Request for Proposal (RFP) N6449824R4063.pdf

CODE

(Hour)

PAGE(S)

unt il 12:00 PM local time 19 Apr 2024

X

A X B X C X D

EX

X

G F 114 - 128

129 - 149 X H 150 - 156 n ichola s.swanson@navy.mil

RATING PAGE OF PAGES

7. ISSUED BY

(Dat e)

IMPORTANT - Award will be made on this Form, or on Standard Form 26, or by other aut horized official writt en not ice.

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

Prescribed by GSA FAR (48 CFR) 53.214(c)

DO-A3 1 156

(If other t han Item 7)

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

AND

ADDRESS

SIGN OFFER (Type or print)

OF

OFFEROR

AMENDMENT NO. DATE

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

IS DIFFERENT FROM ABOVE - ENTER

SUCH ADDRESS IN SCHEDULE.

18. OFFER DATE

1. THIS CONTRACT IS A RATED ORDER

UNDER DPAS (15 CFR 700)

2. CONTRACT NO.

N64498 8. ADDRESS OFFER TO

See Item 7

9. Sealed offers in original and 1 copies for furnishing the supplies or services in t he Schedule will be received at t he place specified in Item 8, or if handcarried, in the depository locat ed in

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

10. FOR INFORMATION

CALL:

A. NAME (NO COLLECT CALLS)

NICHOLAS SWANSON 215-897-1251

11. TABLE OF CONTENTS

SOLICITATION/ CONTRACT FORM

SUPPLIES OR SERVICES AND PRICES/ COSTS

2 - 6

X I CONTRACT CLAUSES

DESCRIPTION/ SPECS./ WORK STATEMENT X

PACKAGING AND MARKING

7 - 51 52 - 54

J LIST OF ATTACHMENTS

INSPECTION AND ACCEPTANCE

DELIVERIES OR PERFORMANCE

55 - 58

X K

REPRESENTATIONS, CERTIFICATIONS AND

OTHER STATEMENTS OF OFFERORS

CONTRACT ADMINISTRATION DATA 60 - 68 X

SPECIAL CONTRACT REQUIREMENTS

OFFER (Must be fully completed by offeror) 69 - 70 X M

L INSTRS., CONDS., AND NOTICES TO OFFERORS

EVALUATION FACTORS FOR AWARD

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

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

13. DISCOUNT FOR PROMPT PAYMENT

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

14. ACKNOWLEDGMENT OF AMENDMENTS

(The offeror acknowledges receipt of amendments

AMENDMENT NO. DATE

to t he SOLICITATION for offerors and related documents numbered and dat ed):

FACILITY

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

SOLICITATION, OFFER AND AWARD

X

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

PART I - THE SCHEDULE

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

EMAIL:TEL: (Signature of Cont ract ing Officer)

CODE CODE

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

AWARD (To be completed by Government)

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

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

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

23. SUBMIT INVOICES TO ADDRESS SHOWN IN ITEM

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

PART IV - REPRESENTATIONS AND INSTRUCTIONS

PART III - LIST OF DOCUMENTS, EXHIBITS AND OTHER ATTACHMENTS

71 - 111

PART II - CONTRACT CLAUSES

NAVAL SURFACE WARFARE CENTER PHILA

CODE 0223, NICHOLAS SWANSON

NICHOLAS.SWANSON@NAVY.MIL

5001 SOUTH BROAD STREET, BUILDING 4

PHILADELPHIA PA 19112

215-897-1251

FAX:

TEL:

FAX:

TEL:

NOTE: In sealed bid solicita tions "off er" and "off eror" m ean "bid" and "bidder ".

SOLICITATION

112 - 113

6. REQUISITION/PURCHASE NO.5. DATE ISSUED

20 Mar 2024

4. TYPE OF SOLICITATION

SEALED BID (IFB)

NEGOTIATED (RFP)

[ X ]

3. SOLICITATION NO.

N6449824R4063

Section B - Supplies or Services and Prices

CONTRACT MINIMUM/MAXIMUM QUANTITY AND CONTRACT VALUE

The minimum quantity and contract value for all orders issued against this contract shall not be less than the minimum quantity and contract value stated in the following table. The maximum quantity and contract value for all orders issued against this contract shall not exceed the maximum quantity and contract value stated in the following table.

MINIMUM

QUANTITY

MINIMUM

AMOUNT

MAXIMUM

QUANTITY

MAXIMUM

AMOUNT

1.00 25.00

CLIN DELIVERY/TASK ORDER MINIMUM/MAXIMUM QUANTITY AND CLIN ORDER VALUE

The minimum quantity and order value for the given Delivery/Task Order issued for this CLIN shall not be less than the minimum quantity and order value stated in the following table. The maximum quantity and order value for the given Delivery/Task Order issued for this CLIN shall not exceed the maximum quantity and order value stated in the following table.

CLIN

MINIMUM

QUANTITY

MINIMUM

AMOUNT

MAXIMUM

QUANTITY

MAXIMUM

AMOUNT

ITEM NO SUPPLIES/SERVICES MAX

QUANTITY

UNIT UNIT PRICE MAX AMOUNT

0001 1 Each First Article LPE Production Unit

FFP

All work to be completed in accordance with Section C, Statement of Work.

NOTE: The requirements in DFARS 252.211-7003, Item Identification and Valuation, are applicable for this line item. The contractor shall provide DoD unique identification or a DoD recognized unique identification equivalent.

FOB: Destination

PSC CD: 2090

MAX

NET AMT

UNIT UNIT PRICE MAX AMOUNT

0002 5 Each LPE Production Unit - Year 1 unique identification or a DoD recognized unique identification equivalent.

UNIT UNIT PRICE MAX AMOUNT

0003 5 Each LPE Production Unit - Year 2

UNIT UNIT PRICE MAX AMOUNT

0004 5 Each LPE Production Unit - Year 3

UNIT UNIT PRICE MAX AMOUNT

0005 5 Each LPE Production Unit - Year 4

UNIT UNIT PRICE MAX AMOUNT

0006 5 Each LPE Production Unit - Year 5

UNIT UNIT PRICE MAX AMOUNT

0007 1 Each Technical Data

FFP

Technical Data in accordance with Contract Data Requirements List (CDRL);

CDRL's A001-A045 unique identification or a DoD recognized unique identification equivalent.

