E2FDS_Attachment_0001-_ATPD_2417.pdf

Beneficial comments (recommendations, additions, deletions) and any pertinent data which may be of use in improving this document should be sent to U.S. Army RDECOM, Tank Automotive Research, Development and

Engineering Center, ATTN: RDTA EN/STND/TRANS MS #268, 6501 E. 11 Mile Road, Warren, MI 48397-5000 or sent by email to usarmy.detroit.rdecom.mbx.tardec-standardization@mail.mil. Since contact information can change, you may want to verify the currency of this address information using the ASSIST Online database at https://assist.dla.mil.

AMSC N/A FSC 3835

DISTRIBUTION STATEMENT A. Approved for public release; distribution is unlimited.

OPSEC #27299

INCH-POUND

Dft ATPD 2417A v3

16 FEB 2016

SUPERSEDING

ATPD 2417

01 DEC 2015

PURCHASE DESCRIPTION

FLUID DISTRIBUTION SYSTEM, EARLY ENTRY

This purchase description is approved for use by the U.S. Army Tank-automotive and

Armaments Command, Department of the Army and is available for use by all

Departments and Agencies of the Department of Defense.

1. SCOPE

1.1 Scope. This purchase description covers a rapidly emplaced, high throughput, fluid distribution hose system, or Early Entry Fluid Distribution System, hereinafter referred to as

E2FDS. The E2FDS complements the Inland Petroleum Distribution System by adding an early entry capability as well as a means for rapidly extending existing pipeline. The system provides

5 miles of fluid transfer hose, along with all the necessary support equipment for deployment, and pumping capability while in operation.

2. APPLICABLE DOCUMENTS

2.1 General. The documents listed in this section are specified in sections 3 and 4 of this purchase description. This section does not include documents cited in other sections of this purchase description or recommended for additional information or as examples. While every effort has been made to ensure the completeness of this list, document users are cautioned that they must meet all specified requirements documents cited in sections 3 and 4 of this purchase description, whether or not they are listed.

mailto:usarmy.detroit.rdecom.mbx.tardec-standardization@mail.mil https://assist.dla.mil/

Draft ATPD 2417A v3

2.2 Government documents.

2.2.1 Specifications, standards, and handbooks. The following specifications, standards, and handbooks form a part of this document to the extent specified herein. Unless otherwise specified, the issues of these documents are those cited in the solicitation or contract.

SPECIFICATIONS

FEDERAL

A-A-52624 - Antifreeze, Multi Engine Type

A-A-52557 - Fuel Oil, Diesel; For Posts, Camps and Stations

A-A-59326 - Coupling Halves, Quick-Disconnect, Cam-Locking Type

A-A-59359 - Fuel Spill Control Kit

DEPARTMENT OF DEFENSE

MIL-PRF-370 - Hose and Hose Assemblies, Nonmetallic: Elastomeric, Liquid

Fuel

MIL-PRF-2104 - Lubricating Oil, Internal Combustion Engine, Combat/Tactical

Service

MIL-DTL-5624 - Turbine Fuel, Aviation, Grades JP-4 and JP-5

MIL-PRF-10924 - Grease, Automotive and Artillery

MIL-PRF-21260 - Lubricating Oil, Internal Combustion Engine, Preservative

Break-In

MIL-PRF-32143 - Batteries, Storage: Automotive, Valve Regulated, Lead Acid

MIL-PRF-46167 - Lubricating Oil, Internal Combustion Engine, Arctic

MIL-DTL-53072 - Chemical Agent Resistant Coating System Application

Procedures and Quality Control Inspection

MIL-DTL-64159 - Camouflage Coating, Water Dispersible Aliphatic

Polyurethane, Chemical Agent Resistant

MIL-DTL-83133 - Turbine Fuel, Aviation, Kerosene Type, NATO F-34 (JP-8), NATO F-35, and JP-8+100

STANDARDS

FEDERAL

FED-STD-595/33446 - Desert Tan 686A

FED-STD-595/37030 - Black

DEPARTMENT OF DEFENSE

MIL-STD-129 - Military Marking for Shipment and Storage

MIL-STD-130 - Identification Marking of U.S. Military Property

MIL-STD-209 - Lifting and Tiedown Provisions

MIL-STD-461 - Requirements for the Control of Electromagnetic Interference

Characteristics of Subsystems and Equipment

MIL-STD-464 - Electromagnetic Environmental Effects Requirements for

Systems

MIL-STD-810 - Environmental Engineering Considerations and Laboratory

Tests

MIL-STD-1179 - Lamps, Reflectors and Associated Signaling Equipment for

Military Vehicles

MIL-STD-1366 - Transportability Criteria

MIL-STD-1472 - Human Engineering

MIL-STD-40051 - Preparation of Digital Technical Information for Interactive

Electronic Technical Manuals (IETMs)

HANDBOOKS

MIL-HDBK-1791 - Designing for Internal Aerial Delivery in Fixed Wing Aircraft

(Unless otherwise indicated, copies of the above specifications, standards, and handbooks are available from Document Automation and Production Service, Bldg 4D, 700 Robbins Avenue, Philadelphia, PA 19111-5094, or at http://quicksearch.dla.mil/).

INSTRUCTIONS

DODI 4630.09 - Wireless Communications Waveform Development and

Management

(Copies may be obtained through the internet from the DoD Issuances web site at http://www.dtic.mil/whs/directives).

