LONG_-_System_Specification.doc

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PMA260C21/3014/V6.0

19 June 2013

Department of the Navy

Program Executive Office PMA260

Naval Air Systems Command

Patuxent River, Maryland 20670-1161

System Specification

For The

Liquid Oxygen/Nitrogen Generator

(LONG)

Distribution Statement A: Approved for public release; distribution is unlimited.

Approved:

Title:

Logistics Integration Management

SE and ALRE Systems Engineering

(AIR-6.6)

(AIR-4.8.1)

Program Manager

(PMA260C)

Revision History

Update of terminology and capitalization to match other program documents.

LSE

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11.0 SCOPE

1.1 Identification

1.2 Document Overview

2.0 APPLICABLE DOCUMENTS

2.1 General

2.2 Government Documents

2.3 Non-Government Documents

3.0 SYSTEM REQUIREMENTS

3.1 Definition

3.2 Characteristics

3.2.1 Performance Characteristics

3.2.1.1 Produce Product from Ambient Air

3.2.1.1.1 Produce Liquid Oxygen

3.2.1.1.2 Produce Liquid Nitrogen

3.2.2 Interface Requirements

3.2.2.1 External Interfaces

3.2.2.1.1 Operator Interface

3.2.2.1.1.1 Generator to Operator Information Link

3.2.2.1.1.1.1 Purity Monitor

3.2.2.1.1.1.2 Hour Meter

3.2.2.1.1.2 Operator to Generator Operations Link

3.2.2.1.1.2.1 Location of Controls and Instrumentation

3.2.2.1.2 Power Source Interface

3.2.2.1.2.1 Power Supply to Generator Power Link

3.2.2.1.2.1.1 Input Power

3.2.2.1.2.1.2 Power Requirements

3.2.2.1.2.1.3 Length, Power Cable

3.2.2.1.2.1.4 Input Power Connectors

3.2.2.1.2.1.5 Mating Connections, Power Cable

3.2.2.1.3 Storage Equipment Interface

3.2.2.1.3.1 Generator to Liquid Storage Tanks Link

3.2.2.1.3.1.1 Length, Liquid Oxygen Hose

3.2.2.1.3.1.2 Construction, Liquid Oxygen Hose

3.2.2.1.3.1.3 Static Bend Radius, Liquid Oxygen Hose

3.2.2.1.3.1.4 Heat Leak Rate, Liquid Oxygen Hose

3.2.2.1.3.1.5 Mating Connections, Liquid Oxygen Hose

3.2.2.1.3.1.6 Caps, Liquid Oxygen Hose

3.2.2.1.3.1.7 Length, Liquid Nitrogen Hose

3.2.2.1.3.1.8 Construction, Liquid Nitrogen Hose

3.2.2.1.3.1.9 Static Bend Radius, Liquid Nitrogen Hose

3.2.2.1.3.1.10 Heat Leak Rate, Liquid Nitrogen Hose

3.2.2.1.3.1.11 Mating Connections, Liquid Nitrogen Hose

3.2.2.1.3.1.12 Caps, Liquid Nitrogen Hose

3.2.3 Physical Characteristics

3.2.3.1 Dimensions

3.2.3.2 Weight

3.2.3.3 Exterior Color

3.2.3.4 Turbo Expander

3.2.4 System Quality Factors

3.2.4.1 Reliability

3.2.4.1.1 Reliability (Quantitative) Mean Time Between Failures

3.2.4.2 Maintainability

3.2.4.2.1 Maintainability (General)

3.2.4.2.2 Maintenance Provisions

3.2.4.2.3 Mean Time To Repair

3.2.4.2.4 Common/Standard Tools

3.2.4.2.5 Special Tools

3.2.4.2.6 Preventive/Scheduled Servicing and Inspections

3.2.5 Environmental Conditions

3.2.5.1 High Temperature Storage

3.2.5.2 Low Temperature Storage

3.2.5.3 High Temperature Operation

3.2.5.4 Low Temperature Operation

3.2.5.5 Humidity

3.2.5.6 Rain

3.2.5.7 Salt Fog

3.2.5.8 Sand and Dust

3.2.5.9 Noise

3.2.5.10 High Altitude Operation

3.2.6 Transportability

3.2.6.1 Fork Lifting

3.2.6.2 Lifting/Tiedown Provisions

3.2.6.3 Truck Shipping Vibration

3.2.6.4 Air Transportability

3.2.6.5 Air Transportation Acceleration Forces

3.2.6.6 Hose and Cable Storage

3.2.6.7 Trailer Mounted System

3.3 Design and Construction

3.3.1 Materials

3.3.1.1 Hazardous Materials

3.3.1.2 Restricted Chemicals

3.3.1.3 Targeted Chemicals

3.3.1.4 Metal Alloys

3.3.1.5 Lead

3.3.1.6 Protective Coatings

3.3.1.7 Hexavalent Chromium

3.3.1.8 Lithium Batteries

3.3.2 Electromagnetic Radiation

3.3.2.1 Electromagnetic Interference

3.3.3 Nameplates and Product Marking

3.3.3.1 Equipment Data Plate

3.3.3.2 Caution and Warning Labels

3.3.3.3 Lifting Data Plate

3.3.3.4 Flow and Electrical Schematics

3.3.4 Workmanship

3.3.4.1 Quality Management Systems

3.3.4.2 Workmanship (General)

3.3.4.3 Workmanship (Electrical)

3.3.5 Safety

3.3.5.1 Oxygen System Design

3.3.5.2 Oxygen Cleaning

3.3.5.3 Material Compatibility

3.3.5.4 Grounding Provisions

3.3.6 Human Engineering

3.3.6.1 Human Factors / Human Engineering / Human System Integration (HF/HE/HSI) (General)

3.3.6.2 HF/HE/HSI (Qualitative)

4.0 QUALITY ASSURANCE PROVISIONS

4.1 Standard Performance Demonstration

4.2 Special Tests and Examinations

4.2.1 Verification of Production of Liquid Oxygen

4.2.2 Verification of Production of Liquid Nitrogen

4.2.3 Power Consumption Test

4.2.4 Size and Weight

4.2.5 Reliability Test

4.2.6 Maintainability Test

4.2.7 Component Environmental Compatibility

4.2.8 High Temperature Storage and Operation Test

4.2.9 Low Temperature Storage and Operation Test

4.2.10 Humidity Test

4.2.11 Rain Test

4.2.12 Salt Fog Test

4.2.13 Sand and Dust Test

4.2.14 Noise Test

4.2.15 High Altitude Test

4.2.16 Shipping Vibration Test

4.2.17 Air Transportability Certification

4.2.18 Air Transportability Acceleration Forces Test

4.2.19 Electromagnetic Interference Measurement

4.2.20 Quality System

4.2.21 Oxygen Cleanliness Test

4.2.22 Generic Analysis

4.2.23 Generic Demonstration

4.2.24 Generic Test

4.2.25 Inspection

4.3 Requirements Cross Reference

5.0 Preparation for Delivery

5.1 Transportation and Shipping

