2.5 System Cost Estimate

4.3 SPARE PARTS (CLIN 0003) (OPTIONAL)

4.4 INSTALLATION SUPPORT, TRAINING, AND COMMISSIONING SUPPORT (CLIN 0004)

(OPTIONAL)

4.5 TELEPHONE AND E-MAIL SUPPORT (CLIN 0005) (OPTIONAL)

4.6 MEETINGS AND VISITS

4.6.1 Meeting Minutes

4.7 DELIVERY SCHEDULE

1. SCOPE

This thermal destruction specification is written to cover a wide variety of technologies. The merit of each offeror’s system will be evaluated on a total system basis, based on many factors. The major factors: performance, size, weight, energy and other utilities, and manpower requirements are described below. The intent is to acquire a thermal destruction system with acceptable risk to the Navy for particular ship installations.

This document contains the following naming conventions: The Government, Navy, Naval Sea Systems Command

(NAVSEA), and Naval Sea Systems Command, Carderock Division (NSWCCD) refers to the various US Navy organizations. Offeror refers to the company that prepares a proposal for this procurement.

2. APPLICABLE DOCUMENTS

The documents listed below are cited in this specification. They do not constitute a comprehensive list of waste destruction system design specifications, but are used herein to define requirements that may be above and beyond existing manufacturing practice. They shall be followed as described within this specification and to the extent that they define best commercial practice.

The stated versions of the following specifications, standards, and handbooks shall be used by the offeror as background and guidance, either mandatory or optional, to meet the military requirements described in this specification.

2.2.1 Department of Defense

NAVSEA S6470-AA-SAF-10 Gas Free Engineering Program, Revision 3, dated 15 October 2006.

(Unless otherwise indicated, copies of the above specifications, standards, and handbooks are available from the

Standardization Documents Order Desk, 700 Robbins Avenue, Building 4D, Philadelphia, PA 19111-5094)

None

2.3.1 AMERICAN SOCIETY FOR TESTING AND MATERIALS (ASTM)

ASTM F-1323-08 Specification for Shipboard Incinerators (Mandatory, portions of ASTM F-

1323-08 are superseded by this document and the Offeror shall meet the requirements of ASTM F-1323-08 unless superceded and meet the requirements of this specification in those cases).

(Application for copies should be addressed to the American Society for Testing and Materials, 100 Barr Harbor

Drive, West Conshohocken, PA 19428-2959.) The Offerors must obtain their own copy.

2.4 Order of Precedence

In the event of a conflict between the text of this specification and the references cited herein, the text of this specification shall take precedence. Nothing in this specification, however, supersedes applicable laws and regulations unless the offeror has obtained a specific exemption from the Government by way of the Contracting

Officer.

1.1 Naming Convention Used

2.1 General

2.2 Government Specifications, Standards, and Handbooks

2.2.2 Other Government Documents, Drawings and Publications

2.3 Commercial Specifications

3. DESIGN REQUIREMENTS

The requirements described below define the thermal destruction system design and installation specifications. The offeror shall provide a system that meets ASTM F-1323-08 and all of the requirements of this specification.

This specification covers a variety of ship classes and processing requirements. The following paragraphs show the ship integration for the required system (for aircraft carriers, 2-3 systems per ship). Other ship classes will have different waste generation rates and therefore may require fewer systems. However, the types of waste do not vary significantly between the various ship classes.

The system weight and space shall be minimized, but not at the cost of performance, operability, reliability or maintainability. The typical size for a thermal destruction system compartment is provided in Table 1. There is some variation in the length and width available from ship to ship. The available height is the same for all ship classes.

Table 1. Thermal Destruction System Compartment, Typical Size

Size Compartment

Length (inches) 224

Length (m) 5.68

Width (inches) 160

Width (m) 4.06

Height (inches) 93

Height (m) 2.36

The system shall be capable of being operated under normal shipboard conditions and motions, including a static list of 15 degrees and a roll of up to 22.5 degrees in combination with a pitching motion of 7.5 degrees, with a roll period of 10-20 seconds. Because the system could be installed in either a fore-aft or athwart ship’s orientation, the system must be able to be operated under these motions in both of these orientations. The operation of this system shall in no way interfere with any other shipboard operation.

The dry weight of the system shall not exceed 40,000 lbs. (18,140 kg). This weight includes all equipment specified herein, any auxiliary equipment needed for system operation, internal piping, and internal wiring. The weight of the foundations, piping and wiring that connect the equipment to the ship services, waste, ash, and water are not included in the above weight.

