SOW for Nitrogen Generator DRAFT.pdf

SOW-PWS Template 3 May 2019 version Page 1

Statement of Work (SOW) for

Membrane Nitrogen Generator

1.0 INTRODUCTION

1.0.1 The Naval Surface Warfare Center Philadelphia Division (NSWCPD) is a

Department of Defense entity responsible for research and development, test and evaluation, engineering and fleet support organization for the Navy’s ships, submarines, military watercraft and unmanned vehicles. This requirement is for NSWCPD Code 418, which is responsible for in-service engineering support, life cycle management, and testing and evaluation for main propulsion steam systems, secondary steam systems, and auxiliary machinery.

1.0.2 This contract is for non-personal services. It does not create employment rights with the U.S. Government whether actual, inherent, or implied.

1.0.3 Government / Contractor Relationship

(a) The services to be delivered under this contract are non-personal services and the parties recognize and agree that no employer-employee relationship exists or will exist under the contract between the Government and the Contractor's personnel. Therefore, it is in the best interest of the Government to provide both parties a full understanding of their respective obligations.

(b) The Contractor employees shall identify themselves as Contractor personnel by introducing themselves or being introduced as Contractor personnel and displaying distinguishable badges or other visible identification for meetings with Government personnel. In addition, Contractor personnel shall appropriately identify themselves as

Contractor employees in telephone conversations and in formal and informal written correspondence

(c) Contractor personnel under this contract shall not engage in any of the inherently

Governmental functions listed at FAR Subpart 7.5 or DFARS Subpart 207.5.

(d) Employee Relationship:

1) The services to be performed under this contract do not require the Contractor or its personnel to exercise personal judgment and discretion on behalf of the Government.

Rather the Contractor's personnel will act and exercise personal judgment and discretion on behalf of the Contractor.

2) Rules, regulations, directives, and requirements that are issued by the U. S. Navy and NSWCPD under its responsibility for good order, administration, and security are applicable to all personnel who enter a Government installation or who travel on

Government transportation. This is not to be construed or interpreted to establish any degree of Government control that is inconsistent with a non-personal services contract.

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(e) Inapplicability of Employee Benefits: This contract does not create an employer-employee relationship. Accordingly, entitlements and benefits applicable to such relationships do not apply.

(f) Notice. It is the Contractor's, as well as the Government's, responsibility to monitor contract activities and notify the Contracting Officer if the Contractor believes that the intent of this Section has been or may be violated.

1) The Contractor shall notify the Contracting Officer in writing via letter or email within three (3) calendar days from the date of any incident that the Contractor considers to constitute a violation of this Section. The notice should include the date, nature, and circumstances of the conduct; the name, function, and activity of each Government employee or Contractor official or employee involved or knowledgeable about such conduct; identify any documents or substance of any oral communication involved in the conduct; and the Contractor's estimated date when, absent a response, cost, schedule or performance will be impacted.

2) The Contracting Officer will, within five (5) calendar days after receipt of notice, respond to the notice in writing. In responding, the Contracting Officer will either:

(i) Confirm the conduct is in violation and when necessary direct the mode of further performance,

(ii) Countermand any communication regarded as a violation,

(iii) Deny that the conduct constitutes a violation and when necessary direct the mode of further performance, or

(iv) In the event the notice is inadequate to make a decision, advise the Contractor what additional information is required, and establish the date by which it should be furnished by the Contractor.

1.1 BACKGROUND

Naval Surface Warfare Center Philadelphia Division (NSWCPD) Code 418 serves as the

Navy's experts for in-service engineering support, life cycle management, and testing and evaluation for main propulsion steam systems, secondary steam systems, and auxiliary machinery while striving for on-time delivery of ships and submarines, fostering a culture of affordability, and enhancing the cybersecurity of our systems.

The previous Membrane Nitrogen Generator was procured under NSWCPD contract No.

N65540-13-D-0020 for CVN O2N2 systems. The purpose of this effort is to procure a new unit for installation on CVNs during their Refueling Complex Overhaul (RCOH) as part of ship alteration (S/A) 9285.

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1.2 SCOPE OF WORK

The Contractor shall supply a shipboard nitrogen producer that employs membrane technology to separate nitrogen from ambient air that is to be installed on CVNs during

Refueling Complex Overhaul (RCOH). The contractor shall demonstrate the operational capacity of the system at the contractor’s facility and ship the system to HII-Newport

News to be installed in the CVN 74 USS John C Stennis.

2.0 APPLICABLE DOCUMENTS

2.1 Government Documents

2.1.1 Federal Standards

FED-STD-595, Colors used in government procurement

2.1.2 Department of Defense Specifications

MIL-S-16032, Switches and Detectors, Shipboard alarm systems

MIL-S-901, Shock test, H.I. (High Impact) shipboard machinery, and systems, requirements for

MIL-DTL-15090, Enamel, Equipment light gray, (Navy formula no.111)

MIL-DTL-24784/7B, Technical repair standards (TRS) for hull, mechanical, and electrical (HM&E) equipment, electronic equipment, and ordnance equipment

MIL-M-24784, Manual, technical, equipment’s and systems content, requirements for

2.1.3 Department of Defense Standards

MIL-STD-1472, Human Engineering

MIL-STD-777, Schedule of Piping, Valves, Fittings, and Associated

Piping Components for Naval Surface Ships

MIL-STD-889, Dissimilar Metals

MIL-STD-167, Mechanical Vibrations of Shipboard Equipment (Type I -

Environmental and Type II - Internally Excited)