5.1.1 Packaging and Packing

6.0 NOTES

6.1 Acronyms and Abbreviations

10 Appendix A - Verification Cross-Reference Matrix

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1.0 SCOPE tc "1.0 SCOPE "

1.1 Identificationtc "1.1 Identification" \f \l2

This document establishes the system requirements for the Liquid Oxygen/Nitrogen Generator.

1.2 Document Overviewtc "1.2 Document Overview" \f \l2

From herein, the Liquid Oxygen/Nitrogen Generator (LONG) will be referred to as "the generator."

Section 2 contains a list of applicable documents referenced in this document.

Section 3 of this specification documents the characteristics needed of the generator. This section begins by identifying the performance characteristics of the new generator through functionality requirements and corresponding performance requirements which will identify what the generator must be capable of doing and how well. Next, this specification identifies the external systems with which the generator must interact, and the physical connections, or links, used in each interaction. The specification then focuses on overall generator requirements such as those for physical characteristics, environmental considerations, design, and construction.

Section 4 indicates the quality assurance provisions of this generator. This section lists each verification method that will be used to verify that the requirements of Section 3 have been met.

Section 5 specifies the packing, packaging, and marking of full-rate production generators.

Section 6 is a list of acronyms and abbreviations used in this document.

2.0 APPLICABLE DOCUMENTS tc "2.0 APPLICABLE DOCUMENTS "

2.1 Generaltc "2.1 General" \f \l2

Sections 2.2 and 2.3 list external documents applicable to this specification. This specification takes precedence if a conflict exists between it and any other document specified herein. In those instances within this specification where commercial and military specifications are indicated as "guidance only," the contractor is given latitude in equipment selection, material selection, component selection, etc. This in no way relieves the contractor from the responsibility of successfully passing the verifications called out in Section 4 of this specification. Military specifications/standards and industry standards identified in this document establish minimum performance requirements. Equivalent or better specifications and standards may be substituted upon approval of the Navy. When a specific requirement or verification procedure (Sections 3 and 4 of this specification, respectively) calls out one of these documents, the revision listed in Section 2.2 or 2.3 shall be used unless otherwise specified.

2.2 Government Documentstc "2.2 Government Documents" \f \l2

SPECIFICATIONS

Military

STANDARDS

Military

STANDARDS

Federal

DRAWINGS

OTHER PUBLICATIONS

Manual

OTHER PUBLICATIONS

Regulation

OTHER PUBLICATIONS

Handbook

OTHER PUBLICATIONS

Other

2.3 Non-Government Documentstc "2.3 Non-Government Documents" \f \l2

STANDARDS

OTHER PUBLICATIONS

3.0 SYSTEM REQUIREMENTS tc "3.0 SYSTEM REQUIREMENTS "

3.1 Definitiontc "3.1 Definition" \f \l2

The Liquid Oxygen/Nitrogen Generator (herein referred to as "the generator") will be a transportable piece of equipment used to produce liquid oxygen and nitrogen at both Marine expeditionary sites and Navy and Marine Corps stateside and overseas activities. Oxygen from the generator will be used to supply Navy and Marine Corps aircraft. Liquid nitrogen will be converted to a gas outside of the generator to fill tires, landing gear struts, accumulators, purging of oxygen lines, and in any other system requiring an inert gas. To accomplish this mission, the generator shall meet the requirements specified herein.

3.2 Characteristicstc "3.2 Characteristics" \f \l2

3.2.1 Performance Characteristicstc "3.2.1 Performance Characteristics" \f \l3

3.2.1.1 Produce Product from Ambient Air [LONG-FCN-0003]tc "3.2.1.1 Produce Product from Ambient Air" \f \l3 The generator shall be capable of producing the following products from ambient air in all operational conditions specified herein.

a. [LONG-REQ-0068] The generator shall be capable of producing at least 1.5 tons/day of product in ambient conditions of 70°F, 1 atm, and 50% relative humidity for a minimum of 240 hours (10 days) of continuous operation.

3.2.1.1.1 Produce Liquid Oxygen [LONG-FCN-0002]tc "3.2.1.1.1 Produce Liquid Oxygen" \f \l3 The generator shall produce liquid oxygen with the following characteristics:

a. [LONG-REQ-0066] The liquid oxygen produced by the generator shall meet the contamination requirements for Type II (liquid) oxygen listed in MIL-PRF-27210H, paragraph 3.3 and subparagraphs.

b. [LONG-REQ-0067] The generator shall produce liquid oxygen that meets the purity requirements for Type II (liquid) oxygen listed in MIL-PRF-27210H, paragraph 3.2.

3.2.1.1.2 Produce Liquid Nitrogen [LONG-FCN-0001]tc "3.2.1.1.2 Produce Liquid Nitrogen" \f \l3 The generator shall produce liquid nitrogen with the following characteristics:

a. [LONG-REQ-0065] The liquid nitrogen produced by the generator shall meet the requirements for Type II (liquid), Grade B, Class 1 nitrogen as defined in A-A-59503.