The system shall be designed to operate with a horizontal exhaust length of 150 to 250 feet (46 to 76 m) with at most

10 feet (3.0 M) of vertical rise. As a result, a fan or other device must be provided to move the exhaust gas from the system. The system must also be able to safely tolerate an emergency shut down or loss of utilities with this exhaust configuration.

The system shall not require shipboard services other that the following, which are available to the extent described below.

Electrical Power - 440V, 60-Hz, 3-phase, less than 120 KW full load

DFM (Diesel Fuel, Marine - similar to #2 fuel oil) or JP-5 (kerosene) liquid fuel. A day tank will be supplied by the Government adjacent to the thermal destruction system compartment.

Seawater - 300 GPM (1,100 lpm) maximum, 100 to 180 PSIG (690 to 1,240 kPa) (will vary over time depending on other ship systems and installation location), 29-100F (-2 to 38C) (will vary depending on

3.1 Ship Integration

3.1.1 Ship Integration Requirements

3.2 Compatibility with Ship’s Services

where the ship is operating). The offeror shall provide the strainer mesh size that is required for correct equipment operation and service life as part of the installation instructions.

Fresh Water – 60 PSIG (410 kPa) up to 5 GPM (18.9 lpm); 70F (21C), total usage shall not exceed 3,600 gallons/day (13,600 liters per day) under all operating conditions.

Ship service compressed air at 80 PSIG (550 kPa) minimum, 10 scfm (0.28 M3/minute) maximum (Air supply to the space at a maximum temperature of 90°F (32C) with a wet bulb temperature of 81F (27C), unlubricated and unfiltered). The offeror shall supply all equipment needed to condition the compressed air for use in the system, including pressure regulation from a maximum of 200 psi (1,380 kPa) inlet pressure.

Process and ventilation air at 0-100F (-17 - 38°C), 0-100% relative humidity, not heated or air conditioned, and potentially salt laden).

The offeror shall provide the auxiliary equipment required to condition these services to meet the requirements of any portion of their system. The offeror shall identify any additional services that any portion of their system requires and provide a list of all ship services and their capacities required for their proposed system as part of the proposal.

The system shall safely and completely process any combination of the wastes shown in Table 2 each day. These wastes have a higher specific heat content (BTU/pound) than is typical for some thermal destruction systems. As a result, the capacity of the system shall be 30,000,000 BTU per day (31,644,000 kJ per day) of high heat content waste. The system shall be capable of processing the day’s waste at this average rate, regardless of the mixtures delivered to the system.

Individual batches of waste may consist of either a single type of waste or a mixture of waste categories.

Subsequent waste batches will vary randomly. Much of the waste material will be delivered in 30 gallon (113 liter) bags, which may be made of either paper or plastic. The waste can range from completely dry to slightly wet with oil (10%) to very wet with food wastes (>90% water by weight). Cardboard will be delivered to the system broken down / folded flat. Wood pieces will be delivered in sizes and shapes that facilitate transport by hand, up to a full pallet in size. The system shall be able to process plastic containers up to 5 gallons in capacity without any sailor modification. Tables 3A through 3F list the form of the various combustible wastes. The system shall be able to process the following combinations of wastes with no manual adjustments by the operator:

1. 25-100% plastic for over 1 hour or until steady state is reached. If the system is not capable of burning 100% plastic, the system will be tested at the maximum allowable percent plastic (with the remainder of the mixture dry paper and/or cardboard). If the system is not capable of burning at least

25% plastic, it will be eliminated from consideration.

2. 25-100% lightly oiled (10% oil by weight) rags for over 1 hour or until steady state is reached. If the system is not capable of burning 100% oily rags, the system will be tested at the maximum allowable percent oily rags (with the remainder of the mixture dry paper and/or cardboard). If the system is not capable of burning at least 25% oily rags, it will be eliminated from consideration.

3. 100% Dry textiles, wood and heavy cardboard for over 1 hour or until steady state is reached.

4. MARPOL Annex VI Type 2 waste mixture (50% food, 15% paper, 20% cardboard, 5% textiles, and 10% plastic).

5. Navy Nominal Waste Mixture from Table 2, without the food, metal, and glass

6. Navy Nominal Waste Mixture from Table 2, including the food, metal and glass.

7. Processing of pilot urine bags and feminine hygiene products is required. These items should not be pre-processed through a shredder or other sizing device. The plan for processing these materials shall be provided.

8. Processing of plywood and tri-wall cardboard will occur on an occasional basis. The plan for processing these materials shall be provided.

3.3 Waste Stream Processing Capability

3.3.1 Waste Stream Compositions

9. The waste composition being fed must be able to be changed suddenly from any one of the above mixtures to any other.

The system will be tested with these waste mixtures after delivery.