2.2.2 Other Government documents, drawings, and publications. The following other

Government documents, drawings, and publications form a part of this document to the extent specified herein. Unless otherwise specified, the issues are those cited in the solicitation.

CODE OF FEDERAL REGULATIONS (CFR)

Title 40 - Protection of Environment

(Copies of the CFR are available from the Superintendent of Documents, U.S. Government

Printing Office, Washington, DC 20402, or at http://www.access.gpo.gov/nara/cfr/).

NATIONAL INSTITUTE OF STANDARDS AND TECHNOLOGY (NIST)

CMVP - Cryptographic Module Validation Program (CMVP)

FIPS 140-2 - Security Requirements for Crytographic Modules, Federal

Information Processing Standards

(Copies of the CMVP and FIPS may be obtained through the internet from the NIST web site at http://www.nist.gov/ and http://csrc.nist.gov/publications/).

NATIONAL TELECOMMUNICATIONS AND INFORMATION ADMINISTRATION

(NTIA)

2013 Edition - Manual of Regulations and Procedures for Federal Radio

Frequency Management http://quicksearch.dla.mil/ http://www.dtic.mil/whs/directives http://www.access.gpo.gov/nara/cfr/ http://www.nist.gov/ http://csrc.nist.gov/publications/

(Copies of the NTIA may be obtained through the internet from the NTIA website at http://www.ntia.doc.gov/).

NORTH ATLANTIC TREATY ORGANIZATION (NATO)

AFLP 3747 - Guide Specifications (Minimum Quality Standards) For

Aviation Turbine Fuels (F-24, F-27, F-34, F-35, F-37, F-40

AND F-44)

STANAG 1135 - Interchangeability of Fuels, Lubricants and Associated

Products Used by the Armed Forces of the North Atlantic

Treaty Nations

STANAG 2413 - Demountable Load Carrying Platforms (DLCP/Flatracks)

STANAG 3756 - Facilities and Equipment for Receipt and Delivery of Aviation

Kerosene and Diesel Fuels

STANAG 4074 - Auxiliary Power Unit Connections for Starting Tactical Land

Vehicles

(Copies of North Atlantic Treaty Organization (NATO) documents are available from NATO

Blvd Leopold III, 1110 Brussels, Belgium, or at http://www.ihserc.com).

PURCHASE DESCRIPTIONS

ATPD 2306 - Suspension Kit, Collapsible Hoseline

(Copies are available from Commander, U.S. Army Tank-Automotive and Armaments

Command, 6501 E. 11 Mile Road, Warren, MI 48397-5000, ATTN: RDTA-SIE-ES-SI, MS-268, Warren, MI 48397-5000, or emailed to usarmy.detroit.rdecom.mail.tardec-standardization@mail.mil).

US ARMY PAMPHLETS

DA Pam 611-21 - Military Occupational Classification and Structure

(Copies are available from the U.S. Army RDECOM, Tank Automotive Research, Development and Engineering Center, ATTN: RDTA-SIE-ES-SI, MS-268, Warren, MI 48397-

5000, or at http://www.apd.army.mil).

US ARMY REGULATIONS

AR 25-2 - Information Assurance

(Copies are available from the U.S. Army RDECOM, Tank Automotive Research, Development and Engineering Center, ATTN: RDTA-SIE-ES-SI, MS-268, Warren, MI 48397-

5000, or at http://www.apd.army.mil).

http://www.ntia.doc.gov/ http://www.ihserc.com/ mailto:usarmy.detroit.rdecom.mail.tardec-standardization@mail.mil mailto:usarmy.detroit.rdecom.mail.tardec-standardization@mail.mil mailto:usarmy.detroit.rdecom.mbx.tardec-standardization@mail.mil http://www.apd.army.mil/

US ARMY TECHNICAL MANUALS

TM 9-2320-304-14&P - Load Handling System, Heavy Expanded Mobility Tactical

Trucks (HEMTT)

TM 9-2320-364-14&P - Palletized Load System (PLS)

TM 9-2330-385-10 - Palletized Load System Trailer (PLST)

TM 10-3930-643-10 - Truck, Forklift, DED Pneumatic Tire, 10,000 lb. Capacity, Rough Terrain, Articulated Frame Steer, (M10A)

TM 10-3930-673-10 - All Terrain Lifter Army System (ATLAS), Clean Burn

Diesel, 10,000 lb. Capacity

TM 5-4310-452-14 - Compressor, Rotary, Air, DED, 250 CFM 100PSI Trailer-

Mounted

(Copies are available from the U.S. Army RDECOM, Tank Automotive Research, Development and Engineering Center, ATTN: RDTA-SIE-ES-SI, MS-268, Warren, MI 48397-

5000, or at http://www.apd.army.mil.)

DRAWINGS

11674728 - Vehicle Receptacle Assembly, NATO Intervehicle Power

13219E0462 - Ground Rod

13228E3612 - Pipe, Culvert, Nestable

(Copies are available from Commander, U.S. Army Tank-Automotive and Armaments

Command, 6501 E. 11 Mile Road, Warren, MI 48397-5000, ATTN: RDTA-SIE-ES-SI, MS-268, Warren, MI 48397-5000, or emailed to usarmy.detroit.rdecom.mail.tardec-standardization@mail.mil).