PSC CD: 2090

Section C - Descriptions and Specifications

STATEMENT OF WORK

1. SCOPE

This specification defines the performance, physical, design, quality assurance, and test requirements for a Low Pressure Electrolyzer (LPE) for submarine life support service.

2. APPLICABLE DOCUMENTS

The following documents are part of this specification to the extent specified herein. Copies of specifications, standards, drawings, and publications required by suppliers in connection with specific procurement functions should be obtained from the procuring activity or as directed by the Government. In the event of a conflict between the provisions of the contract and supplier’s technical proposal, the contract shall take precedence. Nothing in this specification, however, shall supersede applicable Federal, State, or local laws and regulations unless a specific exemption has been obtained.

2.1 Federal Specifications and Standards

A-A-59155 NITROGEN, HIGH PURITY, SPECIAL PURPOSE

TT-C-490 CHEMICAL CONVERSION COATINGS AND

PRETREATMENTS FOR METALLIC SUBSTRATES

(BASE ORGANIC COATINGS)

2.2 Military/DOD Specifications

MIL-A-15303 AUDIBLE SIGNALS: ALARMS, BELLS, BUZZERS,

HORNS, AND SIRENS, ELECTRONIC, SHIPBOARD

MIL-B-17931 BEARINGS, BALL, ANNULAR, FOR QUIET OPERATION

MIL-DTL-2212 CONTACTORS AND CONTROLLERS, ELECTRIC

MOTOR AC OR DC, AND ASSOCIATED SWITCHING

DEVICES

MIL-C-5015 CONNECTORS, ELECTRICAL, CIRCULAR THREADED,

GENERAL SPECIFICATIONS FOR

MIL-DTL-17361 CIRCUIT BREAKERS, AIR INSULATED HOUSING

(SHIPBOARD USE), GENERAL SPECIFICATION FOR

MIL-DTL-28840 CONNECTORS, ELECTRICAL, CIRCULAR, THREADED,

HIGH-SHOCK, HIGH DENSITY, SHIPBOARD, CLASS D,

GENERAL SPECIFICATION FOR

MIL-DTL-38999 CONNECTORS, ELECTRICAL, CIRCULAR, MINATURE,

HIGH DENSITY, QUICK DISCONNECT, ENVIRONMENT

RESISTANT WITH CRIMP REMOVEABLE CONTACTS

OR HERMETICALLY SEALED WITH FIXED,

SOLDERABLE CONTACTS, GENERAL SPECIFICATION

FOR

MIL-DTL-917 ELECTRIC POWER EQUIPMENT BASIC

REQUIREMENTS

MIL-F-16552 FILTERS, AIR ENVIRONMENTAL CONTROL SYSTEM,

CLEANABLE, IMPINGEMENT (HIGH VELOCITY TYPE)

MIL-M-17059 MOTORS, 60 CYCLE ALTERNATING-CURRENT,

FRACTIONAL HORSEPOWER (SHIPBOARD USE)

MIL-DTL-17060 MOTORS, 60 CYCLE ALTERNATING-CURRENT,

INTEGRAL HORSEPOWER (SHIPBOARD USE)

MIL-P-15024 PLATES, TAGS AND BANDS FOR IDENTIFICATION OF

EQUIPMENT,

GENERAL SPECIFICATION FOR

MIL-PRF-15160 FUSES, INSTRUMENT, POWER, AND TELEPHONE,

GENERAL SPECIFICATION FOR

MIL-HDBK-217 RELIABILITY PREDICTION OF ELECTRONIC

EQUIPMENT

MIL-HDBK-454 STANDARD GENERAL REQUIREMENTS FOR

ELECTRONIC EQUIPMENT

MIL-HDBK-472 MAINTAINABILITY PREDICTION

MIL-HDBK-2036 PREPARATION OF ELECTRONIC EQUIPMENT

SPECIFICATIONS

MIL-STD-22 WELDED-JOINT DESIGNS

MIL-STD-108 DEFINITIONS OF AND BASIC REQUIREMENTS FOR

ENCLOSURES FOR ELECTRIC AND ELECTRONIC

MIL-STD-167-1 MECHANICAL VIBRATIONS OF SHIPBOARD

MIL-STD-461 CONTROL OF ELECTROMAGNETIC INTERFERENCE

CHARACTERISTICS OF SUBSYSTEMS AND

EQUIPMENT, REQUIREMENTS FOR THE

MIL-STD-471 MAINTAINABILITY; VERIFICATION

DEMONSTRATION/EVALUATION

MIL-STD-740-1 AIRBORNE SOUND MEASUREMENTS AND

ACCEPTANCE CRITERIA OF SHIPBOARD EQUIPMENT

MIL-STD-740-2 STRUCTUREBORNE VIBRATORY ACCELERATION

MEASUREMENTS AND ACCEPTANCE CRITERIA OF

SHIPBOARD EQUIPMENT

MIL-STD-882 STANDARD PRACTICE FOR SYSTEM SAFETY

MIL-STD-889 DISSIMILAR METALS

MIL-STD-901D SHOCK TESTS HIGH IMPACT SHIPBOARD

MACHINERY, EQUIPMENT, AND SYSTEM

REQUIREMENTS

MIL-STD-1310 SHIPBOARD BONDING, GROUNDING, AND OTHER

TECHNIQUES FOR ELECTROMAGNETIC

COMPATIBILITY AND SAFETY, STANDARD

PRACTICE FOR

MIL-STD-1399 INTERFACE STANDARD FOR SHIPBOARD SYSTEMS

MIL-STD-1472 HUMAN ENGINEERING

MIL-STD-1622 CLEANING OF COMPRESSED AIR SYSTEMS,

STANDARD PRACTICE FOR

MIL-STD-2073-1 STANDARD PRACTICE FOR MILITARY PACKAGING

MIL-STD-2219 FUSION WELDING AEROSPACE APPLICATIONS

MIL-PRF-32006A NAVAL SHIPBOARD PROGRAMMABLE CONTROLLER

PERFORMANCE SPECIFICATIONS

MIL-DTL-32613 AUXILIARY SYSTEM CONTROLLER FOR NAVAL

SHIPBOARD USE

2.2 NAVSEA Specifications

S9074-AR-GIB-010/278 REQUIREMENTS FOR FABRICATION WELDING AND

INSPECTION, AND CASTING INSPECTION AND

REPAIR FOR MACHINERY, PIPING, AND PRESSURE

VESSELS

NAVSEA Standard Item 009-04 (series)