Table 2. Navy Nominal Waste Mixture and Design Waste Generation Rate

Metal/Glass

0.54 7.09 0.076 0 0 17% 245 113.57 2.16 0 0

Food1 1.21 16.78 0.072 1,000 1,210 38% 549 268.79 2.04 2,326 1,275

Cardboard1 0.44 5.03 0.087 6,317 2,779 30% 14% 200 80.57 2.48 14,691 2,930

Paper

0.66 5.59 0.118 5,638 3,721 45% 21% 299 89.54 3.34 13,112 3,922

Plastic1 0.20 3.19 0.063 18,838 3,768 14% 6% 91 51.02 1.78 43,809 3,971

Rags2 0.10 9.24 0.011 11,813 1,181 7% 3% 45 148.01 0.31 27,472 1,245

Wood

0.05 8.39 0.006 6,421 321 3% 2% 23 134.39 0.17 14,933 338

Other

0.01 8.12 0.001 4,500 45 1% 0% 5 130.07 0.03 10,465 47

Total4

Combustible 1.46 0.286 11,816 45% 662 8.11 12,454

Total Solid

Waste 3.21 0.435 13,026 100% 1,456 12.31 13,729 processed in the pulper and discharged overboard. Metal and Glass are not consumed in a thermal destruction system and are destruction systems and are removed as ash.

3. From the Solid Waste Generation Survey Aboard USS CAMDEN (AOE 2), CARDIVNSWC TR-63-94/11, October 1995

Notes: 1. From the US Navy Shipboard Solid Waste Management Program Plan (Green Book), NAVSEA 05V Environmental Engineering Group, April 1993

2. From the Hazardous Waste Generation Rate Survey, CVN71, April 1992 and

Survey of Navy Industrial Cleaning Rags, NSWCCD-TM- 63-98/56, March 1998

4. Although food is combustible, it is not included in the Total Combustible Waste because it can be

Waste Percent of Total

Waste

Generation

Rate in g/sailor/ day

Density kg/m3

Generation

Rate in m3/sailor/ day

Waste

Energy

Content

(kJ/kg)

Heat

Content kJ/sailor

/ day

Generation

Rate in lb/sailor/ day

Density lb/ft3

Generation

Rate in ft3/sailor/ day

Waste

Energy

Content

(BTU/lb)

Heat

Content

BTU/

sailor/day

Percent of

Combustible

Waste

Table 3. Some Examples of the Forms of the Waste

Table 3A. Paper

Material Form

Office Paper Whole Sheets (8 ½ x 11 (A4)) and bound notebooks

Paper Towels Sheets

Kim wipes Nylon Net Reinforced, Single

Sheets

Table 3B. Cardboard

Light Cardboard Cereal Boxes

Heavy Cardboard Corrugated

Coated Cardboard Milk Cartons, Pringles & Cheese

Ball Canisters

Wax Paper Single Sheets

Tri-walls Broken down/folded to 2 feet x 4 feet (0.6 m x 1.2 m) Sheets

Table 3C. Plastic

Polystyrene Foam Coffee Cups Utensils

0.5-2.0 mil LDPE Film

HDPE Milk Jugs and 5 Gallon (19 liter)

Pails

PETE Soda Bottles and Salad Dressing

Bottles

Table 3D. Wood

Pallet Whole, may be broken down for loading

Plywood 2’x4’x1” (0.6m x 1.2m x

0.025m)

Lumber up to 3.5” x 3.5”

(89mm x 89 mm)

4 feet (1.2m) long

Table 3E. Cloth

Rags Cotton or Blends

Dungarees Non-Shredded with Buttons and

Zippers (Plastic or Metal)

Table 3F. Metal/Glass

Metal Aluminum Soda Cans, #10 Steel

Cans, Metal Banding Straps

Glass Jars (up to 1 Gallon (3.78 liters))

Sailors will be instructed to source separate their waste to keep hazardous and flammable materials and other non-combustible items out of the system. Incidental items listed in Table 4 may still be inadvertently delivered to and loaded into the system. The listed items are expected to be relatively few in number, but potentially disruptive to performance of the Thermal Destruction System. The items listed are representative of the broad range of materials that have historically been found in waste delivered to the existing Navy waste treatment systems. The system shall be designed to safely tolerate these items without endangering the operators or equipment if they are accidentally introduced.

Table 4. Typical Incidental Items

5/8 inch (16mm) Diameter x 3 inch (76mm) long Hardened Bolts

Schedule 40 Pipe from 1/8 to 3 Inch (10 to 89mm)Diameter

Steel Wire No. 20 to No. 0

Stainless Tableware (forks, knives, spoons, etc.)