2.3 Non-Government publications. The following documents form a part of this document to the extent specified herein. Unless otherwise specified, the issues of these documents are those cited in the solicitation or contract.

AMERICAN SOCIETY OF MECHANICAL ENGINEERS (ASME)

ASME B1.1 - Unified Inch Screw Threads (UN and UNR Thread Form)

ASME B1.20.1 - Pipe Threads, General Purpose (Inch)

ASME B1.20.3 - Dryseal Pipe Threads (Inch) Revision and Redesignation of

B2.2-1968

ASME-BPVC - Boiler and Pressure Vessel Code (BPVC)

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

Engineers, ASME Information Central Orders/Inquiries, PO Box 2300, Fairfield, NJ 07007-

2300, or on-line at http://www.asme.org.)

AMERICAN SOCIETY FOR TESTING AND MATERIALS (ASTM)

ASTM D 380 - Standard Test Methods for Rubber Hose (DoD Adopted)

ASTM D 381 - Standard Test Method for Gum Content in Fuels by Jet

Evaporation (DoD Adopted)

ASTM D 413 - Standard Test Methods for Rubber Property-Adhesion to

Flexible Substrate (DoD Adopted) http://www.apd.army.mil/ mailto:usarmy.detroit.rdecom.mail.tardec-standardization@mail.mil mailto:usarmy.detroit.rdecom.mail.tardec-standardization@mail.mil http://www.asme.org/

ASTM D 471 - Standard Test Method for Rubber Property-Effect of Liquids

(DoD Adopted)

ASTM D 573 - Standard Test Method for Rubber-Deterioration in an Air Oven

(DoD Adopted)

ASTM D 975 - Standard Specification for Diesel Fuel Oils (DoD Adopted)

ASTM D 1053 - Standard Test Methods for Rubber Property-Stiffening at Low

Temperatures: Flexible Polymers and Coated Fabrics (DoD

Adopted)

ASTM D 1171 - Standard Test Method for Rubber Deterioration-Surface Ozone

(DoD Adopted)

ASTM D 1655 - Standard Specification for Aviation Turbine Fuels

(DoD Adopted)

ASTM D 3389 - Standard Test Method for Coated Fabrics Abrasion Resistance

(Rotary Platform Abrader)(DoD Adopted)

(Copies are available from the American Society for Testing and Materials, 100 Barr Harbor

Drive, West Conshohocken, PA 19428-2959, or at www.astm.org).

AMERICAN WELDING SOCIETY (AWS)

AWS D1.1 - Structural Welding Code - Steel (DoD Adopted)

AWS D1.2 - Structural Welding Code - Aluminum (DoD Adopted)

AWS D1.3 - Structural Welding Code - Sheet Steel (DoD Adopted)

AWS D1.6 - Structural Welding Code - Stainless Steel (DoD Adopted)

(Copies are available from the American Welding Society, 550 N.W LeJeune Road, Miami, FL 33126, or at www.aws.org).

DEUTSCHES INSTITUT FUR NORMUNG (DIN)

DIN EN 14420-6 - Hose Fittings with Clamp Units-Part 6: TW Tank Truck

Couplings

DIN 30722 - Roller Contact Tipper Vehicles, Roller Containers

(Application for copies should be addressed to the Deutsches Institut Fur Normung, Burggrafenstrasse 6; D-10787, Berlin Germany.)

HYDRAULIC INSTITUTE

ANSI/HI 14.6 - Rotodynamic Pumps for Hydraulic Performance Acceptance

Tests

(Copies are available from the Hydraulic Institute, 9 Sylvan Way, Parsippany, NJ

07054-3802, or at http://www.pumps.org/).

INTERNATIONAL ORGANIZATION FOR STANDARDIZATION (ISO)

ISO 228-1 - Pipe Threads where pressure-tight joints are not made on the threads

Part 1: Dimensions, Tolerances and Designation http://www.astm.org/ http://www.aws.org/ http://www.pumps.org/

ISO 668 - Series 1 Freight Containers - Classification, Dimensions and Ratings

(DoD adopted)

ISO 1496-1 - Series 1 Freight Containers - Specification and Testing (DoD Adopted)

ISO 1161 - Series 1 Freight Containers - Corner Fittings - Specification (DoD

Adopted)

ISO 6346 - Freight Containers – Coding, Identification, and Marking

(Applications for copies should be addressed to American National Standards Institute, 11

West 42nd Street, New York, NY 10036 or via the internet at: http://www.ansi.org).

NATIONAL ELECTRICAL MANUFACTURERS ASSOCIATION (NEMA)

NEMA 250 - Enclosures for Electrical Equipment (1000 Volts Maximum)

(DoD Adopted)

(Copies are available from the National Electrical Manufacturers Association, 1300 N

17th St, Suite 1847, Rosslyn, VA 22209, or at http://www.nema.org/).

SOCIETY OF AUTOMOTIVE ENGINEERS (SAE)

SAE J 513 - Refrigeration Tube Fittings (DoD Adopted)

SAE J 614 - Engine and Transmission Dipstick Marking (DoD Adopted)

SAE J 847 - Trailer Tow Bar Eye and Pintle Hook/Coupler Performance

(DoD Adopted)

SAE J 1939-13 - Off-Board Diagnostic Connector

SAE J 2360 - Oil, Lubricating, Gear Multipurpose (Metric) Military Use

(Copies are available from The Society of Automotive Engineers, Department 105, 400 Commonwealth Drive, Warrendale, PA 15096, or at http://www.sae.org).

