N00167-16-T-0061.pdf

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N00167-16-T-0061 16-Jun-2016

b. TELEPHONE NUMBER

301-227-2357

8. OFFER DUE DATE/LOCAL TIME

12:00 AM 18 Jul 2016

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AUTHORIZED FOR LOCAL REPRODUCTION

PREVIOUS EDITION IS NOT USABLE

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Prescribed by GSA – FAR (48 CFR) 53.212

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CODE 10. THIS ACQUISITION IS

SUCH ADDRESS IN OFFER

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BELOW IS CHECKED

TELEPHONE NO.

N001679. ISSUED BY

18b. SUBMIT INVOICES TO ADDRESS SHOWN IN BLOCK 18a. UNLESS BLOCK

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INFORMATION CALL:

a. NAME

SHAWN RYAN

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SMALL BUSINESS

17a.CONTRACTOR/ CODE FACILITY

OFFEROR CODE

NAVAL SURFACE WARFARE CENTER CARDEROCK

CODE 0221, SHAWN.RYAN

301-227-2357, SHAWN.RYAN@NAVY.MIL

9500 MACARTHUR BLVD.

WEST BETHESDA MD 20817

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RATED ORDER UNDER

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TION UNLESS BLOCK IS

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14. METHOD OF SOLICITATION

RFQ IFB RFPX

NAVAL SURFACE WARFARE CENTER CARDEROCK

CODE 634, JAMES MANN

9500 MACARTHUR BLVD, BLDG 17 RM 235

WEST BETHESDA MD 20817-5700

TEL: 301-227-5522 FAX: 301-227-5549

FAX:

TEL: 301-227-2357

SERVICE-DISABLED

VETERAN-OWNED

SMALL BUSINESS

8(A)

HUBZONE SMALL

BUSINESS

SIZE STANDARD:

NAICS:

333994

X

OFFER DATED

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DELIVER ALL ITEMS SET FORTH OR OTHERWISE IDENTIFIED ABOVE AND ON ANY

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EMAIL:

TEL:

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SEE SCHEDULE

SCHEDULE OF SUPPLIES/ SERVICESITEM NO. QUANTITY UNIT UNIT PRICE AMOUNT

24.22.21.19.

WOMEN-OWNED SMALL BUSINESS (WOSB)

ELIGIBLE UNDER THE WOMEN-OWNED

SMALL BUSINESS PROGRAM

EDWOSB

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ACCEPTED, AND CONFORMS TO THE CONTRACT, EXCEPT AS NOTED: ______________________________________________________

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FINALPARTIALCOMPLETE

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CORRECT FOR

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FINAL

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PARTIAL

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STANDARD FORM 1449 (REV. 2/2012) BACK

Prescribed by GSA – FAR (48 CFR) 53.212

AUTHORIZED FOR LOCAL REPRODUCTION

PREVIOUS EDITION IS NOT USABLE

SEE SCHEDULE

20.

SCHEDULE OF SUPPLIES/ SERVICES

21.

QUANTITY UNIT

22. 23.

UNIT PRICE

24.

AMOUNT

19.

ITEM NO.

N00167-16-T-0061

Section SF 1449 - CONTINUATION SHEET

ITEM NO SUPPLIES/SERVICES QUANTITY UNIT UNIT PRICE AMOUNT

0001 1 Each Thermal Destruction System

Contractor will provide a Shipboard Thermal Destruction System per the

SOW/Technical Specifications

FOB: Destination

FFP

NET AMT

0002 1 Each Shipping Charges

Transportation Charges from Contractor's Plant to destination

0003 1 Lot OPTION Spare Parts IAW SOW Section 5.3

0004 1 Lot OPTION Install support IAW SOW Section 5.4

0005 1 Lot OPTION Telephone & Email Support, SOW Sec 5.5

12-month period support, beginning immediately after delivery of equipment, in accordance with SOW/Specifications.

Vendor authorized to submit 1/12 of line item price on monthly basis for services providing during the proceding month.