Steel Cable Up To 1/2 inch (13mm) Diameter

Coat Hanger

Nails and Screws

Disposable Cigarette Lighter (filled)

Steel Toed Work Boots

Aerosol Can (Nearly empty to full)

Batteries of Various Sizes (AAA to D size alkaline and lithium)

Glass Bottles

Steel and Aluminum Cans

Electrical Wire and Cabling No. 22 to No. 10

Padlocks

12 inch (305mm) long steel wrench

The feed system shall include all hoppers, trash chutes, size reduction devices, metal/glass separators, conveyors, augers, mixers, valves, metering devices, heaters, etc. required to take the waste from the sailor’s hands to the destruction stage of the processing. It shall feed, pre-process, and manage the various waste mixtures. It shall be resistant to bridging, jamming, or damage, even when processing waste listed in Table 4. The offeror shall list any materials that their system cannot safely process and the reason why as part of the proposal.

3.3.2 Waste Stream Incidental Items

3.4 Waste Feed System

The system may allow for batch loading prior to operation of the system. If so, the system may be loaded with larger waste than can be loaded with the automatic loading system, during the first batch of the day only. The batch loading door will be locked once the chamber air temperature is above the required system lock set point (302 °F

(150C)). It will not be unlocked until the air temperature inside the chamber is below the system lock set point of

(302 °F (150C)). If a combination of batch loading and loading via the feed system is planned to meet the daily processing requirements, the offeror shall provide calculations that show how the full day’s waste requirement will be processed in one or more batches plus the operation of the feed system while allowing time for heat up and cool down of the system, as part of the proposal.

Alternately, the system may use batch loading for the entire operation of the system. The loading door would be locked once the chamber air temperature is above the system lock set point (302 °F (150C)). Subsequent batches may be loaded only after the chamber air temperature is below the system lock set point (302 °F (150C)). If batch loading is planned to meet the daily processing requirements, the offeror shall provide calculations that show how the full day’s waste requirement will be processed in one or more batches while allowing time for heat up and cool down of the system, as part of the proposal.

The waste feed system shall meet the following requirements:

The operator effort required for preparing and feeding of the waste is included in the total number of man-hours as specified in Section 3.15.

The system shall not require the operator to segregate the waste prior to loading into the waste feed system. The offeror shall provide any separation equipment needed for its system design (if necessary). That separation equipment (if any) shall function in an automatic mode without operator intervention.

The system shall not require the operator to manually reduce the size of the waste prior to loading into the waste feed system as long as it is less than the sizes presented above (see paragraph 3.3.1 and Table 3) except as follows:

1. Pallets may be broken into individual boards.

2. Heavy cardboard may be cut to no larger than 4 feet x 4 feet (1.2m x 1.2m) and folded once to be

2 feet x 4 feet (0.6m x 1.2m).

3. Plywood may be cut to no larger than 2 feet’ x 4 feet’ (0.6m x 1.2m).

Therefore, the opening of the waste feed system must allow the following to be directly fed:

1. Wood boards up to 4 feet long

2. Cardboard up to 2 feet’ x 4 feet’ (0.6m x 1.2m).x 6inch (152mm) thick

3. Plastic buckets and bottles up to 5 gallons (19 liters)

4. Bagged waste up to 30 gallons (113 liters)

5. Boxed waste up to 18 x 18 x 24 inches (0.5 x 0.5 x 0.6m)

If the system allows for batch loading and a waste feed system is also provided, the batch loading door may be sized to accommodate all the day’s waste that does not meet the size limitations of the waste feed system. Therefore a somewhat smaller feeder may be allowable, as long as the daily processing rate can be met per Section 3.3.

If the system only uses batch loading, the loading door and chamber size must accommodate all of the waste sizes listed above.

3.4.1 Operating Personnel

3.4.2 Waste Segregation

3.4.3 Waste Sizing

The feed system or mechanism design shall prevent the system from being overloaded with waste to a magnitude at which the control system cannot maintain the destruction process within allowable limits as defined in paragraph

3.6.1.

The feed system’s design shall permit sufficient self or sailor performed cleaning to guarantee that waste residues will not cause fire hazard, odor, health, or habitability problems.

All equipment shall be designed to allow wash-down with a freshwater garden hose, except the interior of the thermal destruction system combustion chambers. Complete cleaning in accordance with these requirements shall not take longer than 30-minutes, once per day.

A double door or other airlock between the compartment and thermal destruction section shall be provided to prevent hot gases or flames from reaching the operator, the compartment, or any waste storage device while in the process of loading waste into the system. Systems that only have batch loading do not require a double door but must meet all of the other requirements of Section 3.4.