3.2.2 Interface Requirementstc "3.2.2 Interface Requirements" \f \l3

3.2.2.1 External Interfacestc "3.2.2.1 External Interfaces" \f \l3

3.2.2.1.1 Operator Interface [LONG-IF-0001]tc "3.2.2.1.1 Operator Interface" \f \l3

3.2.2.1.1.1 Generator to Operator Information Link [LONG-LNK-0002]tc "3.2.2.1.1.1 Generator to Operator Information Link" \f \l3 The generator shall be capable of displaying the following information:

3.2.2.1.1.1.1 Purity Monitor [LONG-REQ-0055]tc "3.2.2.1.1.1.1 Purity Monitor" \f \l3 A purity monitor shall be provided to monitor the output product of the generator. If the purity monitor provided requires a zero or span gas, these gases shall be provided as part of the generator with proper bracketing/restraint for shipping.

3.2.2.1.1.1.2 Hour Meter [LONG-REQ-0057]tc "3.2.2.1.1.1.2 Hour Meter" \f \l3 A cumulative hour meter shall be provided on the generator as well as for major components that require scheduled maintenance actions based on cumulative operating hours.

3.2.2.1.1.2 Operator to Generator Operations Link [LONG-LNK-0003]tc "3.2.2.1.1.2 Operator to Generator Operations Link" \f \l3 All controls and instrumentation required to properly operate and monitor the generator shall be provided as part of the generator.

3.2.2.1.1.2.1 Location of Controls and Instrumentation [LONG-REQ-0054]tc "3.2.2.1.1.2.1 Location of Controls and Instrumentation" \f \l3 To the greatest extent practical, all controls and instrumentation shall be located in a central location so that one operator can operate the generator properly and safely with protection from the harsh operational environmental conditions specified herein.

3.2.2.1.2 Power Source Interface [LONG-IF-0002]tc "3.2.2.1.2 Power Source Interface" \f \l3

3.2.2.1.2.1 Power Supply to Generator Power Link [LONG-LNK-0004]tc "3.2.2.1.2.1 Power Supply to Generator Power Link" \f \l3 The generator shall operate on facility ("pole") power and current Navy/Marine Corps power generators as specified below.

3.2.2.1.2.1.1 Input Power [LONG-REQ-0059]tc "3.2.2.1.2.1.1 Input Power" \f \l3 The generator shall be capable of operating to the requirements specified herein when supplied with 380 VAC 50 Hertz or 480 VAC 60 Hertz, 3 Phase input power. The generator shall be capable of operating correctly where the steady-state supply voltage is from 90 percent to 110 percent of the nominal voltage and the frequency is from 99 percent to 101 percent of the nominal frequency continuously.

3.2.2.1.2.1.2 Power Requirements [LONG-REQ-0060]tc "3.2.2.1.2.1.2 Power Requirements" \f \l3 The maximum power required to operate the generator under all conditions specified herein shall not exceed 250kVA with a power factor of 0.8 lagging.

3.2.2.1.2.1.3 Length, Power Cable [LONG-REQ-0061]tc "3.2.2.1.2.1.3 Length, Power Cable" \f \l3 A 75ft (minimum) long electrical power cable shall be provided with the generator.

3.2.2.1.2.1.4 Input Power Connectors [LONG-REQ-0062]tc "3.2.2.1.2.1.4 Input Power Connectors" \f \l3 The generator shall have input power connectors installed on the exterior in accordance with MIL-DTL-22992G.

3.2.2.1.2.1.5 Mating Connections, Power Cable [LONG-REQ-0063]tc "3.2.2.1.2.1.5 Mating Connections, Power Cable" \f \l3 One end of the power cable shall have a weatherproof connector in accordance with MIL-DTL-22992G to mate with the weatherproof connector on the generator. The other end of the cable shall have four open leads to accommodate hard wiring into pole power or a Navy/Marine Corps power generator.

3.2.2.1.3 Storage Equipment Interface [LONG-IF-0003]tc "3.2.2.1.3 Storage Equipment Interface" \f \l3

3.2.2.1.3.1 Generator to Liquid Storage Tanks Link [LONG-LNK-0001]tc "3.2.2.1.3.1 Generator to Liquid Storage Tanks Link" \f \l3 The generator shall hook up to liquid oxygen and nitrogen storage vessels to allow filling of that equipment.

3.2.2.1.3.1.1 Length, Liquid Oxygen Hose [LONG-REQ-0040]tc "3.2.2.1.3.1.1 Length, Liquid Oxygen Hose" \f \l3 A 15ft (minimum) long oxygen servicing hose shall be provided to fill liquid oxygen storage tanks.

3.2.2.1.3.1.2 Construction, Liquid Oxygen Hose [LONG-REQ-0041]tc "3.2.2.1.3.1.2 Construction, Liquid Oxygen Hose" \f \l3 The liquid oxygen servicing hose shall have a spiral wrap cover and be designed and constructed in accordance with ASME B31.3, Code for Pressure Piping. This hose shall be distinguishable (by sight) from the nitrogen servicing hose.

3.2.2.1.3.1.3 Static Bend Radius, Liquid Oxygen Hose [LONG-REQ-0042]tc "3.2.2.1.3.1.3 Static Bend Radius, Liquid Oxygen Hose" \f \l3 The liquid oxygen hose shall be flexible and have a minimum static bend radius that prevents kinking and damage to the hose.

3.2.2.1.3.1.4 Heat Leak Rate, Liquid Oxygen Hose [LONG-REQ-0043]tc "3.2.2.1.3.1.4 Heat Leak Rate, Liquid Oxygen Hose" \f \l3 The liquid oxygen servicing hose shall be a flexible vacuum jacketed hose with a heat leak rate of not more than 0.950 BTU/hr-ft when liquid product is the fluid being transferred.

3.2.2.1.3.1.5 Mating Connections, Liquid Oxygen Hose [LONG-REQ-0045]tc "3.2.2.1.3.1.5 Mating Connections, Liquid Oxygen Hose" \f \l3 The liquid oxygen servicing hose shall mate with the liquid oxygen product port on the generator on one end and have a 1 inch female NPT on the other end. Additionally, an adaptor shall be provided to go from the 1 inch female NPT to the Acme threads on a 1212AS140-1 fitting. NAVAIR drawing 1212AS140 shows the details on this fitting. NAVAIR 1212AS140 and associated lower level drawings (1212AS141 and 1212AS142) are provided as part of the solicitation.