NAVSEA Technical Specification 9090-310 (series)

2.3 Other Specifications

American Welding Society SPECIFICATION FOR FURNACE C3.6:1999

BRAZING

DoDI 8500.01 CYBERSECURITY

IEEE/EIA SOFTWARE LIFE CYCLE PROCESSES

12207

SAE WIRE, ELECTRICAL,

AS22759 FLUOROPOLYMER INSULATED,

COPPER OR COPPER ALLOY

2.4 NAVSEA Drawings

8181047 OHIO CLASS TRID 0565 PIPING OXYGEN

GENERATORS 1 & 2 – LOW PRESSURE

ELECTROLYZER

3. REQUIREMENTS

3.1 General. The LPE shall be a self contained electro-chemical oxygen generating plant. Performance characteristics are defined below.

3.1.1 Electrolysis. The electrolysis process produces oxygen. Design of the electrolysis process shall be based upon existing and proven proton-exchange membrane electrolysis-cell processes to the greatest extent possible. A backup electrolysis cell is not required to be integrated into the LPE. The LPE shall provide filters and a demineralizer internal to the unit prior to the electrolysis cell to provide a water quality required to meet the 30,000 hour cell life requirement of para. 3.2.3. All filters and the demineralizer shall be fully accessible and removable for routine maintenance. Filters shall provide a means of indication to inform the operator that the filter needs cleaning or changing. The demineralizer filter bed shall be designed to last for more than 100 days of continuous operation.

The demineralizer bed shall also provide a means of indication to inform the operator that the bed needs cleaning or changing.

3.1.1.1 Cell Design. The cell shall be capable of supporting performance, life and reliability as specified herein.

The design shall be compact in size and volume and shall be based upon the minimum number of cells to meet the capacity stated in para. 3.1.1.2. The electrolysis cell membrane material must be able to support performance, life and reliability requirements as specified herein. The cell materials shall be selected to provide maximum safety and compatibility. The fluoride’s level shall be less than 20 parts per billion (ppb).

3.1.1.2 Oxygen Production. There shall be two types of LPE. The 225 SCFH LPE shall be capable of producing 225 SCFH of gaseous oxygen. The 170 SCFH LPE shall be capable of producing 170 SCFH of gaseous oxygen.

The two types of LPE shall be identical in all ways outside the electrolysis module. Only the 170 SCFH LPE shall be procured. Oxygen shall be discharged from the LPE at ambient pressure and have a dew point of less than 60 F.

The LPE shall be capable of production settings ranging from 15 to 170 SCFH. The quantities and variability of the settings shall be determined during detailed design. The oxygen purity at the point of discharge shall be a minimum of 99.0% at the point of discharge. For the purposes of this specification, standard temperature and pressure at which SCFH shall be calculated is 70 F and 1 atm. The LPE shall be designed such that a 170 SCFH cell stack and a 225 SCFH cell stack are interchangeable. Any components required to make the change shall be provided.

3.1.2 Hydrogen Disposal. The hydrogen produced by the electrolysis process shall be available for disposal at pressures up to 750 psig. The use of pumps and compressors to achieve pressure for discharge is not permitted.

Ambient discharge of hydrogen into the ship shall be limited to an average rate of 3.25 SCFM. The rate of hydrogen inboard discharge shall be limited to 30 SCFH for no longer than 15 minutes. A means shall be provided to discharge hydrogen to ambient which will meet safety and performance goals specified herein. The LPE shall have a gauge from which the pressure at which hydrogen is being disposed at can be monitored.

3.1.3 Nitrogen Usage. The Contractor shall design the LPE to minimize the use of gaseous nitrogen. The design shall provide isolation between the ship’s supply of nitrogen and the LPE to minimize the quantity of nitrogen lost if there is a leak within the LPE. The LPE shall be capable of holding a supply of nitrogen within the unit for purging due to shutdowns. The amount of nitrogen needed to purge the LPE shall be less than 200 SCF.

3.2 Functional Requirements.

3.2.1 Performance Characteristics.

3.2.1.1 Size. The LPE shall use the existing Electrolytic Oxygen Generator (EOG) foundation currently in place aboard OHIO Class submarines, up to and including the mounting bolt locations in the EOG base plate. The LPE footprint shall be kept to a minimum, consistent with the required sturdiness, serviceability, safety and reliability.

The footprint of the LPE shall be less than 32.5 x 41.0 inches. Height of the LPE shall be less than 75 inches.

3.2.1.2 Hatch and Door Requirement. The LPE shall be constructed such that items will pass through a 30 inch diameter hatch. Shipboard replaceable items and subassemblies, which may be stowed onboard ship, shall be able to pass through a minimum of 18 inch x 6 foot 3 inch passageway. Reassembly of LPE subassemblies via bolted construction is preferred. The LPE shall be divided into cabinet subassemblies, each of which will pass through a 30-inch diameter hatch. Each cabinet (i.e. electrolysis power supply) may only be divided into a maximum of six (6) subassemblies when initially installing on submarines. Subassemblies shall be minimized as much as possible. Pins shall be provided to facilitate alignment of components.

3.2.1.3 Weight. The wet weight of the LPE including a water-charged electrolysis cell module shall be less than 5,200 lbs. Items and assemblies in excess of 80 lbs shall be equipped with lifting aids (e.g., eyebolts). Access panels or doors weighing more than 40 lbs shall be provided with alignment pins and handles to facilitate reinstallation of access panels or doors.