0006 1 Lot OPTION Telephone & Email Support, SOW Sec 5.5

12-month period support, beginning 13 months after delivery of equipment, in accordance with SOW/Specifications

Vendor authorized to submit 1/12 of line item price on monthly basis for services providing during the proceding month.

0007 1 Lot Data Deliverables

In accordance with DD Form 1423, Contract Data Requirements List (CDRL) see exhibit 1, attached.

This is a Not Separately Priced (NSP) Item.

SOW/SPECIFICATIONS

Statement of Work (SOW)/Technical Specifications

1. SCOPE

This Thermal Destruction System specification is written to cover a wide variety of technologies. The merit of each contractor’s system will be evaluated on a total system basis, based on many factors. The purpose of this contract 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. Contractor refers to the company that prepares a proposal for this procurement.

2. APPLICABLE DOCUMENTS

The documents listed below are cited in this specification. In each case, the latest version or revision shall apply.

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 latest versions of the following specifications, standards, and handbooks shall be used by the contractor as background and are mandatory to meet the Government 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

1.1 Naming Convention Used

2.1 General

2.2 Government Specifications, Standards, and Handbooks

2.2.2 Other Government Documents, Drawings and Publications

2.3.1 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 contractor shall meet the requirements of ASTM F-1323-08 unless superseded 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). Contractors must obtain their own copy of this document.

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 contractor has obtained a specific exemption from the Government by way of the Contracting

Officer.

3. DESIGN REQUIREMENTS

The requirements described below define the Thermal Destruction System design and installation specifications.

The contractor 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 small ships such as an LCS or the future frigate (one system per ship).

Other ship classes will have different waste generation rates and therefore may require multiple 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. Proposed systems that do not fit within these dimensions will be evaluated for operation and maintenance access. Proposed systems that are significantly larger than these dimensions may be eliminated from consideration due to their size.

Table 1. Thermal Destruction System Compartment, Maximum Size

Size Compartment

Length (inches) 180

Length (m) 4.57

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 ships orientation, the

2.3 Commercial Specifications

3.1 Ship Integration

3.1.1 Ship Integration Requirements

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 12,000 lbs. (5,440 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 be supplied with the following shipboard services:

Electrical Power - 440VAC, 60-Hz, 3-phase, less than 120 KW full load (the system provided under this contract shall be 480VAC, but potential future shipboard systems will be 440VAC)

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 where the ship is operating). The contractor shall provide the strainer mesh size that is required for proper 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 contractor 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 system shall safely and completely process any combination of the wastes shown in Section 3.3.1 and Table 2 each day. These wastes have a higher specific heat content (btu/pound) than is typical for some Thermal

Destruction Systems. The capacity of the system must be greater than 40 pounds per hour (18.1 kg per hour) of the combustible waste mixture in Table 2, for up to 16 hours per day on a 7 days per week basis. The system must use less than 10 gallons per day of either DFM or JP-5 fuel, on a 16 hour per day basis, over the full operation of the system (preheat, operation, burn down, and cool down). 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 or folded into flat rectangles. Wood pieces will be delivered in sizes and shapes that facilitate transport by

3.2 Compatibility with Ship’s Services

3.3 The contractor shall provide the auxiliary equipment required to condition these services to meet the requirements of any portion of their system. Waste Stream Processing Capability

3.3.1 Waste Stream Compositions

hand, up to a full pallet in size. The system shall be able to process plastic containers up to 5 gallons (19 liters) 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 (with the remainder of the mixture dry paper and/or cardboard).

2. 25-100% lightly oiled (10% oil by weight) rags for over 1 hour or until steady state is reached (with the remainder of the mixture dry paper and/or cardboard).

3. 100% Dry textiles, 100% wood and 100% heavy cardboard, each 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.