3.2.2.1.3.1.6 Caps, Liquid Oxygen Hose [LONG-REQ-0046]tc "3.2.2.1.3.1.6 Caps, Liquid Oxygen Hose" \f \l3 The liquid oxygen servicing hose shall have caps or plugs on the end connections affixed to the hose with a lanyard or similar device.

3.2.2.1.3.1.7 Length, Liquid Nitrogen Hose [LONG-REQ-0047]tc "3.2.2.1.3.1.7 Length, Liquid Nitrogen Hose" \f \l3 A 15ft (minimum) long nitrogen servicing hose shall be provided to fill liquid nitrogen storage tanks.

3.2.2.1.3.1.8 Construction, Liquid Nitrogen Hose [LONG-REQ-0048]tc "3.2.2.1.3.1.8 Construction, Liquid Nitrogen Hose" \f \l3 The liquid nitrogen servicing hose shall have a spiral wrap cover and be designed and constructed in accordance with ASME B31.3, Code for Pressure Piping. This hose shall be distinguishable (by sight) from the oxygen servicing hose.

3.2.2.1.3.1.9 Static Bend Radius, Liquid Nitrogen Hose [LONG-REQ-0049]tc "3.2.2.1.3.1.9 Static Bend Radius, Liquid Nitrogen Hose" \f \l3 The liquid nitrogen hose shall be flexible and have a minimum static bend radius that prevents kinking and damage to the hose.

3.2.2.1.3.1.10 Heat Leak Rate, Liquid Nitrogen Hose [LONG-REQ-0050]tc "3.2.2.1.3.1.10 Heat Leak Rate, Liquid Nitrogen Hose" \f \l3 The liquid nitrogen servicing hose shall be a flexible vacuum jacketed hose with a heat leak rate of not more than 0.950 BTU/hr-ft when liquid product is the fluid being transferred.

3.2.2.1.3.1.11 Mating Connections, Liquid Nitrogen Hose [LONG-REQ-0052]tc "3.2.2.1.3.1.11 Mating Connections, Liquid Nitrogen Hose" \f \l3 The liquid nitrogen servicing hose shall mate with the liquid nitrogen product port on the generator on one end and have a 1 inch female NPT on the other end. Additionally, an adaptor shall be provided to go from the 1 inch female NPT to the Acme threads on a 1212AS140-1 fitting. NAVAIR drawing 1212AS140 shows the details on this fitting. NAVAIR 1212AS140 and associated lower level drawings (1212AS141 and 1212AS142) are provided as part of the solicitation.

3.2.2.1.3.1.12 Caps, Liquid Nitrogen Hose [LONG-REQ-0053]tc "3.2.2.1.3.1.12 Caps, Liquid Nitrogen Hose" \f \l3 The liquid nitrogen servicing hose shall have caps or plugs on the end connections affixed to the hose with a lanyard or similar device.

3.2.3 Physical Characteristicstc "3.2.3 Physical Characteristics" \f \l3

3.2.3.1 Dimensions [LONG-REQ-0001]tc "3.2.3.1 Dimensions" \f \l3 The generator shall not exceed maximum dimensions to allow air transport in C-130, C-17, and C-5 aircraft in accordance with MIL-HDBK-1791. See MIL-HDBK-1791 for C-130, and C-5 aircraft; and MIL-HDBK-1791, Appendix B, for C-17 aircraft.

3.2.3.2 Weight [LONG-REQ-0002]tc "3.2.3.2 Weight" \f \l3

Maximum weight shall be governed by the limitations imposed by the modes of transportation to be employed.

Air Movement

The generator's weight shall be governed by the payload and floor loading requirements of MIL-HDBK-1791. See MIL-HDBK-1791 for C-130, and C-5 aircraft; and MIL-HDBK-1791, Appendix B, for C-17 aircraft.

Road Movement

The generator shall be designed for unrestricted transportation via over-the-road trucks in accordance with Department of Transportation (DOT) regulations.

3.2.3.3 Exterior Color [LONG-REQ-0003]tc "3.2.3.3 Exterior Color" \f \l3 The generator shall have an exterior finish in accordance with MIL-PRF-85285E, Type II Polyurethane gloss white color number 17925 per FED-STD-595C.

3.2.3.4 Turbo Expander [LONG-REQ-0080]tc "3.2.3.4 Turbo Expander" \f \l3 If used on the generator, any turbo expander shall be oil-free.

3.2.4 System Quality Factorstc "3.2.4 System Quality Factors" \f \l3

3.2.4.1 Reliabilitytc "3.2.4.1 Reliability" \f \l3

3.2.4.1.1 Reliability (Quantitative) Mean Time Between Failures [LONG-REQ-0069]tc "3.2.4.1.1 Reliability (Quantitative) Mean Time Between Failures" \f \l3 Primary function reliability of the generator shall be as specified herein while being in conformance with all performance requirements, and under all environmental conditions specified. The generator shall have a Mean Time Between Failures (MTBF) of no less than 553 hours. Reliability Demonstration (RDEMO) testing will be executed to a 20% Consumer's Risk and accepted in accordance with the quality assurance RDEMO requirements and provisions of Section 4 of this specification.

3.2.4.2 Maintainabilitytc "3.2.4.2 Maintainability" \f \l3

3.2.4.2.1 Maintainability (General) [LONG-REQ-0004]tc "3.2.4.2.1 Maintainability (General)" \f \l3 Maintainability design of the generator shall focus on simplicity, accessibility, fault location, system test provisions (built-in test and/or test points), component interchangeability and availability, use of common tools and support/maintenance equipment, maintenance safety, and low frequency of corrective (unscheduled) and preventive (scheduled/periodic) maintenance.

3.2.4.2.2 Maintenance Provisions [LONG-REQ-0005]tc "3.2.4.2.2 Maintenance Provisions" \f \l3 Maintenance Provisions shall be in accordance with MIL-S-8512D Paragraphs 3.3.7 - 3.3.7.4. The generator shall be designed such that any non-destructive maintenance inspections and tasks that are required to determine physical wear, condition, suitability for use, and fluid and lubrication level and condition, shall be within the capability of Naval maintenance personnel utilizing common/standard tools and maintenance equipment. The generator design, packaging, and architecture shall facilitate rapid visual and/or measurement determination of all external physically wearing components, consumable fluids, and consumable parts/materials. The generator shall be designed to allow the changing of external air filters while the generator is fully operational without affecting performance.