3.2.1.4 Electric Power Interface. Electric power will be provided to the LPE by the ship’s generation and power distribution system as defined below. The LPE will be provided with 440 VAC, 3 phase main power and 115 Vrms, single phase control power. The equipment shall operate in accordance with MIL-STD-1399, Section 300A.

(a) AC Power. The AC power available from the ship’s service power buses is Type I power per MIL-STD-1399, section 300A. The AC equipment service is 440 Volt, 60 Hz, and 115 Volt, 60 Hz. Equipment shall be fully operational within the normal tolerance limits specified for Type I power. Equipment may shut down or go into standby condition, but not be damaged, when operating outside these limits. See para. 4.6.6.1.

(b) Maximum Power Limit. The LPE shall use less than 117 kVA of power.

(c) Analog/Digital Interfaces. Provisions shall be made to transfer analog or digital interface signals to or from the LPE for the following:

(1) A remote emergency stop (“kill”) switch shall be provided in the design of the LPE and will be located in the ship’s arrangement just outside of the AMR compartment.

(2) The LPE shall allow recording of historical data stored in the LPE’s CPU to download data for failure analysis to a portable data recorder. The LPE shall transmit time and date of a system failure/shutdown as well as information on temperature, pressure, and flow rates which may aid in a failure analysis.

(d) Cable Interface. Provisions shall be made for the entry of the electric power and control cable interface to the top of the unit or as approved by the Government.

(e) Circuit Breaker Control Interface. The LPE power and control subsystem shall be equipped with a circuit breaker unless otherwise approved by the Government.

3.2.1.5 Fluids Interface. The fluids interface shall be as follows:

(a) Oxygen. Oxygen produced by the LPE shall be directed to the ship’s atmosphere at a discharge pressure specified in para. 3.1.1.2 and shall discharge out of the top of the unit.

(b) Demineralized Water. Demineralized water will be provided to the LPE at a maximum flow rate of 0.5 GPM for short term filling and general maintenance. A maximum flow rate of 0.1 GPM will be provided to the LPE during normal operation. The demineralized water delivery pressure to the LPE will be 25 psig to 40 psig with a maximum design temperature of 122 F. The LPE piping from the demineralized water supply shall be designed to withstand 60 psig. An isolation valve will be provided by the Government on the demineralized water inlet pipe to the LPE. The LPE shall be equipped with a 3/8” tube socket union fitting (SSP Part No. 6KSWU or similar) for connection to the demineralized water system piping. Demineralized water quality is available to the LPE as follows:

(1) Conductivity – 2.5 micromho/cm maximum

(2) pH – 5.7 to 8.0

(3) Visual clarity – No turbidity, oil, sediment, or resin beads

(4) Chlorides – Maximum 0.1 ppm

(c) Electronic and Auxiliary Fresh Water. The Electronic and Auxiliary Fresh Water (EAFW) system will provide a supply of fresh water to the LPE at a flow rate of 5 GPM and at a temperature of 95 F +/- 3 F. The conductivity of the EAFW shall not exceed 2.0 micromhos/cm. The EAFW system design pressure will be 125 psia, and the pressure drop across the LPE shall not exceed 10 psi.

Maximum EAFW system pressure is 200 psia. Isolation valves will be provided by the Government on both the EAFW inlet and outlet pipes. The LPE shall be equipped with 5/8” tube socket union fittings (SSP Part No. 10KSWU or similar) for connection to the EAFW system piping.

(d) Chilled Water. Ship’s chilled water (CHW) is available at 45 F +3 / - 2 F and may be used for general cooling of the LPE. The total flow rate to the LPE will be limited to 15.5 GPM and controlled between 3 and 15.5 GPM to maintain LPE temperature control. The Contractor shall attempt to minimize the CHW usage. The ship’s CHW flowrates may fluctuate by +/- 10%. The CHW design system pressure is 150 psig, and the LPE shall be designed to operate and control temperature based on a differential pressure of 35 psi measured between the ship’s supply and return headers. The LPE shall be equipped with welded socket fittings (CPV Part No. 51R-4 Tailpiece to Part No. 50N-4 Nut or similar), for connection to ship’s CHW system.

(e) Hydrogen Inboard Purge Connection. The LPE may provide a hydrogen gas inboard purge union connection to vent hydrogen to ambient via ship’s piping, during LPE shutdown. Average flow rate of the hydrogen during discharge periods shall be limited to 3.25 SCFM.

(f) LPE Drain System. The LPE shall provide a suitable drain system for waste water and condensates which will be drained to the ship’s existing gravity drain system.

(g) Mating Fluids Interface Connections. The Contractor shall supply separately, unless otherwise specified by the Government, all mating union connections and tailpieces/adapters, except for the hydrogen gas overboard connection, which are to be welded to the corresponding ship’s interface pipe by the Government. The tailpieces/adapters must use the same material as the corresponding ship interface pipe to which it will be welded, or as approved by the Government.

3.2.1.6 Interface Locations. The LPE shall connect directly to EOG existing piping aboard OHIO Class submarines whenever possible or as approved by the Government. NAVSEA Drawing 8181047 shall be used as reference. All piping connections shall be located on the “FWD” side of the LPE Configuration, as illustrated in Figure 1 in Paragraph 3.2.7.2. The electrical interface for the LPE shall be on top of the unit or as approved by the Government.

3.2.2 Design Characteristics

3.2.2.1 Ambient Pressure. The equipment shall operate in accordance with all performance requirements at an ambient pressure of 11.8 – 17.6 psia (0.8 – 1.2 atm), and shall not be damaged when subjected to a maximum pressure of 29.4 psia (2.0 atm). The maximum rate of change in ship’s pressure is 2 inHg/min.

3.2.2.2 Temperature. The equipment shall operate in accordance with all performance requirements at ambient temperatures between 40 F and 100 F. In a non-operating mode, equipment shall not be damaged at ambient temperatures between 40 F and 122 F.

3.2.2.3 Humidity. The equipment shall operate in accordance with all performance requirements at 95 percent relative humidity (non-condensing).

3.2.2.4 Vibration. The LPE shall meet the requirements of Type I environmental vibration of MIL-STD-167-1.

The equipment shall remain in operational during vibration testing.