MIL-STD-461E, Requirements for the Control of Electromagnetic

Interference Characteristics of Subsystems and Equipment

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MIL-STD-1330, Standard Practice for Precision Cleaning and Testing of

Shipboard Oxygen, Helium, Helium-Oxygen, Nitrogen and Hydrogen

Systems

MIL-STD-38784, Standard Practice for Manuals, Technical: General Style and Format Requirements

2.1.4 Commercial Item Description

A-A-59155, Commercial item description nitrogen, high purity, special purpose

2.1.5 Department of Defense Handbooks

S9086-H7-STM-010/CH-262, Lubricating Oils, Greases, Specialty

Lubricants and Lubricating Systems

S9074-AR-GIB-010/278, Requirements for Fabrication Welding and

Inspection, and Casting Inspection and Repair for Machinery, Piping and

Pressure Vessels

S9074-AQ-GIB-010/248, Requirements for Welding and Brazing

Procedure and Performance Qualification

T9074-AS-GIB-010/271, Requirements for Nondestructive Testing

Methods

0900-LP-001-7000, Fabrication and Inspection of Brazed Piping Systems

MIL-HDBK-470, Designing and Developing Maintainable Products and

Systems

MIL-HDBK-2036, Preparation of Electronic Equipment Specifications

MIL-HDBK-454, General Guidelines for Electronic Equipment

MIL-STD-740B, Airborne and Structureborne Noise Measurements and Acceptance Criteria of Shipboard Equipment

(Unless otherwise indicated, copies of the above specifications, standards and handbooks are available from the Standardization Document Order Desk, 700 Robbins

Avenue, Building 4D, Philadelphia, PA 19111-5094.)

2.2 Non-Government Publications

2.2.1 National Electrical Manufacturers Association

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NEMA 250, Enclosures for Electrical Equipment (1000 Volts Max)

(Application for copies should be addressed to the National Electrical

Manufacturers Association 1300 North 17th Street suite 1847 Rosslyn, VA

22209)

2.2.2 American Society of Mechanical Engineers (ASME)

Boiler and Pressure Vessel Code, Section VIII, Rules of Construction of

Pressure Vessels

ASME PTD 9, Displacement compressors Performance Test Code

(Application for copies should be addressed to the American Society of

Mechanical Engineers, 345 East 47th Street, New York, NY 10017)

2.2.3 Institute of Electrical and Electronics Engineers (IEEE)

IEEE 45, Recommended Practice for Electrical Installations on

Shipboard

IEEE 12207, Industry Implementation of International Standard ISO/IEC

12207: 1995 (ISO/IEC 12207) Standard for Information

Technology

(Application for copies should be addressed to the Institute of Electrical and

Electronics Engineers, IEEE, P.O. Box 6804, Piscataway, NJ 08854-6804)

2.2.4 Society of Automotive Engineers (SAE International)

SAE J 1739, Potential Failure Mode and Effects Analysis in Design

(Design FMEA); Potential Failure Mode and Effects Analysis in

Manufacturing and Assembly Processes (Process FMEA); and Potential

Failure Mode and Effects Analysis for Machinery (Machinery FMEA)

(Application for copies should be addressed to the SAE International, 400

Commonwealth Drive, Warrendale, PA 15096-0001)

2.2.5 Compressed Gas Association (CGA)

CGA G-10.1, Commodity specification for nitrogen

(May be obtained from the Compressed Gas Association, Inc. 1725

Jefferson Davis Highway, Arlington, VA 22202)

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2.2.6 International Organization for Standardization (ISO)

ANSI/ISO/ASQ Q9001-2015 – Quality Systems

The Contractor shall reference and utilize the latest version available when performing tasks within this SOW.

3.0. REQUIREMENTS

3.1 General

3.1.1 Requirements. The production system shall be configured for installation in a shipboard compartment and be capable of automatically producing nitrogen meeting the flow rate, purity and quality levels specified herein. Product nitrogen will be produced using membrane generation technology assembled in a single skid package. The system shall be capable of performing its function safely in a shipboard environment, undergoing ship’s motion (pitch, roll, list), and induced shock, vibrations, and Electro-magnetic interference (EMI). The producer shall contain a Programmable Logic Controller (PLC) or a similar device that monitors process conditions (pressures, temperatures, flow rates, and nitrogen purity) automatically to control the various components necessary to safely generate nitrogen at the specified pressure, flow, and purity. The producer shall be capable of operating in either manual or automatic modes. In automatic mode, the producer may go into standby mode to allow continuous operation when demand ceases or delivery pressure reaches 5000 psig. The producer shall continue to operate for 10-15 minutes in the standby mode; if no further demand is required during the 10-15 minute standby period, the producer shall shut down. In the manual mode the producer automatically shuts down with no standby mode when

5000 psig is reached.

3.1.2 Characteristics. The production system equipment, components, subcomponents, assemblies and subassemblies shall be constructed for maximum reliability and from materials and construction suitable for a marine environment and the fluid being processed. The nitrogen membrane generator shall be designed for ease of maintenance by shipboard personnel. The system shall be designed so that any component or equipment failure will not cause operator injury or damage to adjacent components. The control system shall automatically detect out-of-specification conditions, record conditions, and secure the plant safely, at which time personnel actions can reestablish proper parameters. The system shall incorporate manual override features to permit operation in the event of controller failures. The system shall be constructed in such a manner as to minimize air borne noise and EMI emissions.