8. Processing of plywood and tri-wall cardboard will occur on an occasional basis.

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

Waste 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

Combust-ible

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

Metal/

Glass1

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

Card-board1

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

Paper1 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

Wood3 0.05 8.39 0.006 6,421 321 3% 2% 23 134.39 0.17 14,933 338

Other3 0.01 8.12 0.001 4,500 45 1% 0% 5 130.07 0.03 10,465 47

Total4

Combust-ible

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

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

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

4. Although food is combustible, it is not included in the Total Combustible Waste because it can be processed in the pulper and discharged overboard. Metal and Glass are not consumed in a Thermal Destruction System and are removed as ash.

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 18 inch x

18 inch (0.5 m x 0.5 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 18 inch x 18 inch x 1 inch (0.5 m x 0.5 m x 25mm)

Lumber up to 3.5” x 3.5”

(89mm x 89 mm)

18 inch (0.5m) 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 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

4.1.1 Waste Stream Incidental Items

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)

Disposal 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 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 shall be locked once the chamber air temperature is above the system lock set point (302 °F (150C)).

It shall not be unlocked until the air temperature inside the chamber is below the system lock set point (302 °F

(150C)).

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)).

The waste feed system shall meet the following requirements:

The system shall not require the operator to segregate the waste prior to loading into the waste feed system. The contractor 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 section 3.3.1 and Table 3).

4.2 Waste Feed System

4.2.1 Reserved

4.2.2 Waste Segregation

4.2.3 Waste Sizing

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

1. Wood boards up to 18 inch (0.5 m) long

2. Cardboard up to 18 inch x 18 inch (0.5 m x 0.5 m).x 6inch (152mm) thick

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

4. Bagged waste up to 13 gallons (49 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.

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

4.5.1.

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.

The system shall be designed to allow wash-down with a freshwater 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 System combustion chamber 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.

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 paragraph 4.3.1 and 4.6.

4.2.4 Feed System Overloading

4.2.5 Feed System Cleaning

4.2.6 System Cleaning

4.2.7 Feed System Airlock

4.2.8 Feed System Liquid Handling

4.2.9 Feed System Interlocks

4.2.10 Feed System Ventilation

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.

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 4.5.1.

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 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 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.

4.4 Combustion By-Product Management

4.3 Destruction Chamber(s)

4.3.1 Process/Temperature Control.

4.3.2 Operator Interface

4.3.3 Process Gas

4.3.4 Destruction Chamber Pressure

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.

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 metal container for storage or disposal. The contractor 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.

4.5 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, which include the 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

CO (ppmv, dry, corrected to 7% O2) 40

Opacity (average) 10%

Particulate Matter (grains per dry standard cubic foot, corrected to 7% O2)

0.013

4.4.1 Automatic Systems for Daily By-Product Collection and Handling

4.4.2 Periodic By-Product Management

4.5.1 Emission Requirements.

O2 (%) Minimum of 6% by volume

HCl (ppmv, dry, corrected to 7% O2) 15

NOx (ppmv, dry, corrected to 7% O2) 103

SOx (ppmv, dry, corrected to 7% O2) 3.1

Dioxins/furans (ng/dscm, corrected to 7% O2) 33

Cadmium (mg/dscm, corrected to 7% O2) 18

Lead (mg/dscm, corrected to 7% O2) 226

Mercury (mg/dscm, corrected to 7% O2) 74

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 designed to be easily replaced or cleaned.

4.6 Control and Alarm Requirements

4.6.1 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 operators 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 contractor 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 the operation of the feeding, thermal destruction, and 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 4.13) 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.

4.5.2 Temperature Requirement

4.5.3 Exhaust Plume

4.5.4 Burning Embers, Sparks, and Fly Ash

4.6.2 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).

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 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 3.2.

During alarm or emergency shutdown. Provision shall be made for remote Emergency Stop Control

Switches, to immediately shut down that component and initiate an entire system shutdown. These switches shall be located in various locations in all system compartments (such as 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 contractor and will trip the main circuit breaker for the system. The system will be shut down immediately due to the loss of utility power.

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.