3.2.4.2.3 Mean Time To Repair [LONG-REQ-0006]tc "3.2.4.2.3 Mean Time To Repair" \f \l3 The generator shall meet a Mean-Time-To-Repair (MTTR) of 5 hours or less at the Intermediate Maintenance Level. The MTTR shall include only corrective maintenance task times. Corrective maintenance task time-to-repair shall include, but not be limited to, the summation of the following time elements: fault/failure detection, localization, isolation, disassembly, interchange (remove and replace), reassembly, alignment, and checkout.

3.2.4.2.4 Common/Standard Tools [LONG-REQ-0077]tc "3.2.4.2.4 Common/Standard Tools" \f \l3 The quantity of tools, accessories, and equipment required for maintenance, and inspections of the generator, and any of its assemblies/components, shall be kept to a minimum.

3.2.4.2.5 Special Tools [LONG-REQ-0078]tc "3.2.4.2.5 Special Tools" \f \l3 Special tools, herein defined as tools, jigs, fixtures, stands, and templates shall be kept to a minimum. Any special tools identified shall be provided with the generator.

3.2.4.2.6 Preventive/Scheduled Servicing and Inspections [LONG-REQ-0079]tc "3.2.4.2.6 Preventive/Scheduled Servicing and Inspections" \f \l3 Servicing, maintenance, and inspection tasks that are identified with a “daily” frequency will be accomplished by, and must be within the capabilities of, the equipment operators. “Daily” inspection and servicing tasks shall include, but not limited to, the following: inspection for leaks, checking fluid levels, checking for corrosion, damage, and security of components. Such tasks shall be listed on the Pre-Operational Checklist as defined in the Acquisition Logistics Support Statement of Work (ALSSOW). Tools shall not be required to perform any routine “daily” task. The time required for one operator/maintenance person to perform the entire “daily” regimen of servicing, maintenance, and inspection tasks shall not exceed 15 minutes.

3.2.5 Environmental Conditionstc "3.2.5 Environmental Conditions" \f \l3

3.2.5.1 High Temperature Storage [LONG-REQ-0007]tc "3.2.5.1 High Temperature Storage" \f \l3 The generator shall be able to be stored at temperatures up to and including 160° F for 30 days. After being stored at the above temperature for 30 days, when placed in ambient conditions of 70° F & 50% relative humidity and allowed to stabilize, the generator shall be capable of being operated and generate product meeting all the requirements indicated herein without corrective maintenance.

3.2.5.2 Low Temperature Storage [LONG-REQ-0008]tc "3.2.5.2 Low Temperature Storage" \f \l3 The generator shall be able to be stored at temperatures down to and including -51° F for 30 days. After being stored at the above temperature for 30 days, when placed in ambient conditions of 70° F & 50% relative humidity and allowed to stabilize, the generator shall be capable of being operated and generate product meeting all the requirements indicated herein without corrective maintenance.

3.2.5.3 High Temperature Operation [LONG-REQ-0009]tc "3.2.5.3 High Temperature Operation" \f \l3 The generator shall be able to be operated in ambient temperatures up to and including 120° F. When operating at 120° F, the generator shall be capable of meeting all the performance characteristics (excluding production rate) indicated herein.

3.2.5.4 Low Temperature Operation [LONG-REQ-0010]tc "3.2.5.4 Low Temperature Operation" \f \l3 The generator shall be able to be operated in ambient temperatures down to and including -25° F. When operating at -25° F, the generator shall be capable of meeting all the performance characteristics (excluding production rate) indicated herein.

3.2.5.5 Humidity [LONG-REQ-0012]tc "3.2.5.5 Humidity" \f \l3

The generator shall be capable of being stored and operated in relative humidity conditions up to 95 percent.

3.2.5.6 Rain [LONG-REQ-0013]tc "3.2.5.6 Rain" \f \l3

The generator shall be fully operational under the following rainy conditions: rain rate of 4 inches per hour, average rain drop size of 0.5 millimeters diameter, wind blowing at 40 miles per hour.

3.2.5.7 Salt Fog [LONG-REQ-0014]tc "3.2.5.7 Salt Fog" \f \l3

The generator shall be capable of being stored and operated in salt-laden environments containing a salt concentration of 5 percent.

3.2.5.8 Sand and Dust [LONG-REQ-0015]tc "3.2.5.8 Sand and Dust" \f \l3 The generator shall operate under blowing sand and dust environments. The sand and dust particle sizes range from 20 to 850 microns. The wind velocity ranges from 1.5 to 8.9 meters per second.

3.2.5.9 Noise [LONG-REQ-0016]tc "3.2.5.9 Noise" \f \l3

The noise level generated by the generator shall not exceed 110 dBA three meters from any point on the generator. The noise level shall also not exceed 110 dBA at the position that an operator would normally be located.

3.2.5.10 High Altitude Operation [LONG-REQ-0017]tc "3.2.5.10 High Altitude Operation" \f \l3 The generator shall be fully functional (excluding production rate) when operated at altitudes up to 7,000 feet above sea level.

3.2.6 Transportabilitytc "3.2.6 Transportability" \f \l3

3.2.6.1 Fork Lifting [LONG-REQ-0019]tc "3.2.6.1 Fork Lifting" \f \l3 Equipment designed for fork lifting shall be provided with heavy-duty reinforced forklift tine guides. The forklift tine guides shall permit safe and positive insertion. The forklift tine guides shall be positioned to assure proper balancing. The forklift tine guide areas shall be constructed to permit the equipment to be lifted without damage.

3.2.6.2 Lifting/Tiedown Provisions [LONG-REQ-0020]tc "3.2.6.2 Lifting/Tiedown Provisions" \f \l3 The generator shall be capable of being lifted by crane without the use of spreader bars. The generator at its rated gross shipping weight shall meet lifting and tiedown provision requirements of MIL-STD-209, and the highest value calculated for any one tiedown provision shall be applied to all tiedown provisions. Tiedown provisions shall not be used as towing provisions. Individual shippable components shall have no more than four tiedown provisions, and not more than two effective in each longitudinal (fore and aft) direction. Systems and equipment in excess of 10,000-lbs will require supplemental tiedown provisions in accordance with MIL-STD-209.