3.2 First Article Test Unit. When specified, a sample shall be subjected to first article inspection in accordance with paragraph 4.3.

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3.3 Performance Requirements. The membrane nitrogen generator shall satisfy the following performance requirements.

3.3.1 Capacity. The nitrogen generator shall be capable of continuously producing not less than 99.5% purity nitrogen at a minimum storage flask accumulation rate of 24 SCFM while processing atmospheric air as specified in paragraphs 3.6.2 through 3.6.5.

3.3.2 Purity and Quality. Purity of the nitrogen produced shall be 99.5 % or greater, shall meet the requirements of A-A-59155, Type I (gaseous), Class 1 (oil-free), Grade B, and meet the following requirement for particulate, moisture, and hydrocarbon content: the product gas generated by the membrane nitrogen generator shall be a combination of Nitrogen, Oxygen, Argon, and trace contaminant gases normally found in ambient air; the product constituent shall not exceed 0.5% oxygen, 0.02 mg/L moisture and 50-ppm total hydrocarbons; no odor shall be detectable from the product. Use of a 10-micron filter on the discharge of the unit ensures compliance with the particulate size requirement.

3.3.3 Product Gas Delivery Pressure. The generator shall be capable of delivering nitrogen product gas at pressures up to 5200 psig under all ambient conditions specified herein.

3.3.4 Air Borne Noise. Continuously produced airborne noise levels shall not exceed 80 Decibels (dB) at any frequency.

3.4 Utilities

3.4.1 Electrical Power. The integrated system shall require only one source of electrical power. The source power shall be 440 volts, 3 phase, 60 hertz (Hz) with a maximum voltage variation of plus 10%, minus 20% of rated voltage at 122 degrees Fahrenheit. The maximum power demand shall not exceed 75 Kilowatts

(kW). The average power demand shall not exceed 60 kW. One circuit breaker or overload protection will be provided by the installing activity. All electrical components necessary to ensure proper operation of the nitrogen producer shall be supplied and integrally mounted within the equipment. Each component making up the producer system shall be completely wired and interconnected. All required breakers and overload protection shall be supplied and integrally mounted. All control power shall be obtained from the main input power. No types of power other than electrical shall be used. The electrical insulation resistance of each independent electric circuit shall have a resistance to ground and to other independent circuits greater than 5 mega ohms. Electrical and thermocouple wire shall be clearly labeled and run through wire harnesses and/or conduits.

3.4.2 Air Supply. Intake air at the conditions specified in paragraph 3.6.2 through

3.6.5 will be supplied to the production system from an independent ventilation

SOW-PWS Template 3 May 2019 version Page 8 supply. If air is required for operation of pneumatic systems or other equipment within the nitrogen producer, the air shall be taken from within the processing system itself.

3.4.3 Water: If any component or subassembly of the membrane nitrogen generator requires a shipboard-cooling medium, then that component or subassembly shall be capable of using seawater at a temperature of 97 degrees

Fahrenheit maximum.

3.5 Physical Characteristics

3.5.1 Dimensions and Weight: The system envelope dimensions shall not exceed

90 inches height, 147 inches width, and 48 inches depth. The height restriction includes the total height of the system component and the height gained by using resilient mounts including anticipated shock excursions. Maintenance clearances for any system component shall be considered as part of the dimensional restriction cited above. Total system weight, excluding mounting hardware, shall not exceed 3 tons (6000 pounds).

3.5.2 Operational Life: Each unit shall be operated in the shipboard environment specified herein for a period of 25 years with no limit on the number of operating cycles. Minimum time between overhauls shall be 30,000 operating hours.

3.5.3 Hatchable: The nitrogen production system shall be capable of fitting through a hatch opening measuring 66 x 26 inches.

3.6 Environmental

3.6.1 Pitch, Roll and List.: Each unit shall operate at rated capacity and purity under the following specified pitch, roll, and list conditions:

Pitch – 4 degrees for an 11 second period

Roll – 15 degrees for a 15 second period

List – 5 degrees continuous

Each unit shall not lose fluids or be damaged under the following conditions:

Operating at a fixed incline of up 15 degrees in any direction.

Operating while pitching at a maximum of 10 degrees up or down from its normal horizontal plane.

Operating while rolling a maximum of 30 degrees to either side of vertical.

3.6.2 Intake Air Contaminants. Each unit shall produce nitrogen that will meet the purity requirements as set forth in paragraph 3.3.2 at the rate specified in

SOW-PWS Template 3 May 2019 version Page 9 paragraph 3.3.1 when the influent air contains contaminants in the concentrations listed below:

Contaminants Concentration Maximum by Volume

Carbon Dioxide (CO2) 1000 p/ml

Water Vapor (H2O) Saturated

Nitrous Oxide (N2O) 5 ppm

Carbon Monoxide (CO) 20 ppm

Methane (CH4) 1 ppm

Sulfur Dioxide (SO2) 1 ppm

Acetaldehyde (C2H4O) 1 ppm

Acetylene (C2H2) 2 ppm

Ozone (O3) 0.8 ppm

3.6.3 Intake Air Temperature: Each unit shall produce nitrogen that will meet the paragraph 3.3.1 when operating in any ambient temperature between 40-122 degrees Fahrenheit. Under extreme ambient conditions, such as temperatures above 100 degrees Fahrenheit, 20 SCFM shall be sufficient as it still satisfies average shipboard demand.