3.2.2.5 Shock. The LPE shall meet Grade A shock requirements in accordance with MIL-S-901D, Interim Change No. 1. Equipment operation shall not be affected to the extent that the equipment is unable to perform its function during and after shock testing in accordance with MIL-S-901D, Interim Change No. 1. The use of shock, noise, or vibration isolation or shock mitigation devices shall require Government approval.

Testing to MIL-S-901D Interim Change #1 is allowed provided that the shock test of the equipment meets the intent of the shock requirements for each submarine class. By shock testing in accordance with MIL-S-901D Interim Change #1, the following shock requirements will be satisfied:

a. MIL-S-901C, Shock Tests, H.I. (High Impact); Shipboard Machinery, Equipment and Systems, Requirements for; of 15 Jan 1963, as modified by the SSBN-726 ship specifications (Pub.

NAVSEA 0902-LP-027-7010, section 9400-1) for SSBN-726 Class.

b. MIL-S-901C, Shock Tests, H.I. (High Impact); Shipboard Machinery, Equipment and Systems, Requirements for; of 15 Jan 1963, as modified by the SSBN-726 ship specifications (Pub.

NAVSEA 0902-LP-027-7010, section 9400-1) and SSGN Conversion Ship Specification Addendum for SSGN-726 Class.

c. PPD No. 802-6335704, Shock Tests, H.I. (High Impact); Shipboard Machinery, Equipment, and

Systems, Requirements for; of 1 May 1987 for SSN-21 (SEAWOLF) Class.

3.2.2.6 Airborne and Structureborne Noise. The structureborne noise generated by the LPE when operating at 120 and Max SCFH shall not exceed that shown in Appendix A for steady state structureborne noise levels.

Equipment generated airborne noise shall be in accordance with Table I of MIL-STD-740-1, Grade D.

3.2.2.7 DC Magnetic Fields. The equipment shall operate in accordance with MIL-STD-1399 Section 070.

3.2.2.8 Electromagnetic Emissions and Susceptibility. Equipment shall meet and demonstrate compliance with the requirements of MIL-STD-461 Revision E dated 20 August 1999 for Submarines, Internal to Pressure Hull installations and Methods RS02 (part 1 – magnetic induction spike) & CS06 of MIL-STD-461C. The standoff distance specified in RE101 is increased from 7 cm to 61 cm for all directions except above the unit and in front of the unit. Above the unit the standoff distance is increased from 7 cm to 10 cm. In front of the unit the standoff distance is increased to 100 cm. Para. 4.2.4.2 of MIL-STD-461E shall not be interpreted to mean that a power supply qualified to previous EMI standards can be installed aboard a ship class other than the ship class it was originally procured for.

3.2.2.9 Boat Motion and Attitude. The equipment shall be designed and installed to operate satisfactorily when inclined 45 degrees from the vertical. Inclination testing shall be for both the fore-aft and athwartship orientation.

3.2.3 Life Expectancy. As a design goal, the equipment shall have a total life expectancy of 33 years, when maintained in accordance with the maintenance instructions, and with a major overhaul allowed after 15 years. All pumps and rotating mechanical components with routine maintenance shall have a life expectancy of 20,000 hours.

Electrical components and other major mechanical components shall have a life expectancy greater than 20,000 hours. The life expectancy of the electrolysis cells shall be greater than 30,000 hours and shall have a maximum average voltage drop per electrolysis cell of 3 volts at end of life. The 30,000 hour life expectancy for electrolysis cells shall be calculated using the maximum LPE production figure.

3.2.3.1 Shelf Life. The LPE components shall be able to meet all the requirements specified in this specification for the following conditions:

(a) Storage Life – When delivered to the Government, the LPE shall be able to be stored for up to 5 years before installation or use on the ship. Critical components which need special storing, handling or maintenance may be packaged separately and shall be provided with instructions on how to store, handle or be maintained properly.

(b) Standdown – The LPE shall be able to withstand a non operational use while the ship is docked for a period of 3 months without any disassembly of components. Critical components which will require special maintenance and handling shall be provided with instructions on how to handle or maintain properly.

(c) Mothballing – The LPE shall be able to withstand a non operational use while the ship is docked for longer than 3 months. Disassembly of components is allowed. Critical components which need special storing, handling or maintenance may be packaged separately and shall be provided with instructions on how to store, handle or be maintained properly.

3.2.4 Reliability. The LPE shall have a minimum mean-time-between-failure (MTBF) of 2,000 hours. A reliability prediction shall be performed to the requirements of MIL-HDBK-217.

3.2.5 Maintainability. The complete LPE shall have a mean time to repair (MTTR) of not more than five hours except where affected components require a pressure test and/or a cool down period. Components that must be cooled and/or pressure tested shall have an MTTR of not more than fifteen hours. MTTR includes trouble shooting and repair time. A prediction for MTTR shall be performed using MIL-HDBK-472.

3.2.6 Heat Rejection. The LPE shall be designed to minimize total heat rejection to the electronic auxiliary cooling water, chilled water, and the ambient air.

3.2.7 LPE Controls and Operability. The LPE controls and operability shall meet the requirements defined in the following paragraphs.

3.2.7.1 LPE Control Power Interruption. The LPE control system shall be designed to preclude failure or damage to any LPE component due to a temporary loss of power. Such an interruption could occur with an ABT transfer of 115 Volt shipboard buses. In the event of a transfer of this nature, shut down of the LPE is allowed and the unit must shut down safely.

3.2.7.2 Controls and Operator Interface. All controls and indicators required for normal operations shall be located on the front side of the LPE. See Figure 1 for OHIO Class Configuration. Valves required for normal operation shall be readily accessible (behind hinged panels if necessary). The control interface system shall consist of a display and control panel. The display will provide operating parameters, system and failure messages, and diagnostic information to assist in operation, maintenance, and troubleshooting of the LPE. The controls shall include indicator lights for LPE status and critical operating functions. The control panel shall provide all of the necessary functions to operate and control the LPE. The LPE shall provide visual indicators to allow for limited continuous operation in the event of a display system failure, or as approved by the Government. If volatile memory is capable of being lost due to a loss of power to the LPE, then a 72 hour battery backup capable of saving volatile memory shall be provided by the LPE. The controller shall be capable of system diagnostics to warn or alert the operator of potential problems. The LPE alarms shall conform to MIL-A-15303, and shall be capable of being silenced by the operator.

