SOW 5-21.docx

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STATEMENT OF WORK

REPLACEMENT PHOTOCATALYTIC REACTOR FOR ANNEALING AIR POLLUTION CONTROL SYSTEM

1.0 INTRODUCTION

The Naval Surface Warfare Center, Indian Head (NSWC IHD) has a requirement to anneal extruded double-base propellant billets before further processing. The annealing process creates a waste stream of exhaust air primarily laden with nitroglycerin (NG) vapor, which is scrubbed in real time by an in-situ Pollution Control System (PCS) to remove NG from the air stream before release to the environment via packed bed scrubbers utilizing recirculating process water as the scrubbing medium. NG and other propellant associated volatiles (trace levels) that are captured in the scrubber process water are mineralized (converted to inorganic solids and gases) to maintain scrubbing medium efficiency while controlling the risk of an explosive hazard from excessive NG concentration build-up in the process water system. NG and other organics that are dissolved in the scrubber process water are mineralized by photocatalytic reactor systems in real time to maintain efficient operation of the PCS and allow the occasional disposal of spent scrubber water as non-hazardous waste. The existing photocatalytic reactor has operated well beyond the Original Equipment Manufacturer (OEM) recommended service life of 20 years, with performance trends showing that the reactor systems are at the end of useful life. Additionally, the reactor model used is no longer supported by the OEM, and many replacement parts have become obsolete and unavailable as well, threatening the continued operability of the PCS. As a result, a project has been approved to procure and install state-of-the-art, chemical free, advanced oxidation photocatalytic (AOP) reactor systems and reverse osmosis (RO) salt removal systems with control system communication interfaces compatible with the facility control system. This upgrade serves to realize significant operational and maintenance cost savings compared to the failing obsolete reactor systems.

1.1 SCOPE

The Contractor must configure and deliver an AOP reactor system composed of commercial off-the-shelf (COTS) components and modules designed to take the place of existing, reactor systems in building 3067. The system must include a means to prevent the catalyst material from escaping into the rest of the PCS system. The government will purchase up to two reactor systems for full PCS efficiency with reactor redundancy. The reactor system must be furnished with an OEM control system that integrates seamlessly with the building system and can control two (2) reactor systems together or independently. The Contractor must configure and deliver redundant reverse osmosis (RO) membrane nanofiltration systems (2 each). Each RO unit must include an integrated clean-in-place sub-system for operational membrane maintenance. A membrane protective chemical feed system to remove free chlorine from the potable water supplying the RO system must be supplied by the contractor. The systems provided by the contractor are to be installed in building 3067 by Government forces with the guidance of the contractor as an installation consultant. The Contractor must train Government engineers, operators, and mechanics to operate and maintain the new reactor systems, RO systems, and chemical feed system. Controlled by: Department of Navy Controlled by: NSWC IHD/M12 CUI Category: CTI Distribution/Dissemination Control: DISTRO D POC: Timothy Brennan, 240-585-2999

2.0 REQUIREMENTS

2.1 PHOTO-CATALYTIC REACTOR

2.1.1 The reactor system will meet the following requirements:

1. The reactor must be an advanced oxidation photocatalytic system that does not require the use of additional chemicals for reaction success.

2. The reactor construction must meet the following requirements:

a. 316L or better stainless steel must be used for all wetted surfaces.

b. All O-rings and seals must be made of Viton.

c. All electrical components must be made of UL approved components.

d. The electrical components must be housed in an enclosure that conforms to NFPA70 and UL508A.

3. The reactor must have the capability to process opaque water of any color.

4. The reactor control system must integrate seamlessly into the existing building control system.

5. The reactor must incorporate a 0-100% turndown capability.

6. Each reactor must integrate into the current 240V, 3-phase power supply provided.

7. The reactor footprint must allow two reactors to fit within the footprint of one of the existing reactors, while maintaining complete functionality and accessibility to both reactor systems.

8. The lamps must be powered by a system of lamp drivers that are able to detect and communicate to the control system which individual lamp is not operational.

9. The lamp drivers must have the ability to determine if a fault is present and identify the fault.

10. The reactor must be able to handle flow rates of at least 40gpm of process water.

11. The reactor must use 220W instant start high output low pressure ultra-violet (UV) light emitting lamps.

12. The reactor must use a suitable grade of TiO2 powder as the catalyst.

13. The reactor system must include a system to recover the catalyst from the reactor effluent prior to returning it to the process water tank.