3.6.4 Intake Air Pressure: Each unit shall produce nitrogen that will meet the paragraph 3.3.1 when operating at any ambient sea level pressure between 14.0 to

15.0 psia.

3.6.5 Intake Air Humidity. Each unit shall produce nitrogen that will meet the paragraph 3.3.1 when processing air at atmospheric temperatures between 40 –

122 degrees Fahrenheit and relative humidity between 0-95% RH (non condensing).

3.6.6 Shock. Each unit shall meet Grade A, Class I and/or Class II, deck mounted equipment shock requirements in accordance with MIL-S-901. The use of previous shock tests extensions shall be used to the maximum extent practical.

The use of resilient mounts requires the use of flexible interface connections for all shipboard interfaces. These interfaces shall be provided with the production system. (CDRL A014, A015, A016)

3.6.7 Vibration. Each unit shall meet the requirements of MIL-STD-167–1

Type I and Type II. (CDRL A017, A018)

3.6.8 Electromagnetic Interference (EMI). Each unit shall meet and demonstrate compliance with the requirements of MIL-STD-461 Rev E (dated 20 Aug 1999) for Surface Ship, Below Deck, Metallic Hull installations. (CDRL A019, A020)

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3.7 Materials: The materials used shall meet the requirements specified herein. The selected material shall conform to the requirements of MIL-STD-777 with the following exceptions: brazed base bosses are not allowed. The materials used in the nitrogen system shall be suitable for use in a marine environment at the pressures and temperatures specified. Incompatible oil or grease shall not be used. Pipe threaded (tapered threads) materials are not approved, except in certain auxiliary equipment approved by NSWCPD.

Materials used shall be limited to 300 series corrosion resistant steels, copper and copper alloys, silicon-bronze, 70/30 Cu-Ni, brass, aluminum, ductile iron, or Monel. Carbon steel alloys may be used for structural supports. Materials selected shall be treated to prevent corrosion and provide a corrosion allowance for a 25-year life. Cast iron shall not be used except when used in a lubricated environment not subject to marine contaminates.

3.7.1 Dissimilar Materials. The use of dissimilar metals shall be minimized to preclude galvanic corrosion and shall be in accordance with MIL-STD-889 requirements for selection and protection of dissimilar materials. Where dissimilar metal joints are used, the joint construction shall preclude metal-to-metal contact and moisture entrapment at the gasket.

3.7.2 Nonmetallic Materials. Nylon, combustible materials, or nonmetallic materials adversely affected or deteriorated by continued use shall not be used.

Materials, including gaskets and valve packing’s, shall be compatible with cleaning solvents as specified in MIL-STD-1330.

3.7.3 Compressor Heat Exchangers. Material in all heat exchanger tube bundles that contact seawater shall be titanium or 70-30 Cu-Ni. Heat exchanger shells and compression cylinders contacting seawater can be made of non-corrosion resistant material if Zinc anodes are provided in the design. Heat exchangers shall be constructed to be suitable for their intended operating environment. Painted or coated carbon steel pipe and fittings shall not be used.

3.7.4 Toxic Chemicals, Hazardous Substances, or Ozone Depleting Chemicals

(ODC’s). The use of toxic chemicals, hazardous substances, or ODCs shall be avoided whenever feasible. Materials used in the construction of the producer shall have no effect on the health of personnel when the materials are used for their intended purpose. Regardless of other requirements, materials and parts containing asbestos, cadmium, lithium, mercury or radioactive materials shall not be used.

3.7.5 Recycled, Recovered or Environmentally Preferable Materials. Recycled, recovered or environmentally preferable materials should be used to the maximum extent possible provided that the material meets or exceeds the operational and maintenance.

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3.8 Compressors: All compressors shall be an oil free design. The compressor shall be capable of operating continuously at the maximum delivery pressure (5000 psig) under environmental conditions specified herein without having to stop for cool-down. The lubricants used shall be of an approved type listed in NAVSEA Technical manual S9086-

H7-STM-010/CH-262.

3.9 Nitrogen Separation Modules: Membrane modules used in the generator shall be semi-permeable membrane gas separation modules capable of processing air from a suitable oil free air compressor and through its selectivity, permeability and solubility characteristic output a product gas conforming to the capacity and quality requirements indicated in paragraphs 3.3.1 and 3.3.2, respectively. The modules shall be capable of withstanding the environment in which they will be used. Otherwise, they shall be protected against chemical attacks from atmospheric contaminants, using known state of the art technology for their separation, such as dust filter, coalescent filter, ozone eliminators, etc.

3.10 Piping, Valves and Fittings: Unless otherwise specified, all piping, valves and fittings shall be in accordance with MIL-STD-777. Glass Reinforced Pipe (GRP) shall not be used. Pipe or tube made from Bessemer steel shall not be used. Piping, valves and fittings containing tapered pipe threads are not approved. Piping/tubing joints and terminals shall use straight threads with a face type O-ring seal, gasket or equivalent. O-rings used in the system piping shall be made of fluorocarbon material. Flexible hose connections are acceptable where installation on resilient mounts is required.

3.11 Vessels. Pressure containing vessels shall be in accordance with the ASME Boiler

Pressure Vessel Code Section VIII for unfired pressure vessels.