UNDERWRITERS LABORATORIES, INC.

UL 711 - UL Standard for Safety Fire Extinguishers, Rating and Fire

Testing (DoD Adopted)

(Copies are available from Underwriters Laboratories, Inc., 12 Laboratory Drive, Research

Triangle Park, NC 27709-3995, or at http://ul.com).

2.4 Order of precedence. In the event of a conflict between the text of this document and the references cited herein, the text of this document takes precedence. Nothing in this document, however, supersedes applicable laws and regulations unless a specific exemption has been obtained.

3. REQUIREMENTS

3.1 First article. Unless otherwise specified (see 6.2), a sample shall be subjected to first article inspection in accordance with (IAW) 4.1.1.

3.2 Materials. The contractor shall verify that the materials used in the E2FDS are as identified and shall meet all of the operational and environmental requirements specified. The components incorporated into the E2FDS shall be newly fabricated from recovered materials

(see 6.6.1) to the maximum extent practicable, provided the components meet all other requirements of this document. Pump assemblies shall be constructed of materials suitable for http://www.ansi.org/ http://www.nema.org/ http://www.sae.org/ http://ul.com/ fuel pumping service, and for non-potable water pumping service. Lead shall not be used. The material shall have no adverse effect on the health of personnel when used for its intended purpose.

3.2.1 Deterioration prevention and control. The E2FDS shall be fabricated from compatible materials, inherently corrosion resistant or treated to provide protection against corrosion and deterioration during storage and operational conditions experienced.

3.2.2 Dissimilar metals. Dissimilar metals shall not be used in intimate contact with each other unless protected against galvanic corrosion.

3.2.3 Recycled, recovered, or environmentally preferable materials. Recycled, recovered, or environmentally preferable materials shall be used to the maximum extent possible provided that the material meets or exceeds the operational and maintenance requirements, and promotes economically advantageous life cycle costs. Used, rebuilt, or remanufactured components shall not be incorporated into the pump assembly.

3.2.4 Usage of COTS items. Commercial-off-the-shelf (COTS) items shall be used whenever available.

3.2.5 Welding. All welding shall be IAW AWS D1.1, AWS D1.2, AWS D1.3, AWS

D1.6 and the ASME Boiler and Pressure Vessel Code.

3.3 Operating requirements.

3.3.1 System level performance.

3.3.1.1 Flow capacity. The E2FDS shall be capable of transferring a minimum of

850,000 gallons of fuel (650,000 gallons of raw/non-potable water) per 20-hour operational day

(Threshold), with a desired transfer capability of 1,000,000 gallons of fuel (750,000 gallons of raw/non-potable water) per 20-hour operational day (Objective). This shall be achieved over the system distance of 5 miles, at an increasing grade of 1% slope.

3.3.1.1.1 Fuel consumption. The E2FDS shall deliver the requirement in 3.3.1.1 at a ratio of 225 gallons of fuel product throughput for every gallon consumed by the pump stations

(Threshold), with a desired ratio of 450 gallons of throughput for every gallon consumed by the pump stations (Objective). The product throughput and fuel consumed shall both be JP-8 per

3.4.3.

3.3.1.2 Hoseline length. The E2FDS shall provide a minimum of 5 linear miles of layflat hose per 3.3.2. This does not include length from hose sections required for repair sections or lengths less than 250 feet (ft) per 3.3.2.14.1.

3.3.1.3 Displacement and evacuation. The E2FDS shall provide a means to remove liquid, vapor, and air from the hose. The hose may be defueled prior to recovery by the

Emplacement and Retrieval System. After displacement, no more than 0.3 percent (%) of fluid by weight of the emplaced hose capacity shall remain. The displacement and evacuation operations shall be completed without damage or degradation of the hose. The E2FDS shall provide procedures and interface equipment for recovering liquid fuel from the hose.

3.3.1.3.1 Optional equipment. Any need for compressed air shall be compatible with

250 cubic feet per minute (cfm), 100 pounds per square inch gage (psig) trailer-mounted compressors, including those described by TM 5-4310-452-14, and commercial compressors of equivalent capabilities. Use of other standard military equipment would be available for carrying out displacement operations for the recovery of displaced liquid, and moving of displacement equipment, to include bulk liquid storage bags, tanker vehicles, forklifts, or other wheeled tow vehicles.

3.3.1.3.2 Tow interface. Any displacement and evacuation equipment designed to be towed shall have a towing eye (lunette) IAW SAE J 847 with a nominal height of 26 inches when the unit is level and on a level surface. Towed equipment shall also be provided with hand-crank style stabilizing leg(s) to permit operation without tipping over when not attached to the tow vehicle. When not in use, the stabilizing leg(s) shall be positioned in such a way as to not affect the towing of the equipment.

3.3.1.4 Mobility. The E2FDS, when transported by any designated prime mover (see

3.3.1.4.1), shall have mobility not less than that described below without malfunction, permanent deformation, or damage.

3.3.1.4.1 Prime movers. The E2FDS shall be capable of being transported by standard

US Army Tactical Cargo Trucks and trailer of the types and series described below:

a. HEMTT Load Handling System (HEMTT-LHS), TM 9-2320-304-14&P.

b. Palletized Load System (PLS), TM 9-2320-364-14&P.

c. PLS trailer, TM 9-2330-385-10.