3.2.6.3 Truck Shipping Vibration [LONG-REQ-0021]tc "3.2.6.3 Truck Shipping Vibration" \f \l3 The generator shall withstand the vibration forces associated with being transported on a flat bed truck traveling over improved unpaved roads at a maximum speed of 40 miles per hour.

3.2.6.4 Air Transportability [LONG-REQ-0022]tc "3.2.6.4 Air Transportability" \f \l3 The generator shall be air transportable, without shoring, bracing, or protective packing in C-130, C-17, and C-5 aircraft in accordance with MIL-HDBK-1791. See MIL-HDBK-1791 for C-130 and C-5 aircraft and MIL-HDBK-1791, Appendix B for C-17 aircraft. Reconfiguration from an operational state will be allowed for transit. The generator, or its reconfigured assemblies, shall not exceed worst-case limits for dimensions, axle loading, ramp angle, g-loading, or floor loading.

3.2.6.5 Air Transportation Acceleration Forces [LONG-REQ-0023]tc "3.2.6.5 Air Transportation Acceleration Forces" \f \l3 The generator shall withstand the following acceleration forces without damage: 3.0 G forward, 1.5 G aft, 1.5 G lateral, 2.0 G up, 4.5 G down.

3.2.6.6 Hose and Cable Storage [LONG-REQ-0024]tc "3.2.6.6 Hose and Cable Storage" \f \l3 Storage provisions within the generator shall be provided for storing of hoses, cables, and other unattached parts for shipment of the generator.

3.2.6.7 Trailer Mounted System [LONG-REQ-0025]tc "3.2.6.7 Trailer Mounted System" \f \l3 If the generator has an integral trailer, the generator shall meet the mobility requirements specified in SAE AS 8090 for Type II, Group C towed ground support equipment.

3.3 Design and Constructiontc "3.3 Design and Construction" \f \l2

3.3.1 Materialstc "3.3.1 Materials" \f \l3

3.3.1.1 Hazardous Materials [LONG-REQ-0070]tc "3.3.1.1 Hazardous Materials" \f \l3 Hazardous materials shall be avoided at all times in the design, manufacture, testing, operation, maintenance, and disposal of the generator. A hazardous material is any material that due to its chemical, physical, or biological nature causes safety, public health, or environmental concerns. For the purpose of this contract, this includes but is not limited to the following materials:

a. Materials regulated as a hazardous material 49 CFR 173.2, or

b. Materials requiring a Material Safety Data Sheet (MSDS) per 29 CFR 1910.1200, or

c. Materials that during end use, treatment, handling, packaging, storage, transportation, or disposal meet or has the potential to meet the definition of a Hazardous Waste as defined by 40 CFR 261 Subparts A, B, C, or D, or

d. Materials regulated as an Ozone Depleting Substances (ODS) per 40 CFR 82 Subpart A, Appendices A and B, or

e. Materials identified in the Clean Air Act as a Hazardous Air Pollutant per 40 CFR Part 63, or

f. Materials regulated as an Extremely Hazardous Substance per 40 CFR 355, Appendices A and B, or

g. Materials regulated as a toxic chemical or as a Persistent, Bio accumulative, Toxic (PBT) chemical under Section 313 of the Emergency Planning and Community Right-to-Know Act (EPCRA) per 40 CFR Part 372, or

h. Materials referred to in section 101(14) or Section 102 of the Comprehensive Environmental Response, Compensation, and Liability Act (CERCLA) per 40 CFR 302.4, or

i. Materials identified as a Volatile Organic Compound (VOC) per 40 CFR Part 51.100(s).

j. Materials regulated as a toxic or flammable substances under section 112(r) of the Clean Air Act per 40 CFR Part 68.

3.3.1.2 Restricted Chemicals [LONG-REQ-0071]tc "3.3.1.2 Restricted Chemicals" \f \l3 The following hazardous materials are identified as restricted chemicals: Asbestos, Class I ODS, Class II ODS, and Polychlorinated Biphenyls (PCBs). Restricted chemicals shall be prohibited from use in all generator parts/components.

3.3.1.3 Targeted Chemicals [LONG-REQ-0072]tc "3.3.1.3 Targeted Chemicals" \f \l3 The following hazardous materials are identified as targeted chemicals: Arsenic & Arsenic Compounds , Benzene, Beryllium & Beryllium Compounds , Cadmium & Cadmium Compounds , Chloroform, Chromium & Non-Hexavalent Chromium Compounds, Cyclotrimethylenetrinitramine (RDX), Cyanide Compounds, Ethylene Glycol, Formaldehyde, Glycol Ethers, Hydrazine, Hydrofluoric Acid, Isocyanates, Lead & Lead Compounds, Mercury & Mercury Compounds, Methyl Ethyl Ketone (MEK), Methyl Isobutyl Ketone (MIBK), Methylene Chloride, Methylene Dianiline (MDA), Naphthalene, Nickel & Nickel Compounds, Perchlorates, Perchloroethylene, Perfluorooctanoic Acid (PFOA), Phenol, Polybrominated Diphenyl Ethers (PBDEs), Radioactive Materials, Toluene, Trichloroethylene (TCE), and Xylene & Xylene Isomers. Targeted Materials shall require justification and NAVAIR approval for use in all Long parts/components. Approval will not be given unless the contractor can document that there is no viable technically feasible alternative.

3.3.1.4 Metal Alloys [LONG-REQ-0073]tc "3.3.1.4 Metal Alloys" \f \l3 Chromium and nickel as a constituent of metal alloys are exempt.

3.3.1.5 Lead [LONG-REQ-0074]tc "3.3.1.5 Lead" \f \l3

Lead as a constituent of lead solder is exempt.

3.3.1.6 Protective Coatings [LONG-REQ-0075]tc "3.3.1.6 Protective Coatings" \f \l3 Coatings shall contain no pigments in concentrations that will render the coating residues toxic during application or removal. The unit will be finished and coated using an epoxy primer and a polyurethane topcoat. The primer will have a maximum VOC content of 420 grams/liter (3.5 pounds/gallon). The topcoat shall have a maximum VOC content of 340 grams/liter (2.8 pounds/gallon).