3.12 Pressure Gauges: If used to manually operate the system, pressure gauges shall be simplex for indicating gauge pressure. Only pressure gauges utilizing a C-type bourdon tube as the elastic element shall be used for nitrogen service. The bore diameter throughout the element shall be not less than .025 inch. Liquid filled gauges shall not be used for nitrogen service. The gauge shall have a circular scale; dial configuration, style, pointer rotation and pointer interface shall be in accordance with ANSI B40.1.

3.13 Pressure Transmitters: Pressure transmitters shall be 4-20 mA, two-wire, loop powered type. Dedicated pressure transmitters shall be provided to measure critical pressures.

3.14 Flow Meters: Flow meters shall be two-wire differential pressure cell transmitter type, employing a rupture proof bellows design. Flow meters shall have a LCD indicator and shall generate a 4-20 mA output. Meters will read in inches of water or pounds per hour and shall be accurate to within plus or minus 4 percent of actual flow measurements.

Normal operating readings shall be indicated within the middle one-third range of the indicator. The indicator shall be installed on a common instrumentation panel and/or the

PLC display and measure, as a minimum, the production rate of the system in SCFM.

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3.15 Temperature Indicating System: A temperature indicating system measuring critical temperatures within the system shall be provided for automatic and manual operation.

The system shall consist of individually installed resistance temperature detectors (RTDs) which are connected to one common temperature-indicating unit mounted on the front of the generator components and to the PLC input/output modules.

3.16 Intake Filter: Adequate intake filters shall be used to prevent particulate matter, fluids and other contaminants from potentially damaging membrane modules. The filter shall be removable and cleanable.

3.17 Product Filter: A 10-micron product filter shall be provided to prevent contaminating the shipboard nitrogen distribution system. The filter shall contain a removable and cleanable CRES 300 series filter element or suitable replacement element.

3.18 Product Purity Analyzer: The producer shall be provided with a gaseous analyzer that is capable of measuring the nitrogen gas streams. The analyzer shall be of paramagnetic type (Servomex Model 1800) accurate to within plus or minus 0.1 percent for measuring nitrogen purity. When nitrogen purity drops below 99.5 percent, the analyzer shall send a signal to dispose of or recycle the impure nitrogen. The delivery of nitrogen to storage when within purity specifications shall be automatic. Analyzer calibration equipment suitable for ship operator use and stowage shall be provided with the nitrogen producer, and shall include: calibration gas, cylinders, associated hoses, fittings, regulators, etc.

3.19 Programmable Logic Controller (PLC): A PLC or similar device programmed for complete, safe and reliable operation shall be contained within the oxygen generation and storage system. The PLC shall automatically sense control system parameters

(temperature, pressure, bulk purity, etc,) and energize the system, produce and store nitrogen product in accordance with the capacity and purity requirements of this specification. The PLC shall be designed so that installation, operation, inspection, maintenance and adjustments can be accomplished without causing injury or damage to equipment. It shall be designed so that one failure will not cause or produce an unsafe condition nor shall it cause a ripple effect. The PLC’s electrical system shall provide built-in safety features comprised of both hardware and software to guarantee safe system operation. The controller shall incorporate safety features for out of tolerance electrical voltages, and current. The PLC shall automatically detect out-of-specification conditions, record conditions, and secure the plant safely, at which time personnel actions would reestablish proper parameters. All software executables (PLC and PC), PLC ladder logic and PC source code; software tools (and/or licenses if applicable) and other software support information shall be provided with the producer. If PLC is password protected those passwords shall be supplied with the producer. (CDRL S002, S003, S007)

3.19.1 Program Requirements: The PLC shall be programmed to include functionality for Controlling, Alarming, and Data Storage (alarms and data). Data values shall be scaled in standard U.S. engineering units (PSI, Deg F, Gallons, SOW-PWS Template 3 May 2019 version Page 13

Pounds, Feet/Inches etc.) in the PLC throughout the program, and made available to the operator interface and network as such. The PLC shall detect and record alarm conditions and shutdown data (i.e. overpressure conditions, controller memory faults, controller execution faults, heater over temperature and out of specification product purity levels) in the central processing unit for failure analysis. The failure data (time and date of system failure/shutdown as well as vital information on temperature, pressure, flow, liquid levels and valve position) shall be available for downloading.

3.19.2 Inputs/Outputs (I/O): The controller shall have sufficient I/O capability to input all process variables required for safe operation and output all manipulated variables required to completely and safely control the nitrogen production system. In addition, inputs for the following process variables are required to be entered into the controller for monitoring and remote data acquisition purposes:

temperature, pressure, flow rate, and product purity. The generation system shall be provided with all necessary analog and digital interfaces to enable safe control of nitrogen production at the specified purity and rates. Provisions shall also be made to accept the analog/digital interface necessary as follows:

3.19.2.1 A remote emergency stop (kill) switch located just outside of the nitrogen producer compartment.

3.19.2.2 Signal interface from and to Damage Control (DC) Central to alert personnel staffing this space of an abnormal operational condition.

3.19.2.3 Ventilation failure alarm interlock.

3.19.3 Network: The PLC shall be provided with network interfaces for Ethernet and/or Serial interfaces. The Ethernet interface must support both TCP/IP and

UDP/IP protocols. The serial interface must support IEEE 1174 standard which adds interface functionality to serial communication links. This communication port shall allow temporary installation of a portable laptop to enable displaying information in the event of display failures.