The system shall be designed to contain and manage all liquids contained within the waste stream and/or generated during the pre-processing. These liquids shall be treated within the system and shall not be discharged.

The feed system shall be designed to prohibit the access to any hot, rotating or moving machinery. Interlocks shall prevent the operator from feeding the system until it is ready to receive waste and will not allow the waste into the destruction chamber until the system has reached the proper operating conditions (temperature, pressure, etc.). Also, the feed system interlocks shall not cause any shutdown of the thermal destruction process. Thermal destruction system interlocks are described in paragraphs 3.5.1 and 3.7.

If the feed system includes a shredder or other waste sizing device, the shredder shall be kept at a negative pressure at all times; isolated from the combustion chamber using an airlock; be vented overboard at a rate of 8 cubic feet per minute (cfm) (0.22 meters cubed per minute) for every cubic feet of shredder and feed system volume up to the airlock; have blow out flaps with a metal screen to relieve internal pressure and direct it away from the operator in the event of an explosion; have latches to keep the door shut in the event of an explosion; and an electrical interlock to stop the shredder motor when the door is not closed and latched or if the ventilation is less than 8 cfm for every cubic feet of volume.

3.4.4 Feed System Overloading

3.4.5 Feed System Cleaning

3.4.6 System Cleaning

3.4.7 Feed System Airlock

3.4.8 Feed System Liquid Handling

3.4.9 Feed System Interlocks

3.4.10 Feed System Ventilation

3.5 Destruction Chamber(s)

3.5.1 Process/Temperature Control.

The system shall automatically control the destruction process to maintain efficient operation and protect internal components from damage. The automatic control shall not require any operator feedback other than commands for process startup, emergency or normal shutdown, waste feed initiation, ash removal initiation, and maintenance/ troubleshooting. The destruction technology must allow processing of all combustible shipboard waste specified herein, in any combination of waste mixes, based on the values in Table 2, within the 24 hour period (including maintenance, repair, and cleaning downtime), while maintaining emissions requirement as described in Section

3.6.1. Calibration of all sensors and gauges shall not be required more often than once every 5,300 hours (based on a normal Navy ship deployment).

The system shall have a required system lock set point of 302 °F (150C).

The system shall be interlocked so that startup shall not occur until all combustion chamber doors are closed and locked.

If the system allows batch loading, the loaded waste shall not be ignited until the downstream equipment has reached its minimum operating temperature and all other operating parameters needed for complete combustion of the waste are met.

The waste feed system shall be interlocked to prevent the loading of waste until the downstream equipment has reached its minimum operating temperature and all other operating parameters needed for complete combustion of the waste are met.

Operation of the system shall not allow operators to be directly exposed to the destruction chamber(s) or to radiant, convected or conducted heat from the destruction chamber(s). In addition, the operation shall not require manual stoking or raking of materials while they are in any portion of the system.

The system design shall limit and safely contain flammable process gas that is generated at any point in the destruction process. The system shall consume the process gas as it is generated (no storage).

The system shall be designed to maintain a constant negative pressure within the combustion chamber during normal operating conditions. The system shall restore combustion chamber pressure to less than atmospheric pressure within 10 seconds after a loss of negative pressure. Disturbances that could cause a loss of negative pressure can include a sudden change in the type of waste being fed into the system (item 9 of Section 3.3.1) or a wind gust. The system shall activate an alarm before the negative pressure rises to atmospheric pressure and start the shutdown process if negative pressure is not restored within 10 seconds.

The design of the system shall be such that no system components will be damaged as a result of loss of pressure control.

It is expected that the system will generate some by-products during the destruction process. This by-product frequently takes the form of ash and slag and other residual undestroyed wastes. The bottom ash shall contain less than 10% unburned residue by weight as measured by a loss on ignition test. The ash must be removed daily.

3.5.2 Operator Interface

3.5.3 Process Gas

3.5.4 Destruction Chamber Pressure

3.5.5 Combustion By-Product Management

3.5.5.1 Automatic Systems for Daily By-Product Collection and Handling

The system shall provide for the safe collection, removal, storage, and disposal of both bottom and fly ash with minimal interference to the destruction process, and within the 24-hour period. The introduction of metal or glass into the system shall not negatively impact operation, maintenance or the ash removal processes (with the exception of longer ash removal times). The process for the collection and removal of bottom and fly ash or slag shall be automatic or, at most, require minimal operator interaction (where such interaction is limited to “pushing buttons” on the control panel and removing ash containers when they are full). The system architecture and the ash containers shall not require exposure of the operator to temperatures above 140 °F (60 °C), ash, airborne particles, hazardous gases, or other system by-products during the process of transferring ash or slag into a container for storage or disposal. If stored, the ash and/or slag will be transferred to and stored in metal containers. The offeror shall define the size/shape of the containers. One container shall be provided with the system. The exhaust fan or other device that moves the exhaust gas per Section 3.1 shall be operating whenever by-products are being removed to ensure that all ash that becomes airborne does not enter the compartment.