Note: The following information is provided for guidance only. Triglycidyl Isocyanurate (TGIC) polyester powder coating has been found to meet Navy requirements. Primer in accordance with MIL-DTL-53022 Type II and topcoat in accordance with MIL-PRF-85285E Type II or Type III has been found to meet the Navy primer and topcoat requirements.

3.3.1.7 Hexavalent Chromium [LONG-REQ-0082]tc "3.3.1.7 Hexavalent Chromium" \f \l3 Hexavalent Chromium exceeding 0.1 percent by weight in any homogeneous material is banned in the delivered system per DFAR 223-7008 except as provided in 223.7304 and 223.7305. Use of Hexavalent Chromium where an exception from 223.7304 does not apply requires Program Executive Office (PEO) and Corrosion Control and Prevention Executive (CCPE) approval per DON Hexavalent Chromium Authorization Process, 22 November 2011. If exemptions provided in DFAR 223.7304 and 223.7305 apply, approval by NAVAIR is required.

Any use of Hexavalent Chromium not cited by DFAR 223-7008 shall also require NAVAIR approval.

Approval will not be given for any use of Hexavalent Chromium unless the contractor can document that there is no viable technically feasible alternative.

3.3.1.8 Lithium Batteries [LONG-REQ-0076]tc "3.3.1.8 Lithium Batteries" \f \l3 All lithium batteries proposed for use in the generator shall require approval in accordance with NAVSEA Instruction 9310.1B and Interim Guidance for Deployment of Lithium Battery Systems of 2 April 2009. Detailed instructions for the approval process including testing requirements are contained in TM S9310-AQ-SAF-010. In some cases, the testing requirements can be waived if particular conditions are met, per TM S9310-AQ-SAF-010. Documentation shall be submitted in accordance with the LONG Statement of Work.

3.3.2 Electromagnetic Radiationtc "3.3.2 Electromagnetic Radiation" \f \l3

3.3.2.1 Electromagnetic Interference [LONG-REQ-0064]tc "3.3.2.1 Electromagnetic Interference" \f \l3 The generator shall comply with MIL-STD-461F, requirements CE102, CS101, CS114, CS115, CS116, RE102, RS101, and RS103 for ground equipment. For requirement RS103, the unit shall be tested to a field strength of 10 Volts per Meter.

3.3.3 Nameplates and Product Markingtc "3.3.3 Nameplates and Product Marking" \f \l3

3.3.3.1 Equipment Data Plate [LONG-REQ-0026]tc "3.3.3.1 Equipment Data Plate" \f \l3 A data plate shall be installed on the exterior of the generator. This data plate shall contain the following information as a minimum: contract number, part number, model number, Commercial And Government Entity (CAGE) code, and a serial number unique to the generator. The data plate shall be constructed from photosensitive aluminum in accordance with A-A-50271, composition c.

3.3.3.2 Caution and Warning Labels [LONG-REQ-0027]tc "3.3.3.2 Caution and Warning Labels" \f \l3 Caution and warning labels indicating the location, nature, and extent of a hazard shall be provided on the generator. The labels shall be located as close as possible to the point of danger. Letters of the labels shall be clearly legible. Warning or caution markings shall have a high contrast between the letters and background colors.

3.3.3.3 Lifting Data Plate [LONG-REQ-0028]tc "3.3.3.3 Lifting Data Plate" \f \l3 A data plate with instructions on safely lifting the generator shall be mounted on the exterior of the generator. If components of the generator are lifted separately, data plates with instructions on safe lifting shall be mounted on each component. The data plate shall be constructed from photosensitive aluminum in accordance with A-A-50271, composition c. Information on the data plate shall include, but not be limited to, the location of the center of gravity, weight, and locations of lifting points.

3.3.3.4 Flow and Electrical Schematics [LONG-REQ-0029]tc "3.3.3.4 Flow and Electrical Schematics" \f \l3 Placards showing the flow and electrical schematics of the generator shall be mounted on the generator. The schematic placards shall be constructed from photosensitive aluminum in accordance with A-A-50271, composition c. The placards shall be sized so the information on the placards is legible from a distance of two feet. The placards shall be located where the maintainer or the operator can access them easily.

3.3.4 Workmanshiptc "3.3.4 Workmanship" \f \l3

3.3.4.1 Quality Management Systems [LONG-REQ-0030]tc "3.3.4.1 Quality Management Systems" \f \l3 The generator shall be designed, manufactured, and tested under a quality management system in accordance with ISO 9001-2000 or ISO 9001-2008.

3.3.4.2 Workmanship (General) [LONG-REQ-0031]tc "3.3.4.2 Workmanship (General)" \f \l3 The generator shall be manufactured to a quality standard of workmanship that does not adversely affect safety, function, performance, serviceability, interchangeability, and appearance (includes painted surfaces). Completed parts and assemblies shall not exhibit defective material, out of tolerance dimensions, or under rated materials. Defects such as: seams, laps, laminations, cracks, fins, extraneous material, visible steps or irregularities, sharp edges, nicks, scratches, burrs, tool scores, and gouges shall be avoided. Deformations, missing operations, improper assembly, missing parts, stains, corrosion, non-specified oxidation (rust), and unauthorized salvaging operations (e.g., hammering to shape, repair by welding, straightening, bending, etc.) shall also be avoided.

3.3.4.3 Workmanship (Electrical) [LONG-REQ-0032]tc "3.3.4.3 Workmanship (Electrical)" \f \l3 Electrical components of the generator shall be certified or built to an industry standard such as Underwriters Laboratory, the National Electrical Code, National Electrical Association Standards, National Fire Protection Agency standards, or similar.

3.3.5 Safetytc "3.3.5 Safety" \f \l3

3.3.5.1 Oxygen System Design [LONG-REQ-0033]tc "3.3.5.1 Oxygen System Design" \f \l3 The generator shall be designed and constructed using the guidelines provided in ASTM G88-05 and ASTM G128-02 for prevention of oxygen fires.