14. The reactor must be configurable as to the number of active UV-lamps per reactor and the total number of lamp cells required per reactor to tailor the reactor systems to the actual organic loads presented by the building PCS.

15. The reactor system must include a fully developed SCADA system that is capable of controlling the system and generating data reports, including time-stamped data collection from the lamp drivers.

16. The reactor system must have a mounted display screen for an HMI to accomplish requirement 15.

2.1.2 The Contractor must supply the following for each photo-catalytic reactor:

1. Piping and instrumentation drawings (P&IDs) and process electrical schematics capable of incorporation into existing drawing packages.

2. A list of main and relevant equipment and all instruments including manufacturer and model.

3. A general process description, to include process parameters with limits and units (English units required), general interlocks and alarms.

4. An operations description to include, but not limited to, normal operating conditions, actions to take upon detecting abnormal conditions, and startup and shutdown procedures.

2.1.3 The Contractor must show proof of the following:

1. The Contractor must have provided a reactor system of similar design and functionality to another client and the reactor must have been operational for more than 5 years.

2. The Contractor must complete a pilot scale process to show that their process can perform the necessary reactions and does not produce undesirable intermediates. Contractors who have a proven record with this process, as determined by the government, may be exempted from this requirement.

2.2 REVERSE OSMOSIS AND DECHLORINATION UNIT

2.2.1 The Contractor must configure and deliver redundant RO systems (2 each) with integrated membrane protection raw water feed de-chlorination units to remove calcium and magnesium salts chlorine from potable water used to supply make-up water to the reactor system. The RO systems and de-chlorination units must meet the following requirements:

1. The RO system must come with a system and instructions to clean the membranes in the RO unit.

2. The RO unit must have sufficient automation to be turned on and off through the building HMI.

3. The dechlorination unit must work seamlessly with the RO system in series.

4. The RO system must have sufficient pumping capabilities to pump potable water from a tank, through the dechlorination unit and RO system, and back into the process water holding tank.

5. The RO system and dechlorination unit must be capable of processing at least 2.5 gallons of potable water per minute.

6. The RO system and dechlorination unit must integrate into the current power supply seamlessly.

2.2.2 The Contractor must supply the following for the RO system and dechlorination unit:

1. A list of main and relevant equipment and all instruments including manufacturer and model.

2. A general process description, to include process parameters with limits and units (English units required), general interlocks and alarms.

3. An operations description to include, but not limited to, normal operating conditions, actions to take upon detecting abnormal conditions, and startup and shutdown procedures.

3.0 PERSONNEL TRAINING

The Contractor must provide in person training on all systems to designated government representatives. This training must, at minimum, include the following:

1. Start-up

2. Normal Shut-down

3. Normal Operation

4. Emergency shut-down

5. Preventative maintenance

6. Common points of failure and associated required actions

7. Control system operation

4.0 REQUIRED ITEMS

1. Two reactor system.

2. Two reverse osmosis systems.

3. Two clean-in-place systems for the reverse osmosis units

4. One dechlorination unit.

5. A list of all parts and equipment with parts number and manufacturer.

6. Training to NSWC IHD personnel on all equipment.

6.0 FINAL ACCEPTANCE TESTING

The Government will conduct an inert test of the equipment to ensure that the equipment is free from leaks and defects. After inert testing, the reactor systems will be tested using 2 annealing cycles with 5 ovens. A mixture of propellants will be annealed. The reactor system must keep the NG concentration below 1000ppm at all times. The reactor must be able to reduce the NG concentration to a non-detectable level within 2 weeks after the end of the annealing cycles. After the process water reaches a non-detectable level, the reactor system will be checked for leaks, broken components, and any clogged flow paths.

The Government will reserve the right to inspect and test all systems or materials provided by contractor prior to acceptance. If the Government discovers any defective parts before accepting the products, the Contractor must fix such parts before the government accepts the products.

7.0 CONTRACTOR CERTIFICATIONS / QUALIFICATIONS

Installation and Instruction team should be composed of experts with in-depth industry experience. Each instructor must have hands on knowledge and be a qualified professional Subject Matter Expert with strong communication skills.

Distribution D: Distribution authorized to the Department of Defense and U.S. DoD contractors only. CTI, NOV 2024. Other requests shall be referred to Commanding Officer, NSWC Indian Head Division Destruction Notice: Destroy by any method that will prevent disclosure of contents or reconstruction of the document

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Distribution D: Distribution authorized to the Department of Defense and U.S. DoD contractors only. CTI, NOV 2024.

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