The controller shall be capable of system diagnostics to warn or alert the operator of potential problems. The LPE alarms shall conform to MIL-A-15303, and shall be capable of being silenced by the operator.

Figure 1. OHIO Class Configuration Reference

3.2.7.3 Controller Hardware. The LPE Controller shall be A real time electronic microprocessor which coordinates all control functions and provides a continuous update on the status and condition within the LPE. The central processing unit (CPU) will consist of logic and memory blocks. The CPU will perform the logical and computational operations on the signals as directed by the control program held in memory and based on the process conditions. The controller system shall incorporate Built In Test Equipment (BITE) watchdog timers and hard wire sensors to shut down separately as appropriate for safety. If required, the display shall have its own watchdog timer and hard wire sensors to shut down separately as appropriate for safety. The watchdog timers shall continuously update and monitor shutdowns for both processes and software. The microprocessor or chips shall be commercially available and widely used, to minimize premature obsolescence.

3.2.7.4 Controller Software. The Government shall have a copy of the software program with the ability to maintain configuration control and to make changes to address Cyber security and safety issues to the software installed on the LPE Controller. The Contractor shall provide a copy of the program installed on the LPE Controller (DD1423 A0045). The Government's rights in technical data and computer software shall include but not be limited to the foregoing.

3.2.7.5 Design Analysis. The Contractor shall submit to the Government for review and approval an analysis of the proposed LPE operator interface. This report shall include a detailed description of each function, mode of operation, and interaction between these modes. The report shall then describe (with both written descriptions and diagrams) the proposed operator interface for each of these functions, and what will occur if the interface is used improperly or fails. For programmable/interactive interfaces, the report shall also detail how and under what conditions the operator can initiate actions, and for each action what occurs to the interface. The report shall also contain information concerning viewability, character font size and type, choice of icons(s), mnemonics, etc., that will be in the proposed interface. The Contractor shall perform the following design analyses, development plan, and system specifications for the following unless otherwise specified in the Contract. The format content for each report shall follow the respective MIL STD format, unless otherwise approved by the Government.

Software Development Plan (SDP) (DD1423 A006) in accordance with IEEE/EIA 12207 Reliability Prediction (DD1423 A002) in accordance with MIL-HDBK-217 Software Requirements Specification (SRS) (DD1423 A003) in accordance with IEEE/EIA 12207 Failure Modes, Effects, and Criticality Analysis (FMECA) (DD1423 A004) in accordance with MIL-STD-

System Safety Hazard Analysis Report (SSHA) (DD1423 A005) in accordance with MIL-STD-882

3.2.7.6 Controls, Instrumentation and Safety Circuits. The LPE shall contain all necessary controls, and instrumentation and safety circuits required to ensure safe and reliable unattended operation after initial start-up.

The LPE shall be designed so that installation, operation, inspection, maintenance and adjustment can be accomplished without causing injury or damage to the equipment. No double failure shall cause a personnel hazard.

The LPE shall be designed so that one failure or anomaly that may produce an unsafe condition will shut down the LPE. The LPE shall be designed so one failure does not cause a ripple effect. The control system shall continually monitor critical mechanical and chemical processes, and in the event of a problem or malfunction, shall place the LPE in a fail-safe shutdown condition. The control system shall report the cause of the shutdown, and shall save the status of the various controls and sensors in memory. No improper switch or valve actuation shall cause a casualty.

The LPE control system shall provide the necessary circuitry and interface connectors to allow the unit to be shut down remotely.

3.2.7.7 Failure Recording. The LPE shall record operational data once every minute. The past 30 minutes of data will be available for review by the operator. When one of the following events occurs, the LPE shall automatically save the prior 30 minutes of data. Saved data shall be available for download through the LPE USB port or review by the operator. The LPE shall be capable of saving data from up to the past 100 events.

(a) Message displayed

(b) Operation mode change

(c) Failure

3.2.8 Human Engineering. The unit shall meet the human engineering requirements specified in MIL-STD- 1472 unless otherwise specified herein. In general the unit shall be designed for ease of operation and maintenance.

Design of the unit shall reflect efficient arrangement of equipment, control and displays to ensure optimal task performance. Equipment design shall provide for adequate physical, visual, auditory and other communication links between personnel and equipment under both normal and emergency conditions. Controls, displays, markings, coding, labeling and arrangement schemes (equipment and panel layout) shall be uniform for common functions of all equipment. Where off-the-shelf equipment requires modification in order to interface with other equipment, the modification shall be designed to comply with the criteria contained in MIL-STD-1472.

3.2.9 Safety. In general the unit shall conform to the safety standards issued by the Occupational Safety and Health Administration (OSHA). Safety features shall be incorporated into the unit to prevent damage to equipment and ensure optimal personnel protection. An operating safety analysis shall be performed to identify activities or operations which have the potential for injury to personnel or damage to equipment. The area of the analysis shall include, but not be limited to the following:

(a) Specific safety installation requirements

(b) Specific safety testing requirements

(c) Specific operating/maintenance requirements including impact on submarine atmosphere control

(d) Specific safety handling requirements

(e) Specific training requirements

3.3 Materials and Processes

3.3.1 Materials. Contractor and Suppliers shall be governed by these requirements.

(a) Corrosion. Metals and alloys shall be corrosion-resistant or shall be given a corrosion-resisting treatment or coating. Incompatible metal combinations, as identified in MIL-STD-889, shall be protected

(b) Toxic hazards. The equipment shall be designed to prevent exposure of personnel to toxic substances. The design of the LPE shall provide control and leak detection methods required to prevent exposure and to alert personnel of a leak of hydrogen into the ship's atmosphere.