3.3.1.4.2 Mobility terrain.

a. Improved (paved) roads at an average speed of 50 miles per hour (mph).

b. Unimproved (unpaved) roads at an average speed of 20 mph.

c. Over trail and cross country terrain at an average speed of 8 mph.

3.3.1.5 ISO containerization. Unless otherwise specified (see 3.3.4.10), the E2FDS shall be configured and packed into International Organization for Standardization (ISO) twenty-foot equivalent unit (TEU) containers in accordance with (IAW) ISO 668, Type 1C (20 feet length and 8 feet height). Container(s) shall not exceed 8 feet in height; they may be less than 8 feet in height.

3.3.1.5.1 Container ISO requirements. The container shall have external dimensions and permissible tolerances that conform to Table 2 of ISO 668 for 1C containers. The container shall have 8 corner fitting locations that conform to ISO 668 for a 1C container. The container shall have ISO corner fittings that conform to ISO 1161. The container shall be capable of lifting from the four top corner fittings, the four bottom corner fittings, be capable of withstanding longitudinal external restraint, have forklift pockets, and have stacking capability and rigidity in the transverse and longitudinal directions that meet ISO 1496-1.

3.3.1.5.2 Container handling. All ISO twenty-foot equivalent unit (TEU) containers shall be capable of being handled by the Palletized Load System (PLS), the HEMTT Load

Handling System (HEMTT-LHS), and PLS trailer, using only the load handling system. The container shall have an A-Frame structure at one end with the bail bar (hookbar), and rollers on the opposite end to allow the container to be loaded on the PLS trailer, and a rail system to provide the PLS and HEMTT-LHS handling capability. DIN 30722 and STANG 2413 shall be used for the vehicle interface requirements. The bottom and exterior frame of the container shall duplicate M1077 flat rack IAW MIL-STD-1366, particularly the A-frame interface point and bottom rails. In addition, the frame and envelope of the container, when prepared for shipping and storage, shall meet the requirements for an ISO type 1C container IAW MIL-STD-1366.

The exterior frame shall include all fittings, interfaces, and tie-down points IAW an ISO type 1C container.

3.3.1.5.3 Container quantity. Ten E2FDS (50 mile capability), and including all the

E2FDS equipment packed outside of the 5-mile sets (see 3.3.1.5.4), shall be packed into a maximum of 105 ISO twenty-foot equivalent units (Threshold); it should be packed into a maximum of 87 ISO twenty-foot equivalent units (Objective).

3.3.1.5.4 Set packaging. The E2FDS shall be packaged and containerized into 5-mile system sets, consisting of 10 sets in a 50-mile capability. Each set shall contain all equipment sufficient for emplacement and retrieval for 5 miles of hoseline, and support equipment per

3.3.2.14. Each 5-mile set shall contain a minimum of one Emplacement and Retrieval System

(ERS) (see 3.3.3). Pump assemblies shall be included in each 5-mile set such that each set has the same number of pump assemblies in each. A minimum of one pump assembly shall be included in each 5-mile set. Gap Crossing Kit (see 3.3.2.14.3), Command and Control Module

(C2M)(see 3.3.5), adapters (see 3.5.11), and trace planning tool (see 3.5.14) are not included in each set, and packed outside of the 5-mile sets; suggested quantities per each 50-mile capability

(see 6.15).

3.3.1.5.5 Reserved.

3.3.1.6 Pressure reduction. The E2FDS shall include capability to reduce pressure from hoseline operating pressure, to pressure of 150 pounds per square inch gage (psig) or less, for connection to fuel storage facilities.

3.3.1.6.1 Reserved.

3.3.1.7 Service and storage life. The E2FDS hose shall have a minimum shelf life of at least 15 years (Threshold), with a desired shelf life of 25 years (Objective). The E2FDS hose shall have a service life of at least 3 years (Threshold), with a desired service life of 6 years

(Objective), once wetted with fuel. The remaining components of the E2FDS system, less the hose, shall have a minimum service life of 20 years (Threshold), with a desired service life of 25 years (Objective).

3.3.2 Hose. The transfer conduit of the E2FDS shall be collapsible (layflat) hose. A hose assembly is defined as a section of hose with end fittings (see 3.3.2.5) installed.

3.3.2.1 Hose diameter. The hose shall be a minimum of 6-inches in diameter and a maximum of 10 inches in diameter. All of the hose in the E2FDS shall be of the same diameter.

3.3.2.2 Working pressure. All of the hose in the E2FDS shall have the same working pressure. The minimum rated working pressure of the hose shall be 200 pounds per square inch gage (psig). The working pressure shall be the hose manufacturers’ rated working pressure.

3.3.2.3 Burst pressure. Construction and design of the flexible hose and end fittings shall include a minimum burst to maximum allowable working pressure (MAWP) ratio of 3 to 1.

The burst and working pressures used to establish this ratio will be the hose manufacturers’ rated pressures.

3.3.2.4 Proof pressure. The hose assembly shall be subjected to a proof pressure of 1.5 times their rated working pressure for a minimum of one hour. Hose assemblies shall not leak nor have deleterious imperfections when subjected to the proof pressure. There shall be no indication of slippage or pullout of the fittings when the hose assembly is pressurized to proof pressure.