3.19.4 Memory: The PLC shall be equipped with sufficient memory to perform all of the above functions. The PLC microprocessor shall operate the producer, store pertinent data and transmit data to a graphical display via the computer.

3.19.5 Programming Interface: The PLC shall be equipped with a local programming interface for a standard laptop computer using programming software. Software shall conform to requirements detailed in section 3.19.8.

Controller software shall not be used as a final safety check for over temperature and over pressure fault detection. The controller shall be programmed for data acquisition from pressure and temperature transducers, differential pressure transducers, analog inputs and outputs and any other pertinent data points. The

PLC shall input system parameters and shall use this data to provide operator

SOW-PWS Template 3 May 2019 version Page 14 prompting for system start up, operation, shutdown, emergency start up and shut down via a PC computer interface.

3.19.6 Power Supply: The PLC power supply shall be sufficient to power all the modules (Processor, I/O, Network). Controller, computer and graphics display power shall be obtained from the main input power of the producer. These power supplies shall be able to withstand/tolerate a 10% to 15% variation in line voltage and frequency change. When the voltage or frequency exceeds 1 to 3 AC cycles in duration the power supply shall issue a shutdown command to the processor.

3.19.7 Operator Interface (OI): The PLC shall be equipped with a direct interface to a programmable OI display in combination with switches and pushbuttons. The

OI shall be a flat panel color touch screen display with programmable screen views. The OI shall contain graphical (programmable) pushbuttons and data displays as required for an operator to manually control and view all processes required for safe nitrogen producer operation such as failure messages and diagnostic information to assist in operation and troubleshooting. The OI shall have separate screen views for alarming, trending, operator control and process monitoring of the nitrogen producer. Furthermore, the following OI are required

(combination OI display, switches, and buttons): Power ON/OFF, Auto/Manual, Start, Stop, and indicators for Power ON, Warm-up Mode, Running, Standing By, etc. The PLC shall be capable of accepting input from the operator to allow for emergency operation. The operator shall be able to monitor and modify maintenance requirement messages, access troubleshooting test functions and monitor alarm set points and incident histories. The controller shall also be capable of interfacing with a computer and/or a touch screen display to enable transmission of real time data when prompted. The data recorder shall be able to download and record information from the controller processor via a suitable and portable communication interface (e.g. an RS-232 or RJ-45 port).

3.19.7.1 Operator Screen View: The operator screen view shall provide a means for the operator to control the nitrogen producer. It shall have the ability to start and stop the producer via soft pushbuttons, and to manually take control of start up and shut down. Hard-wired buttons are acceptable provided they are located in close proximity to the PLC screen.

3.19.7.2 Alarm Screen View: The alarm screen view shall provide a display of all relevant alarm conditions associated with the nitrogen producer. The alarm screen shall provide a means for the operator to acknowledge and clear alarm conditions as appropriate.

3.19.7.3 Trend Screen View: The Trend screen view shall provide a means to graphically view several processes in real-time.

3.19.7.4 Process Monitoring Screen View: The process monitoring screen view shall provide a graphical view of the most relevant process variable

SOW-PWS Template 3 May 2019 version Page 15 to provide the operator a quick view of the nitrogen producer operation. It shall contain only the most relevant parameters (purity, pressures, temperatures, flows) needed to assess operation. Secondary level graphical views may be provided for display of additional detailed data parameters.

3.19.8 PLC/PC Software Documentation: All software (PLC and PC) shall be developed in compliance with IEEE/EIS 12207. If commercially available software meets all requirements specified herein, compliance to IEEE/EIS 12207 is not required. This would only be allowed if the commercially available software is utilized “as is” and NO software changes are required. Compliance with IEEE 12207 requires that all software development shall be planned, managed and documented appropriately throughout the software development life cycle. Those requirements of IEEE/EIS 12207 that are to be adhered to during the software development lifecycle shall be identified in the Statement of Work

(SOW), Contract Deliverable Requirements Lists (CDRLs) and the associated

Data Information Descriptions (DIDs). All developed software must have defined software requirements that are traceable from design to code and test. All software requirements must be consistent, feasible and verifiable. All developed software executables, source code and documentation shall be the property of the

US Navy. The software shall NOT be considered proprietary. If passwords or other security measures are employed, those passwords, security measures and codes shall be delivered with the producer. Commercially available software for

PC and PLC communication can be used to enable the prompts/interactions stated herein. If this option is pursued, the government shall be supplied with all rights and licensing agreements for use of said software. All embedded software shall not be susceptible to potential viruses when using communication ports specified herein. (CDRL A025, S008)

3.20 Hour Meters: A cumulative hour meter capable of recording up to a minimum of

99,999 hours shall be provided.

3.21 Master Switch Shutdown: The producer shall be provided with a master switch to shutdown all production equipment in the event of an emergency.

3.22 Motors and Controllers: Motors and controllers shall be in accordance with paragraph 33.6 of IEEE 45: “Electrical equipment in hazardous locations should be of a type suitable for such locations (Class, Division, or Zone and Group) and be type tested and certified or listed to a specific American national product standard by an independent testing laboratory acceptable to the regulatory authority (authority having jurisdiction)”.