(c) Prohibited. The materials listed on the Submarine Material Control List (SMCL) as prohibited shall not be used. Trace amounts of Mercury in backlights is allowed in color displays.

(d) Exclusions. Brittle materials are of concern due to performance under shock and fatigue. General guidance is provided in the notes section of MIL-S-901D, Interim Change No. 1 and modifications for elongation requirements. Zinc alloy and magnesium alloy castings shall not be used. Aluminum wire shall not be used.

(e) Flammability. Equipment shall be noncombustible or fire retardant under the most hazardous conditions to be expected in the application. Fire retardance shall not be achieved by use of nonpermanent additives to the equipment. Internal cable and wire flammability shall conform to the requirements of SAE AS22759.

(f) Recovered Materials. Unless otherwise specified, all equipment, material, and articles incorporated in the products covered by this specification shall be new and shall be fabricated using recovered materials to the maximum extent practicable where cost effective. Recovered materials are materials that have been collected or recovered from solid waste and reprocessed to become a source of raw materials.

3.3.2 Processes

3.3.2.1 System Cleaning. The following LPE systems (i.e., the demineralized water, nitrogen, hydrogen gas and oxygen) must be thoroughly cleaned of all foreign matter prior to operational tests in accordance with MIL-STD- 1622, or as approved by the Government. The electrolysis cell, due to its special materials, shall be cleaned in accordance with a Supplier procedure approved by the Government. (DD1423 A30)

3.3.2.2 Assembly. The LPE shall be assembled in a clean work area. All tools, fixtures, test equipment, etc., shall be clean and free of oi1, and grease. Test fixtures operated within the oxygen clean boundary must also be oxygen clean. The LPE assembly area shall be segregated from all non-clean fabrication/assembly areas.

3.3.2.3 Welding and Brazing. All welding and brazing shall conform to NAVSEA S9074-AR-GIB-010/278.

Pressure vessels shall be class A-2 and process piping shall be class P-1. Welded joints shall conform to MIL-STD-

22. The following exceptions are noted below:

(a) Shell and tube heat exchanger braze joints, which are not accessible and do not meet the requirements of paragraphs 5.21, 5.2.2 and 9.1.5(c) of NAVSEA Specification 0900-LP-001-7000, shall be hydrostatic tested in lieu of ultrasonic inspection.

(b) MIL-STD-2219 may be used in lieu of NAVSEA S9074-AR-GIB-010/278 for welding aluminum material.

(c) The power supply shall be welded in accordance with MIL-STD-2219 or as approved by the Government.

(d) Furnace Brazing of temperature sensor housings and plugs shall be in accordance with AWS C3.6 or as approved by the Government.

(e) Vacuum furnace brazing of chilled water blocks and tubing shall be in accordance with AWS C3.6 or as approved by the Government.

3.3.2.4 Soldering. Soldering shall be in accordance with MIL-HDBK-454A

3.3.2.5 Painting. Before any coat is applied, bare spots on the previous coat shall be "touched up" and the entire surface allowed to dry thoroughly.

(a) Aluminum and aluminum alloy pretreatment. The basic metal shall be cleaned to remove grease, oil, welding flux, or other foreign matter. The components shall receive a chemical conversion coating.

(b) Ferrous metal pretreatment. After all machining, welding, and brazing operations are completed, rust or other corrosion products and flux shall be removed by abrasive blasting, sanding, wire brushing, or other mechanical means. Surfaces shall be cleansed of all grease, oil, and dirt by solvent wiping and rinsing, vapor degreasing, or caustic washing followed by rinsing. Ferrous metals shall then be pretreated in accordance with type I or III of TT-C-490.

(c) Coatings. Framing, electrical boxes, and other miscellaneous structural components that require corrosion protection, may be epoxy-powder coated, if they meet the following criteria:

(1) Parts must be small enough to fit in the curing oven.

(2) Parts must not be adversely affected by heating to process temperatures or by other process conditions.

(3) Powder coating of fasteners is not authorized. If powder coating cannot be used the parts shall be painted.

(4) Powder coating that are categorized as prohibited on the SMCL shall not be used.

(d) Plating. Cadmium plating of fasteners is allowed.

3.3.3 Electrical/Electronics Component Selection. Electronic and electrical equipment shall meet the requirements of MIL-E-917E.

3.3.3.1 Electronic Component Derating. In the application of electronic parts and materials, the parts and materials selected shall be used within their electrical ratings and environmental capabilities (e.g., any ambient or hot spot temperatures, voltage, current, or power dissipation). Derating shall be accomplished as necessary to assure the required equipment reliability within the specified operating conditions.

3.3.3.2 Electrical Connectors. The types of electrical connectors that shall be utilized are MIL-C-38999 Series 111, MIL-C-5015 Series 3400 Class D and/or MIL-C-28840. A request for waiver of these requirements can be submitted to the Government for specific circumstances. Shipboard interface connectors shall be selected as specified in MIL-STD-1683, which lists all standard electrical connectors.

3.3.3.3 Electric Motors and Associated Controllers. Electric motors and associated controllers shall be in accordance with, MIL-C-2212, MIL-M-17059 and MIL-M-17060 as applicable. Exhaust and recirculating fans, pumps and blowers shall be driven by AC induction motors. Non military specification motor driven auxiliaries or motors for special applications, shall be approved by the Government.

3.3.3.4 Electromagnetic Interference Filters. Where EMI filters are required, line-to line filters are preferred to line-to-ground filters. AC line-to-ground capacitance shall be in accordance with MIL-STD-1399, Section 300A and MIL-STD-461E. EMI filters shall be located on the load side of the power on/off switch where practical.

3.3.3.5 Personal Safety Leakage Current. The equipment shall comply with Appendix B of MIL-HDBK-2036 and paragraph 5.2.4 of MIL-STD-1399 Section 300A. The value of input filter capacitance to ground shall not exceed 0.1 uF per phase for 60 Hz equipment. On equipment which has an unavoidable leakage current in excess of 5 milliamperes a warning plate shall be attached to the front panel and read as follows:

"DANGER: Do not energize this equipment unless frame and all exposed metal parts are grounded."