Any ram or other device used to stir, move, or remove waste or by-products in the system shall be sealed to prevent the propagation of smoke or fire from the system into the compartment.

By-products that remain within the destruction chamber(s) after daily ash removal will have to be removed manually on a periodic basis. This includes waste that may hide out in corners of the system, large items that the automatic system cannot manage and other products that may stick to the walls of the destruction chamber. The system shall be designed to not require this cleanout more than once every 14 days. Any incidental ash that is not automatically removed from the chambers by the automatic ash removal equipment shall not interfere with combustion at the rated capacity.

The destruction chamber shall be designed so there shall be no obstructions around any access panels or doors that can cause accidental exposure of maintenance personnel to ash either directly or through the air or interfere with the by-product removal process. The exhaust fan shall be in operation whenever by-products are being removed to ensure that all ash that becomes airborne does not enter the compartment.

3.6 Exhaust Gas Treatment and Emission Requirements

The emissions limits and operating parameters and the emission requirements listed in Table 5 shall be met when processing all combinations of combustible shipboard waste specified herein and for the potential operating scenarios. This will include feeding of subsequent batches of the highest and lowest possible heat values, and feeding at any rate up to the maximum that the control system allows. The control system shall reduce or stop the feeding of waste automatically to maintain the emissions values below the limits. Interlocks and/or automatic controls shall be provided to minimize system emissions while initiating an automatic shutdown of the system and/or if the exhaust system is not functioning properly.

Table 5 Exhaust Emission Requirements

Type of Emission Limit

O2 Minimum of 6% by volume

CO 200 milligrams/MegaJoule

Opacity (average) 20%

3.5.5.2 Periodic By-Product Management

3.6.1 Emission Requirements.

3.6.2 Temperature Requirement

The exhaust gas shall be rapidly cooled to less than 662F (350C) within 2.5 meters of the combustion chamber outlet. The exhaust as it leaves the ship shall be less than 662F (350C).

The system shall include any equipment necessary to prevent a visible steam plume of more than 10% opacity, including the water droplets, from the output stack when the outside ambient temperature is at 32°F (0

°C), with a seawater temperature of 40°F (4

°C).

Under all normal operating conditions the exhaust stack shall not emit any burning embers. A spark arrestor shall be provided that will not permit passage of spherical objects with a diameter of 13.7 mm (0.5 inch) nor block the passage of spherical objects having a diameter of 9.5 mm (3/8 inch). The spark arrestor shall be replaceable/cleanable by shipboard personnel while underway.

3.7 Control and Alarm Requirements

3.7.1 Process Monitoring

The system shall have a fully integrated control system housed in a NEMA 4X or IP65 stainless steel enclosure, and its size shall be of the minimum volume required to house and allow for maintenance of components. The control panel shall include a main disconnect switch or circuit breaker that is capable of being locked with three padlocks simultaneously to suit shipboard tag out requirements. All branch circuits shall be protected using circuit breakers instead of fuses. The number of circuits less than 2 amps shall be minimized and may be protected using fuses. All programmable devices must be able to be re-programmed with the electrical enclosure door closed using an external plug or receptacle with watertight cover, or an external watertight access door that allows access to the programming plug or receptacle only.

The control system shall automatically control the start-up, processing, and shut down (normal and emergency) at the operator’s command. The control system shall provide sufficient process monitoring and automated controls to maintain controllable, stable, safe, and non-destructive operating conditions while providing the required daily processing rate for all of the waste mixtures in Table 3 above. Set points shall be set for temperatures, pressures, feed rates, O2 level, or any other parameters required by the system manufacturer to control the destruction process to meet the exhaust gas requirements described in Table 5. The offeror shall provide the sensors, analyzers, and actuators needed to perform the system control functions. The control/operator interface shall communicate only the information to the operator that is required for feeding, thermal destruction, and the ash removal processes. A separate control panel interface or separate screens on the same interface that is accessible only by password control or key-lock shall provide the maintenance personnel (see Section 3.14) with more detailed status information on system components, and identification of failures and where in the technical manual to turn for troubleshooting and effecting repair.