4.6.3 Fail-Safe and Emergency Shut Down

4.7 Guards and Safety Interlocks

4.8 Doors and Other Accesses

4.9 System Strength

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

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 contractor shall provide transformers and/or regulated power supplies to create all signal 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 contractor 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 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

4.10 Electrical Systems

4.11 Piping Systems

4.12 Equipment Life, Reliability and Maintainability

4.12.1 Life Expectancy

4.12.2 Cleanliness

4.12.3 Reliability Requirements

4.12.4 Maintainability

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. All other maintenance required to maintain function for the 25-year 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.

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 (delivered 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 courseware training (delivered 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.

The manpower required to prepare and feed the waste, 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

4.12.5 U.S. Navy Ship Material Compatibility

4.12.6 Service Life

4.12.7 Paints and Coatings

4.13 Human Engineering

4.14 Manning

contractor shall propose, subject to Government approval, the types and hours of manpower necessary for safe operation and maintenance of the system.

(CDRL) Data Item A001 of the DD FORM 1423)

The contractor shall provide classroom training materials for the system. The training materials for the operators shall cover all operational techniques, safety, alarms, cleaning, and theory of operation of the system. The training materials for the maintainers shall cover all aspects of troubleshooting and maintaining the system. The maintainers will also take the operator training. A set of training aids for on-the-job training of the operators and maintainers shall be provided to reinforce the training in the computer based training.

(CDRL Data Item A001 of the DD FORM 1423)

The contractor shall provide their standard technical manual. The manual shall include the installation instructions for the system when installed on a concrete floor. The manual shall also include an illustrated parts breakdown and a complete list of all parts.

The system design shall limit the use of consumable materials and shall provide a list of them and their quantities as part of the proposal. The manning, cost, risk, space and weight to manage all consumable materials will impact system suitability. The usage requirements (how much, cost, how frequently, technical difficulty in using, criticality in using correctly, etc.) and the storage requirements (size, volume, weight, special storage and handling requirements, etc.) must be clearly defined and documented. Any consumable materials will have to be approved by the Navy for shipboard use.

The system shall be free from internal vibrations that could result in damage or the potential of damage to the ship structure, machinery, equipment, and systems, or interferes with the operation of the ship, its cargo systems, or any ship component.

The contractor shall provide a 120 VAC circuit from the control panel through a set of contacts on the emergency stop switch located outside the compartment, to open the fuel valves to supply fuel to the Thermal Destruction

System. The circuit breaker shunt trip should be connected to a separate set of contacts on the emergency stop switch via a 440 VAC circuit that is separate from the system controls. Therefore the emergency stop push button will trip the breaker and interrupt power to the fuel valves directly.

The system shall be designed in a way to minimize the damage to the system and minimize the hazard to occupants of the Thermal Destruction System compartment in the event of loss of any ship supplied service listed in Section

3.2; failure of any component; or during normal operation, ash removal, system start up, system shut down, or alarm/emergency shutdown. Note: a bypass duct, a backup quench of fresh water or air can be used to prevent system damage; however, these systems shall not be used during normal operation. Also, routing of the bypass stack will be restricted by ship structure and configuration similar to the main exhaust. See also Section 4.6.3

Failsafe Operation.

(CDRL Data Item A002)

4.15 Training Materials

4.16 Technical Manuals

4.17 Consumable Materials

4.18 Reserved

4.19 Shock and Vibration

4.20 Safety

4.20.1 Emergency Requirements

4.20.2 Forbidden Materials.

The Thermal Destruction System shall minimize the use of hazardous materials. Hazardous materials of concern are defined on the NAVSEA Target Chemicals List (N-LTC) in Appendix A. Appendix A, Table A-1 materials shall not be used. Table A-2 materials can be used assuming the risk is acceptable to the Navy.

The contractor shall provide the list of hazardous materials, what components they are used in, and their quantities.

The Navy will review the materials used, assess the risk, and determine whether the material is approved for use in the system. The contractor shall not use any hazardous materials in the system without prior approval by the Navy.

4.20.3 Surface Temperature

Outside or exposed surfaces which can attain a temperature of 125F (52C)or higher during any service condition shall be insulated wherever…