3.3.2.5 End fittings. All end fittings shall be securely attached to the hose to prevent slippage or leakage under normal operation and when subjected to hydrostatic proof pressure.

The end fittings shall have a minimum burst to working pressure ratio of 3 to 1. The end fittings shall be reusable. When reusing the end fittings, no special tools shall be required to remove the end fitting from one hose section and install it on another hose section. End fittings that are not connected during storage shall be protected with dust covers.

3.3.2.5.1 End fitting interface. The end fittings shall be sexless, also referred to herein as unisex.

3.3.2.5.2 End fitting gasket. The end fitting gasket shall not be of cork or cork/rubber combination materials. The end fitting gasket(s) shall be included with either the coupling clamp or the end fitting itself.

3.3.2.5.3 End fitting coupling clamp. The end fitting coupling clamps shall not require the use of special tools to install and remove.

3.3.2.6 Pull strength. Hose assemblies with end fittings, installed according to the manufacturers’ instructions, shall withstand a repeated, longitudinal pull at each fitting of a minimum of 450 pounds (lb) without the fittings becoming detached from the hose. Field repairs of hose sections using the Hose Repair Kit, shall meet the same pull strength requirement.

3.3.2.7 Cycles, emplacement and retrieval. The hose assembly shall withstand repeated cycling on and off the Emplacement and Retrieval System (ERS) without damage or degradation of performance. Hose repairs per 3.3.2.14.1 withstand repeated cycling on and off the

Emplacement and Retrieval System (ERS) without damage or degradation of performance

3.3.2.8 Section length. Unless otherwise specified, the hose assembly shall be provided in sections with a minimum length of 500 feet.

3.3.2.9 Elongation. Elongation of the hose assembly at the maximum allowable working pressure shall be no greater than ± 3 percent (%).

3.3.2.10 Twist. The hose assembly shall not twist more than 1/8 turn of a turn over 100 feet in length when pressurized to working pressure.

3.3.2.11 Physical and chemical properties. The hose assembly shall meet the physical and chemical properties for collapsible hose listed in Table III of MIL-PRF-370.

3.3.2.12 Color. Unless otherwise specified (see 6.2), the hose outside color shall be

Desert Tan 686A, #33446 of FED-STD-595.

3.3.2.13 Hose marking. Hose shall be permanently marked with the following information (see 6.2):

a. Date of manufacture (month and year)

b. Manufacturer’s name or trademark, and CAGE code

c. “E2FDS Hose”

d. “Liquid Fuel” and “Non-Potable Water”

e. Maximum Allowable Working Pressure

The letters shall be a minimum of 0.5 in. high. Hoses shall be marked at 10-ft intervals or by continuous impression branding, provided that the pattern shall be repeated every 5 ft. or less.

Marking color shall contrast with the hose cover color. Each hose shall be marked with a longitudinal stripe of a contrasting color, not less than 0.125 in. wide, and extending the full length of the hose line. The marking may be within the longitudinal strip, provided the stripe is at least 0.2 in. greater than the height of the letters. The marking may substitute for the longitudinal stripe, provided it is continuous and extends the full length of the hose line. Labeling and longitudinal stripe shall remain clear, distinct and legible for the life of the hose line. Handling, bending, water, oil, and environmental effects shall not adversely affect the marking or stripe.

3.3.2.14 Hose support equipment. The support equipment shall consist of, but not limited to: Hose Repair Kit, Culvert Kit, Gap Crossing Kit, and Flow Control Kit.

3.3.2.14.1 Hose Repair Kit. Each 5-mile set shall include one Hose Repair Kit. The

Hose Repair Kit shall have enough hose assemblies (with end fittings) for a minimum of 10 hose repairs at minimum of 20 feet in length each. The Hose Repair Kit shall include three 100-foot length hose sections (without end fittings). Open ends shall be protected with a protective cover.

Protective cover(s) shall have storage space or tethers to prevent loss.

3.3.2.14.1.1 Pinch clamps. The Hose Repair Kit shall include a method for stopping leakage or drainage during the repair process, such as hose pinch clamps. The pinch clamp shall not cause damage to the hose when being used to stop fluid drainage. A minimum of 5 pinch clamps shall be provided with the Hose Repair Kit.

3.3.2.14.1.2 Extra clamps and end fittings. The Hose Repair Kit shall include 40 hose end fittings. The end fittings shall not require special tools for installation. The Hose Repair Kit shall include 30 end fitting clamps and gaskets for joining hose assemblies together.

3.3.2.14.1.3 Spill cleanup kit. The Hose Repair Kit shall include spill cleanup for the containment and clean up of minor and incidental spills and leaks. Each Hose Repair Kit shall include a fuel spill control kit in accordance with A-A-59359, Type I.

3.3.2.14.1.4 Hose repair time. The time to complete a hose repair using two MOS personnel specified in 3.7 shall not exceed 30 minutes. This time includes isolation of the repair section with pinch clamps, removal of the damaged section, installation of end fittings, installation of replacement section with hose assembly, and removal of pinch clamps.