3.7.2 Alarms

The system shall provide warnings and alarms for any operating condition that result from the system exceeding acceptable operating parameters, including those that require action by the operator. These include, but are not limited to, high destruction chamber temperatures, improper chamber pressure, or loss of utilities. Each individual alarm shall have only a single cause to expedite troubleshooting (for example, “flame failure” alarm, not “auxiliary burner failure” alarm).

3.6.3 Exhaust Plume

3.6.4 Burning Embers, Sparks, and Fly Ash

The system shall provide for an automatic fail-safe shut down capability for any operating condition that might result in damage to the system, or endanger the ship or personnel. It shall be capable of safely shutting down per

Section 3.21 under all of the following conditions:

Normal operation of the equipment.

The gradual or sudden and total loss of any one or more services in Section 3.4.

During alarm or emergency shutdown. Provide remote Emergency Stop Control Switches, to immediately shut down that component and initiate an entire system shutdown. These switches shall be located next to the feed hopper, on the control panel, etc. Emergency shutdown shall be a controlled shutdown to minimize cleaning/maintenance prior to the next start up, but must shutdown fast enough not to cause a hazardous condition to personnel or damage to equipment. Alarm conditions that affect the safety of equipment or personnel shall use this shutdown sequence.

An emergency shutdown switch that is located outside the compartment door will be provided by the offeror and will trip the main circuit breaker for the system. The system will be shut down immediately due to the loss of utility power.

The offeror shall provide a discussion of the risk of damage to the equipment and danger to personnel for each of these shutdown conditions as part of their proposal.

Guards shall be provided to prevent operator contact with rotating or moving parts, hot surfaces, or other hazards.

The guards shall be designed so that they cannot be removed without the use of tools. Guards do not require safety interlocks or locking mechanisms.

Safety interlocks and locking mechanisms shall be provided to ensure that while the system is in operation, the operator cannot access any area of the system that can cause harm to either operating personnel or equipment. They shall be provided on all doors and other accesses that do not require tools to open. The interlock and/or locking devices shall be resistant to damage from accidental impact from hand-carried objects and compromise (i.e. they shall not be easily over-ridden by an individual wanting to compromise them).

Doors, access ports, view ports, and special tools shall be provided so that the operator can inspect and clean the destruction chambers without entering a “confined space” as defined by NAVSEA S6470-AA-SAF-10 Gas Free

Engineering Program (Personnel shall not break the plane of any confined space with their hand, head, or other body part during operation or maintenance. Tools may break the plane). In addition, the doors shall have a structure, hinges, and latches sufficient to contain an explosion of a 14 ounce propane container. Doors and other accesses shall be sealed to maintain system pressure (vacuum) under normal operation and emergency shutdown.

The system shall be resistant to damage from operator carelessness (e.g. bumping into components or stepping on components that make convenient steps).

3.7.3 Fail-Safe and Emergency Shut Down

3.8 Guards and Safety Interlocks

3.9 Doors and Other Accesses

3.10 System Strength

Sharp corners and edges shall be avoided in the design.

All motors shall use 480V - 60 Hz, 3-phase electrical power. System controls and sensors may use 12VDC, 24-

30VDC, or 120 VAC for their power. Thermocouples may use thermocouple cables for their connections. All

480VAC and 120 VAC devices shall be grounded to a single point in the system electrical panel. The DC power systems may be grounded to a common signal ground or ungrounded. System controls and sensors may use either discrete wiring or data bus connections for their signals. All thermocouple, 12 VDC and 24-30 VDC wiring shall use shielded cables with the shield grounded at the control panel end. The offeror shall provide transformers and/or regulated power supplies to create all signals and control power from the 480VAC inlet power. The equipment frames shall include a copper ground lug to allow grounding to the ship foundation.

All pipes shall use flanges where disassembly is required or where the pipe connects to the ship services. The use of polyvinyl chloride (PVC) and chlorinated polyvinyl chloride (CPVC) piping components is prohibited.

The system shall be designed and constructed to provide a 25-year operational life. The Navy ship 3-year operational cycle consists of a repair period, limited underway periods, and a 7 month (210 days) continuous deployment. The ship is expected to be underway and processing waste for a total of 330 days during the 3-year operational cycle. The reliability and maintainability characteristics of the thermal destruction system shall ensure that the crew of a U.S. Navy ship can, with a high degree of confidence, consistently dispose of the various waste streams, as defined in Section 3.3, for the 7 month underway deployment.

The system shall be designed to facilitate the ease of cleaning and minimize manpower requirements and life cycle costs while insuring the safety of the ship’s personnel who are performing the cleaning procedures.