3.23 Enclosures: Enclosures shall be NEMA 3 as defined by NEMA 250.

3.24 Valves:

3.24.1 Control valves: Valves shall be in accordance with MIL-STD-777 and as specified herein. Gate valves shall not be used in any throttling service. Valves

SOW-PWS Template 3 May 2019 version Page 16 shall have replaceable seats and discs. All control valves shall be equipped with an actuator-positioner assembly for automatic operation.

3.24.2 Drain Valves: A valve for oil sampling with locking device on the valve or cap shall be included on the compressors. Drain valves shall also be supplied to enable draining the heat exchangers.

3.24.3 Automatic Shut Off and Safety Valves: Electrically operated automatic shut-off valves shall be furnished with electric actuators at the producer or compressor air inlet. The generation process shall be protected from abnormal pressures by safety valves. Safety valves shall be located in one region to facilitate inspection and shall be equipped with flanged or union type outlets connected to a single vent header. Safety valves shall conform to MIL-S-16032 or be approved by NAVSEA.

3.24.4 Check Valve: A check valve shall be supplied and installed on the nitrogen compressor discharge to protect the compressor from nitrogen distribution system surges.

3.25 Pressure Switch: A pressure switch capable of interacting with the PLC and the shipboard distribution system pressure shall be supplied with the unit to enable automatic start and stop of the generating system.

3.26 Welding/Brazing: Welding shall be in accordance with NAVSEA S9074-ARGIB-

010/278. All welding procedures and personnel shall be qualified in accordance with

S9074-AQ-GIB-010/248. All brazing shall be performed in accordance with NAVSEA

0900-LP-001-7000. No component or piping system shall be soldered.

3.27 Paint: When tested the color shall match color number 26307 of FED-STD-595.

3.28 Flexibility: When tested in accordance with MIL-DTL-15090 the enamel shall show no evidence of cracking or flaking.

3.29 Ergonomics: MIL-STD-1472 takes precedence for ergonomics requirements not provided in this section. (CDRL A009)

3.29.1 Access: Adequate space shall be provided for personnel, their equipment, and free volume for the movements and activities that are required during operation and maintenance tasks under normal and emergency conditions.

3.29.2 Fail-safe: A fail-safe design shall be provided in those areas where failure can cause catastrophe through damage to equipment, injury to personnel, or inadvertent operation of critical equipment.

3.29.3 Simplicity of Design: The equipment shall represent the simplest design consistent with functional requirements and expected service conditions. It shall

SOW-PWS Template 3 May 2019 version Page 17 be capable of being operated, maintained and repaired in the specified operational environment by personnel with a minimum of training.

3.29.4 Functional Use of Colors: Where not in conflict with color codes specified herein, colors used for functional purposes (e.g. visual displays, controls, workspaces, equipment connections) shall accommodate users with color deficient vision.

3.29.5 Hazard Protection: Personnel protection from thermal, toxicological, radiological, mechanical, electrical, electromagnetic, pyrotechnic, visual, and other hazards shall be provided.

3.30 Reliability and Maintainability: The Mean Time between Failure (MTBF) shall not be less than 10,000 hours and a Mean Time to Repair (MTTR) of not greater than 4 hours. The scheduled general overhaul periodicity shall be at a minimum 10,000 operating hours for all wear parts excluding valves, rings, and filters. The minimum run time before maintenance of filters shall be 1000 hours. No more than 200 man-hours shall be required for all maintenance, planned and unplanned, between 10,000 hour overhauls. Required skill level for all maintenance, excluding overhauls, shall be shipboard level. Required skill level for overhauls shall be intermediate level. (CDRL

A006, A007)

3.31 Operating Cycle: The producer shall generate nitrogen at rated capacity within 15 to 20 minutes of start-up at ambient temperature. Upon starting the producer, it shall be capable of operating continuously and in a steady-state mode of operation for at least six hours at a time, with up to six start-ups per 24 hours. The producer shall power up automatically when system pressure drops to 4,000 psig and shall run until system pressure is restored to 5,000 psig. At that time, the producer shall run for 10-15 minutes in standby mode in anticipation of further demand. If no such demand is created, the producer shall safely shut down.

3.32 Identification Plates and Placards: Identification plates and placards shall be provided for the identification of all piping, valves, vessels and subcomponents in the system, for emergency shutdown and start-up operating procedures and flow schematic of the process components. The placards are to be installed on the generating system panels.

3.33 Logistics: The logistic data shall be provided in electronic formats as follows:

3.33.1 Drawings: System drawings shall be provided in Auto Cad format. Other formats may be acceptable with NAVSEA written approval. (CDRL A001)

3.33.2 Provisioning list: A detailed list of maintenance and repair parts shall be provided in electronic format, including all the drawings required to catalog parts in the US Navy supply system. (CDRL L001)

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3.33.3 Technical Manual. The technical manual shall include information for installation, operation, troubleshooting, lubrication, outline drawings showing overall dimensions and motor and controller drawings. Also included shall be exploded views, list of repair parts down to the lowest level, electrical data and diagrams, repair procedures, maintenance procedures and programmable controller program sequence. Installation instructions shall also be provided. The manual shall be in digital format. It shall contain links to the various sections in the technical manual for illustration purposes or for increased understanding of the matter being discussed. In order to demonstrate complicated maintenance items, a video link may be included. The manual shall be in accordance with

MIL-STD-38784 and MIL-M-24784. (CDRL A021, A022, A023)

4.0 TESTING/VERIFICAIONS

The Contractor shall perform the required testing at the Contractor’s facility to verify that the generation and storage system delivered to the US Navy conforms to all requirements specified. Testing shall be witnessed by a technical representative from NSWCPD Code

418.