3.3.2.14.2 Flow Control Kit. Each 5-mile set shall include one Flow Control Kit. The

Flow Control Kit shall consist of all valves and associated components to set up and operate the

5-mile set. The Flow Control Kit shall include sufficient pressure relief components, to prevent over pressurization of hose, on decreasing grade of 1% for the length of the 5-mile set; a minimum of one pressure relief component shall be included with each Flow Control Kit. The

Flow Control Kit shall include 90 degree elbows, minimum quantity of 4, and 45 degree elbows, minimum quantity of 4. The Flow Control Kit shall include 100 sand bags. The Flow Control

Kit shall include 100 pickets (stakes) for securing the hose on adverse slopes.

3.3.2.14.3 Gap Crossing Kit. It is recommended that every ten (10) 5-mile sets (50-mile capability) shall include one Gap Crossing Kit. The Gap Crossing Kit shall be capable of spanning a 100 foot crossing. The Gap Crossing Kit shall include all tools required for set up.

The use of specialized tools shall be minimized to the maximum extent possible. The Gap

Crossing Kit, after installation, shall support hose across a minimum gap of 100 feet, fully loaded with water. A Gap Crossing Kit requirements document, ATPD 2306, is referenced here for guidance.

3.3.2.14.4 Culvert Kit. Each 5-mile set shall include a minimum of 40 feet of culvert in accordance with drawing 13228E3612.

3.3.3 Emplacement and Retrieval System (ERS). The E2FDS shall have the capability to emplace and retrieve the hoseline of 3.3.1.2 and 3.3.2, hereinafter referred to as the ERS. The

ERS shall be operable by the prime mover operator (driver) and three additional personnel. The hose may be stored separately from the emplacement/retrieval device; if so, the emplacement/retrieval device and hose storage are considered the ERS. A minimum of one ERS shall be included in each 5-mile set. A maximum of four (4) HEMTT-LHS or PLS, each with a

PLS trailer (see 3.3.1.4.1), and one 10K forklift (see 3.4.1.7) will be available for concurrent use in emplacement/retrieval operations. The forklift, if necessary for use, may only be used at the single staging location. The available equipment may be concurrently planned for use and travel time, but the emplacement/retrieval of hose and pumps shall be a linear, sequential operation;

pump must be accurately placed and connected before hose may continue from that location.

3.3.3.1 Emplacement rate. The Emplacement and Retrieval System (ERS) shall be capable of emplacing layflat hose (mechanically powered or unpowered) at a minimum average rate of 25 miles per 20-hour operational day (Threshold), with a desired capability of 30 miles per 20-hour operational day (Objective), when all equipment is at the single staging location at the start. The ERS shall be capable of emplacing layflat hose without powered assistance. The appropriate placement and connection of pump assemblies shall be part of the emplacement of the hose, and included in the emplacement rate.

3.3.3.2 Retrieval rate. The ERS shall be capable of powered retrieval at a minimum average rate of 10 miles per 20-hour operational day (Threshold), with a desired 15 miles per 20-hour operational day (Objective), when all hose storage equipment is at the single staging location at the start and all equipment returned to the same location at the completion of retrieval. The disconnection and retrieval of pump assemblies shall be part of the retrieval of the hose, and included in the retrieval rate.

3.3.3.3 Duty cycle. The ERS shall be rated for continuous emplacement and retrieval of the hose stored by the ERS. If hose storage is separate from the emplacement/retrieval device, the ERS shall be rated for continuous emplacement and retrieval of the maximum amount of hose that can be transported by the prime mover (see 3.3.1.4.1).

3.3.3.4 Power source. The ERS shall be powered by the electrical onboard power sources of the prime mover (see 3.3.1.4.1), or powered by a self-contained onboard power source. Prime mover power available is nominal 24 volts direct-current (VDC), 3400 watts under worst case conditions; see 3.4.2 for NATO intervehicle receptacle interface, if applicable.

A 20-foot cable and plug assembly, for connection to the NATO intervehicle receptacle, is included with the prime mover; any necessary length of power cable longer than this shall be included with the ERS.

3.3.3.5 Hose storage. The ERS shall be sized to accommodate the maximum amount of hose possible within the safe operation and transportation limits required herein. The same amount of hose shall be able to store back to the ERS upon retrieval. The ERS shall store the hose without damaging the hose or end fittings. A means shall be provided to secure both the first and last hose section end fitting during storage and transport. Sufficient space and weight allowance shall also be allotted to allow longer hose length (not more than 250 feet) or extra volume and weight due to hose repairs (no more than 2 repairs). Open ends shall be protected with a protective cover. Protective cover(s) shall have storage space or tethers to prevent loss.

3.3.3.6 Control unit. A control unit shall provide operators with the capability to perform all operations necessary to emplace and retrieve hose. The control unit shall contain a deadman switch to stop ERS from powered operation if released. The control unit shall be weatherproofed.

3.3.3.6.1 Shock. If the control unit is a manual, man-portable pendant, then the control unit shall perform as specified after exposure to the shock of being dropped 36 inches on each face for a total of six drops. This shall be conducted while in the non-functional transport condition.

3.3.3.6.2 Shock, functional. If the control unit is a manual, man-portable pendant, then the control unit shall perform as specified during exposure to a 30g, 11 millisecond duration, half-sine shock, on each axis for a total of six shocks. This shall be conducted in the operational condition.

3.3.3.6.3 Vibration. If the control unit is a manual, man-portable pendant, then the control unit shall perform as specified after exposure, in a non-functional transport condition, to transportation vibrations of 40 minutes per axis for each of 3 axis.