3.3.5.2 Oxygen Cleaning [LONG-REQ-0034]tc "3.3.5.2 Oxygen Cleaning" \f \l3 Any component of the generator that will contact gaseous or liquid oxygen shall be cleaned, packaged, and assembled to the requirements of ASTM G93-03. All surfaces that contact gaseous or liquid oxygen shall be free of visible particulates (50 microns and larger), free of visible fluorinated lubricants, and free of hydrocarbon contamination to a level no greater than 3 milligrams per square foot (mg/ft2).

3.3.5.3 Material Compatibility [LONG-REQ-0035]tc "3.3.5.3 Material Compatibility" \f \l3 All materials used in the construction of the generator that will contact gaseous or liquid oxygen shall be selected in accordance with the guidelines provided in ASTM G63-99 and ASTM G94-05.

3.3.5.4 Grounding Provisions [LONG-REQ-0036]tc "3.3.5.4 Grounding Provisions" \f \l3 A grounding connection for static discharge shall be provided on the generator. An eight (8) foot (minimum) long copper grounding rod and a grounding cable assembly shall be provided with the generator. The grounding cable assembly shall be in accordance with MIL-DTL-83413C with either one or two grounding clamps in accordance with MIL-DTL-83413/7 D, as applicable. The maximum resistance of the cable configuration shall not exceed 10 ohms. Storage provisions for the grounding rod and grounding cable assembly shall be provided on the generator.

3.3.6 Human Engineeringtc "3.3.6 Human Engineering" \f \l3

3.3.6.1 Human Factors / Human Engineering / Human System Integration (HF/HE/HSI) (General) [LONG-REQ-0037]tc "3.3.6.1 Human Factors / Human Engineering / Human System Integration (HF/HE/HSI) (General)" \f \l3 Human Factors / Human Engineering / Human System Integration (HF/HE/HSI) design of the generator shall focus on simplicity and ease of use, efficiency of human effort, optimization of performance effectiveness and readiness, and personnel safety during operation and all other life-cycle phases.

3.3.6.2 HF/HE/HSI (Qualitative) [LONG-REQ-0038]tc "3.3.6.2 HF/HE/HSI (Qualitative)" \f \l3 Qualitative HF/HE/HSI requirements and features to be incorporated into the design of the generator shall include, but not be limited to the following:

All equipment, work stations, consoles, displays, and controls involving human interface shall be designed, located, and arranged to permit efficient, reliable, and safe operation and maintenance by appropriately clothed and equipped personnel. Human engineering design criteria shall be established and incorporated for all operating and environmental conditions. MIL-STD-1472G and MIL-STD-46855A, and other human engineering design handbooks may be used as guidance for establishing human engineering design criteria, and shall specifically address environment, anthropometry, maintainability, and controls. Human engineering for hazards and safety shall be in accordance with MIL-STD-1472F, paragraphs 5.13 through 5.13.9. The generator design shall also incorporate applicable system and personnel safety factors and features, including minimizing potential human error in the operation and maintenance of the system, particularly under the conditions of alert, battle stress, or other emergency or non-routine conditions.

4.0 QUALITY ASSURANCE PROVISIONS tc "4.0 QUALITY ASSURANCE PROVISIONS "

4.1 Standard Performance Demonstrationtc "4.1 Standard Performance Demonstration" \f \l2 This process will be used to measure performance characteristics of the generator during various stages of certain environmental tests. Verifications requiring this procedure to be performed will indicate so within this specification. If this test is being used to establish a baseline and the generator operates satisfactorily, proceed to the first test procedure as determined from the test plan. If not, resolve the problems and reestablish a baseline. At the contractor’s discretion, previous testing performed in accordance with this section for the test generator may be used as the performance baseline. If this test is being run under extreme environmental conditions, or after an environmental test, failure of this test as outlined below shall result in a failure of environmental test for which it is performed

Unless otherwise specified, ambient conditions for this test shall be a temperature of 25 +/- 10° C (77 +/- 18° Fahrenheit), a relative humidity of 20 to 80%, and site atmospheric pressure.

The generator shall be set-up to produce liquid oxygen. The generator shall be configured to supply liquid oxygen directly to an external liquid oxygen storage tank. A liquid oxygen storage tank with a minimum storage capacity of 200 gallons shall be used for this test. This storage tank shall be filled to 25% of its capacity with liquid oxygen for the start of this test. A sample of the liquid oxygen in the storage tank shall be analyzed prior to the start of this test. The analysis of the sample shall meet the requirements of Sections 3.2.1.1.1.a and 3.2.1.1.1.b. If the analysis does not meet the requirements of Sections 3.2.1.1.1.a and 3.2.1.1.1.b, the liquid oxygen in the storage tank shall be replaced with liquid oxygen that does meet the requirements prior to starting this test. When the generator has reached steady state conditions, the generator shall be operated continuously for 24 hours. The production rate shall be a minimum of 1.5 tons/day or this test shall be deemed a failure. At the end of the 24 hours, a representative sample of the liquid oxygen shall be taken from the storage tank and analyzed. The results of the analysis shall meet the requirements of Sections 3.2.1.1.1.a and 3.2.1.1.1.b or this test is deemed a failure. The production rate shall be determined using one of the following methods:

Method 1

The liquid oxygen produced shall be routed to a cryogenic storage vessel with a calibrated liquid level gauge. The production rate shall be the increase in liquid level as read on the gauge divided by the test time interval. The boil-off from the transfer line and the storage vessel may be added to determine the production rate.

Method 2

The liquid oxygen produced shall be routed to a cryogenic storage vessel that is placed atop a calibrated weighted device. The production shall be the increase in weight divided by the test time interval. The boil-off from the transfer line and storage vessel may be added to determine the production rate.

4.2 Special Tests and Examinationstc "4.2 Special Tests and Examinations" \f \l2 This subsection specifies special tests and examinations required for sampling, lot formation, qualification, and any other tests or examinations as necessary. Each test and examination is described in a separate section.

Unless otherwise specified in the contract, the contractor is responsible for the performance of all inspection requirements specified herein. The contractor may use his or any other facilities suitable for the performance of the inspection requirements specified herein. The government reserves the right to witness or separately perform all tests specified or otherwise inspect any or all tests.

Unless otherwise specified, ambient conditions for all testing shall be a…