The design of all components shall be consistent with an at sea working environment. The system shall have a

Mean Time Between Critical Failures (MTBCF) of greater than 7 months of daily operations at the required capacity. A critical failure is defined as one that requires the system to be non-available for service for a time period that prevents processing of one day’s waste. Any failure that the ship’s crew cannot repair is a critical failure, because it requires Navy or Contractor Intermediate maintenance to travel to the ship for the repairs, and will have more than 1 days delay.

The offeror shall provide one set of all special tools needed for the operation and maintenance of the system. The following repair times shall be calculated when using standard mechanic’s tools and the special tools as needed.

Routine cleaning and preventive maintenance shall not require more than one hour per day. For organizational level

(i.e. maintenance performed by the ship’s crew) corrective maintenance, the system shall have a geometric Mean

Time to Repair (MTTRg) of less than four (4) hours 95% of the time and a Maximum Repair Time (Mmax) of less

3.11 Electrical Systems

3.12 Piping Systems

3.13 Equipment Life, Reliability and Maintainability

3.13.1 Life Expectancy

3.13.2 Cleanliness

3.13.3 Reliability Requirements

3.13.4 Maintainability

than twelve (12) hours 95% of the time. Repair times do not include the time required to cool down or heat up the system. Organizational maintenance shall include any maintenance required during ship deployments, which are up to 7 months in duration. Organizational maintenance shall not require skills beyond that which is expected of a 19-year-old enlisted sailor with the minimum training from a Navy school for their specialty (pipefitter, mechanical, electrical) and training on the specific system per Section 3.14. All other maintenance required to maintain function for the 25-yr. life expectancy shall be performed by an intermediate level maintenance organization. Intermediate level maintenance is to be performed by trained Government repair specialists or contractors and is to include the replacement of combustion chamber liners and any other major maintenance required to ensure safe and reliable operation for a 7-month deployment. Intermediate maintenance will require personnel to travel to the ship for the repairs. As a result, any repair that requires intermediate maintenance is a critical failure per Section 3.13.3.

The materials used to fabricate the system shall be compatible with the Naval/marine environment, including the salt-water environment, ship structural vibrations, and ambient temperatures of up to 120°F (49°C). The shipboard environment includes salt laden mist and condensation entering from compartment ventilation, fresh or salt-water if used in the shock cooling process, and the waste components and their resulting combustion products (for example, sulfur in the waste is converted to SOx/H2SO4).

Refractory materials, if used, shall have a life expectancy of at least 10 years. Materials used in parts that are to be replaced on a preventative maintenance schedule shall have a life expectancy of 150% of that part’s scheduled service life. All other materials, including those subject to exposure from the waste being processed, or to the gases and liquids formed from the process, shall have a service life of at least 25 years.

Paints and coatings shall be suitable for a marine environment and shall be chrome and lead-free. The paints and coatings will be evaluated as part of the testing of the system by the Government.

Components that are made from materials that are compatible with the shipboard saltwater environment (Hastelloy

C-276, Inconel, titanium, stainless steel, and other metals (approved by procuring activity on a case by case basis)) may be left unpainted. No elastomers (rubbers and plastics) shall be painted, unless painted in accordance with manufacturer's instructions. Fiber reinforced plastics shall be provided with coatings inside and out as specified by the manufacturer for the service intended.

The system shall conform to human engineering principles to the degree that it can be operated and maintained by a

5-ft (152-cm) tall male or female as well as 6-ft 1-in. (185-cm) tall male or female. Its design shall also reflect system and personnel safety factors, including the elimination or minimization of the potential for human error during operation and maintenance, under both routine and non-routine or emergency conditions. Machinery, systems, equipment, and fixtures shall be intrinsically safe as far as practicable, and in the event of failure, shall fail to a safe mode. Man-machine interfaces shall minimize both the potential for and the consequence of human error.

The system shall be designed assuming a 19-year-old operator who has been provided with no more than four hours of interactive computer based training on Compact Disc (not part of this contract) and four hours of on-the-job training. The system shall be designed to be maintained at the organizational level by a 19-year-old sailor that has the minimum training from a Navy school (pipefitter, mechanic, electrical) and no more than 8 hours of interactive computer based training on Compact Disc (not part of this contract) plus 24 hours of on-the-job-training for the thermal destruction system, for a total of 32 hours of training.

3.13.5 U.S. Navy Ship Material Compatibility

3.13.6 Service Life

3.13.7 Paints and Coatings

3.14 Human Engineering

3.15 Manning

The manpower required to operate, maintain, clean, and repair the system shall be no more than 48 man-hours per day. In addition, the following equipment must be manned when in operation: Shredders, pulpers, ash transfer systems, and the destruction system (while waste is being consumed). The offeror shall propose, subject to

Government approval, the types and hours of manpower…