4.1 General Inspection Requirements

4.1.1 General provisions for inspection: Inspection, as used herein, shall be understood to mean the examination and applicable testing of materials, fabricated components, the manufacturing processes and the completed assemblies to determine and ensure conformance to the specifications set forth in the contract or purchase order.

4.1.2 Responsibility for inspection: The contractor shall provide and maintain a written inspection system which will assure that all supplies and services submitted to the Government for acceptance conform to contract requirements whether manufactured or processed by the contractor, or procured from subcontractors or vendors. The contractor shall perform or have performed the inspections and tests required to substantiate product conformance to drawings, specifications, and contract requirements and shall also perform or have performed all inspections and tests otherwise required by the contract. The contractor's inspection system shall be documented and shall be available for review by the Naval Surface Warfare Center Philadelphia Division - Philadelphia

Site, Naval Business Center, Bldg. 4, 5001 S. Broad Street, Philadelphia, PA

19112-5083, Attn. Code 418, via the DCMA, fifteen (15) days after award of contract and throughout the life of the contract. The contractor shall notify the

Naval Surface Warfare Center Philadelphia Division - Philadelphia Site in writing of any change to the inspection system. The inspection system shall be subject to disapproval if changes thereto would result in nonconforming product.

4.1.3 Responsibilities for compliance: All items shall meet all requirements of section 3. The inspection set forth in this specification shall become part of the

SOW-PWS Template 3 May 2019 version Page 19 contractor’s overall inspection system. The absence of any inspection requirements in the specification shall not relieve the contractor of the responsibility of ensuring that all products or supplies submitted to the

Government for acceptance comply with all requirements of the contract or purchase order. Sampling inspection, as part of the manufacturing operations, is an acceptable practice to ascertain conformance to requirements; however, this does not authorize submission of defective material, either indicated or actual, nor does it commit the Government to accept defective material. Requests for waivers or deviations shall be submitted using Forms DD 1694 and MIL-STD-973 as a guide. A "Request for Waiver" shall be used for government acceptance of all

Type I and Type II nonconformance.

4.1.4 Government Participation: The contractor shall notify the procuring activity regarding the starting date of tests and examinations as soon as it is determined.

4.1.5 Inspection System/Design Verification Test Plan: A test and inspection system program plan shall be prepared and approved by the procuring agency prior to commencement of all tests and examinations required herein. The test plan shall address all required test procedures for verification of performance and functional compliance with the stated requirements of the complete system. The test plan shall also include all instrumentation, electrical hookups, test sequences, facilities, etc., which the contractor intends to use. All special test equipment shall be fully identified and provided to the government upon request as an accessory of the system. All special tools shall be identified and recommended as a requirement for the maintenance of the system. The use of special tools shall be kept to a minimum. In addition, the contractor shall perform a Failure Mode and

Effects Criticality Analysis (FMECA), which shall be reviewed during the critical design review phase. The FMECA shall be performed in accordance with SAE J

1739. The analysis shall indicate clearly the design approach to mitigate all risk areas found during the FMECA analysis. (CDRL A012, A013)

4.2 Classification of inspections

The Inspection requirements specified herein are classified as follows:

a. First article inspection (see paragraph 4.3)

b. Capacity conformance inspection (see paragraph 4.4)

4.3 First article inspection

First article inspection is accomplished for verification purposes to validate the vendor’s conformance to this specification. The first article inspection shall consist of examinations and tests specified in paragraphs 4.6.1 through 4.6.20.

The first article test unit is the same unit as the first production unit provided it passes all tests specified in paragraphs 4.6.1 through 4.6.20 or test is waived by the government.

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4.4 Capacity conformance inspection

This inspection shall consist of examination and tests specified in paragraphs 4.6.2 through 4.6.5, 4.6.7 through 4.6.9, 4.6.18, 4.6.19 and 4.6.20. Software quality assurance shall be developed, reviewed, tested and controlled in accordance with tailored requirements of IEEE/EIS 12207. Nonconformance to one or more requirements of this specification or failure of any one or more tests shall be cause for rejection of unit.

Except for the first article unit, each unit shall be subjected to conformance inspection.

4.5 Examination

Each unit shall be examined thoroughly both during and after manufacturing to ensure total conformance to the requirements specified herein. The inspection shall be performed in accordance with ANSI/ISO/ASQ Q9001-2015, quality systems, or MIL-STD-740 and

MIL-STD-1330. Subsequent units manufactured under each contract shall be examined to ensure conformance. Failure to conform in any respect with the requirements specified herein shall be grounds for rejection of a unit. (CDRL A012)

4.6 Testing

Testing shall be conducted as specified herein. Upon completion of each test, all parts damaged by that test shall be replaced. A plan outlining procedures for all tests included herein shall be submitted to the government prior to commencement of any test. (CDRL

A008, A010, A011)

4.6.1 Membrane module compatibility to Ozone and other contaminants testing.

A small breadboard size membrane module shall be tested separately to verify conformance with the shipboard environment, as specified in paragraph 3.9. This test shall be performed before beginning the system manufacturing process. Air containing contaminates cited in paragraph 3.6.2 shall be supplied to the sample membrane modules to verify conformance with the operational life, as specified in paragraph 3.5.2.