3.3.3.6 Protective Shields. Protective shields shall be provided to protect personnel from accidental contact with parts in excess of 30 Vrms or 30 VDC during operation or maintenance actions. The electrolysis cell module shall be provided with warning labels stating that the module is charged (see para. 3.3.5.3).

3.3.3.7 Grounding. Equipment shall be grounded in accordance with MIL-STD-1310. Equipment shall be suitable for operation in each operating mode with any one of the three phase input power lines shorted to ground.

Grounding shall be tested in accordance with para. 5.3.5 of MIL-STD-1399, section 300.

3.3.3.8 Internal Wiring Practices. Internal wiring practices shall be in accordance with MIL-HDBK-454.

3.3.3.9 Power Supply Design. The power supply shall be in accordance with MIL-HDBK-2036. The power supply shall be compatible with the ship's power supply as defined in 3.2.1.4. Power supplies shall not be damaged by any load between an open circuit and a short circuit.

3.3.3.10 Electrical Protective Devices. Electrical protective devices where used as circuit breakers shall conform to MIL-C-17361 and fuses shall be in accordance with MIL-PRF-15160.

3.3.3.11 Instrumentation. As a minimum, the following instruments shall be provided.

(a) Electrolysis cell stack and major component electrical power consumption (if not provided on the display).

(b) Indicator lights shall be provided on the LPE interface control panel to alert the operator on the following functions:

(1) Electrolysis process operating light on when in operation, and off when not in operation

(2) A blinking light to alert the operator of a potential shut down or other pending corrective actions

(3) A light to alert the operator that each function is in shut down and/or purge mode

(4) Audio alarm indication light shall be provided to indicate that the unit's alarms have been inhibited

3.3.3.12 Hardware Shutdowns. The LPE shall be equipped with hardware shutdown mechanisms that are independent of the software. These mechanisms shall ensure that the generator shuts down safely when a potentially unsafe operating condition is detected.

3.3.3.13 Insulation Resistance. Insulation resistance shall be in accordance with the requirements of MIL-HDBK- 2036 except as noted below or as approved by the Government.

3.3.3.14 Dielectric Withstanding Voltage. Dielectric withstanding voltage shall be in accordance with the requirements of MIL-HDBK-2036 or as approved by the Government.

3.3.4 System Mechanical Design

3.3.4.1 Enclosures. The cabinet enclosures for the LPE shall be rigid and of adequate strength to support and maintain alignment of the assembled components. The enclosures shall be capable of venting the overpressure from an internal detonation without coming adrift. Equipment enclosures shall be in accordance with MIL-STD-108 and MIL-HDBK-2036. The degree of enclosure shall be drip proof to 45 degrees. The exterior and interior surfaces of metallic enclosures shall be painted as specified herein, except the interior of treated aluminum enclosures need not be painted. Corrosion resistant enclosures are not required to be painted. Prior to painting, the applicable pretreatment and primer shall have been completed.

3.3.4.2 Ventilation. The LPE cabinet(s) shall be designed to minimize and disperse the build-up of explosive vapors within the cabinet. The LPE shall provide sensing devices to determine gas leaks within the unit. The LPE shall shut down all gas producing processes safely and alert the operator when a potentially dangerous gas leak is detected.

Ventilation fans shall automatically turn on to disperse gas leaks, once they have been detected. Ventilation fan selection and actuation shall comply with safety requirements specified herein. Air filters, if used, shall be removable for cleaning without disassembly of the equipment. Air filters shall be in accordance with MIL-F-16552.

3.3.4.3 Piping Design. The demineralizer will be allowed to use a tapered pipe thread, provided that a tapered thread to straight pipe thread interface fitting is installed. All joints shall be welded in accordance with NAVSEA Specification S9074-AR-GIB-101/278, but parts requiring replacement or maintenance may be mounted with straight-thread or "Koncentric"(TM) union fittings and sealing devices. Fluid system components shall be selected from the existing ILPE and AEOG designs to the extent practical.

3.3.4.4 Bearings. Bearings for use in noise critical applications shall be in accordance with MIL-B-17931 or as approved by the Government. The use of alternate bearings are allowable provided the Supplier meets the acoustic and life requirements defined herein.

3.3.4.5 Drip Pan. The LPE shall incorporate a drip pan under the unit, if required. The drip pan shall be incorporated into the LPE design to the greatest extent possible. Provision for drain connections shall be provided as required to drain any fluid into the ship's drain system. The drip pan shall be arranged so that it can be visibly inspected.

3.3.5 Marking

3.3.5.1 Plates. Identification and information plates are required and shall conform to MIL-P-15024.

An identification plate shall be located on the front of the plant. The label plates shall contain the following data:

(a) Title of equipment

(b) U.S. Navy serial numbers (to be furnished)

(c) Manufacturer's name, model, and serial numbers

(d) Contract or procurement order number

3.3.5.2 Special Equipment Plates. Plates for water pumps, special valves, and flowmeter shall be supplied which contain the following information:

(a) Manufacturer's name

(b) Manufacturer's identification numbers such as model number, part number, size, serial number, etc.

(c) Design characteristics, such as capacity, pressures, heat transfer characteristics, speed, calibration data, horsepower, test pressure, etc.

(d) Contract or procurement order number

All process components and instruments shall be clearly marked with their process-schematic identifying number.

3.3.5.3 Warning Plates. Warning plates shall be installed at critical locations to warn against danger or hazards.

Warning plates shall conform to MIL-P-15024.

3.3.6 Computer Software. All software shall be developed in compliance with IEEE/EIA 12207, except that commercial processor is allowed. Requirements of IEEE/EIA 12207 shall be tailored in a cost effective manner with respect to the needs of the LPE. Software shall not be utilized as the final safety check for over pressure or over temperature fault detection. Computer software components may be individually grouped, developed and controlled as a function of their purpose, including but not limited to failure effects and mission criticality. Computer software and components used in the LPE design shall be built and designed to avoid obsolescence.

3.3.7 Workmanship. Workmanship shall be uniform in quality, and the surfaces shall contain no foreign matter, corrosion, or detrimental defects such as perforations, sharp edges or corners, seams,…