3.3.3.7 ERS handling equipment. Any required mechanical handling of the ERS or ERS modules shall be limited to the use of a single forklift (3.4.1.7) at the single staging location of the ERS and hose storage containers, for exchange of hose storage modules, or for exchange of modules to assist in emplacement/retrieval of hose. Modules to be handled by a forklift shall be limited to 10,000 lbs, shall have forklift pockets conforming to those described in 3.4.1.7 or have other provisions for forklift handling if forklift pockets are not used.

3.3.4 Pump assembly performance.

3.3.4.1 Hydrostatic pressure. The pump assembly shall be rated for a minimum differential pressure of 200 pounds per square inch gage (psig). The pump assembly, with the valves open and with end fitting caps installed (see 3.3.4.4.3), shall withstand an internal hydrostatic pressure of 1.5 times the rated differential pressure of the pump assembly, or 1.5 times the rated working pressure of the hose, whichever is less, for not less than 5 minutes without rupture or distortion to any component, and without leakage through the assembly, fittings, piping, or joints.

3.3.4.2 Capacity. The pump assembly shall meet the rated flow capacities indicated below at standard conditions, as specified by the Hydraulic Institute ANSI/HI 14.6 Rotodynamic

Pumps for Hydraulic Performance Acceptance Tests. Minimum rated flow rates are as follows:

a. Fuel - 708 gpm with a total dynamic head of 460 feet.

b. Water - 540 gpm with a total dynamic head of 460 feet.

3.3.4.2.1 Tilting. The pump assembly shall perform at rated flow as specified in 3.3.4.2 when tilted a maximum of 6 degrees from horizontal in any direction.

3.3.4.2.2 Pump priming. The pump assembly may rely on external sources for priming, and deliver not less than the rated flow (see 3.3.4.2) in less than 2 minutes, when operating at atmospheric conditions of 29.92 inches of mercury, using water with a specific weight of 62.3 pounds per cubic foot (lbs/ft3) at 68 degrees Fahrenheit (F).

3.3.4.3 Reserved.

3.3.4.4 Pump assembly characteristics and components. All threaded parts shall conform to ASME B1.1, ASME B1.20.1, or ASME B1.20.3, as applicable.

3.3.4.4.1 Pump housing. The pump housing shall be provided with a drain port and manual valve for draining the case without tilting, and capable of being fully drained in five (5) minutes or less. The valve discharge shall be routed for easy accessibility and to allow for collection of the discharge and prevent spillage into the environment (see 3.3.4.9.1 and 3.5.3).

3.3.4.4.2 Piping and fittings. All piping and fittings shall be mounted securely and shall withstand an internal working pressure of 1.5 times of the shutoff pressure or maximum differential pressure, whichever is higher, at rated speed without leaking or deformation. The discharge piping shall contain a vent valve, with NPT thread IAW ASME B1.20.1, to remove air during priming. The vent shall be located at the highest point in the discharge piping. The vent valve discharge shall be routed for easy accessibility and to allow for collection of the discharge and prevent spillage into the environment (see 3.3.4.9.1 and 3.5.3).

3.3.4.4.3 Suction and discharge components. The pump assembly shall have the following suction and discharge components:

a. Discharge check valve, having a minimum six-inch diameter, flanged housing of a durable, corrosion resistant material, suitable to the application and compatible with discharge housing.

b. A valve, minimum six-inch diameter, shall be incorporated on the suction port, and on the discharge port, of the pump. The valves shall be supported by brackets connected to the assembly chassis, and shall be labeled to indicate the open-close direction. The valves shall be positioned to accept both hose and pipe. Butterfly valves are prohibited in this application.

c. The suction side of the pump shall terminate in unisex, quick-disconnect end fittings with gaskets and clamps as necessary, and fitted with tethered caps.

d. The discharge side of the pump shall terminate in unisex, quick-disconnect end fittings with gaskets and clamps as necessary, and fitted with tethered caps.

e. A suction strainer assembly, consisting of two strainers capable of removing debris from the inlet fuel flow larger than 0.25 inches in diameter. The strainers shall be configured such that one strainer can be cleaned out safely while the other is still in service (during pump operation). The strainers shall be easily accessible to maintenance personnel for inspection and cleaning.

3.3.4.5 Engine. The engine shall be rated by the manufacturer for continuous power duty adequate to power the assembly to meet the performance requirements of 3.3.4.2. The engine shall meet the performance requirements herein with JP-8 as the primary fuel (see 3.4.3).

Diesel engines shall have an EPA Tier 3 emission certification for non-road diesel engines as required by 40 CFR Parts 9, 86, and 89 at its power rating; emission waiver will be made available per the contract or order (see 6.2). The engine shall be equipped with, but not limited to, the following items:

a. A nominal 24-volt direct current (VDC) electric cranking system.

b. An electrical charging system.

c. A heavy duty, dry type, air cleaner with replaceable cartridge.

d. Fuel filters: primary, water-separating type, and secondary (final); each with provision for drainage into an external container (see 3.3.4.9.1).

e. Exhaust system with guard and rain cap.

f. Engine oil drain, easily accessible for maintenance and to minimize the potential for spillage to the environment (see 3.5.3).

g. Heavy duty cooling system capable of maintaining the manufacturers recommended operating temperature when performing at maximum rated capacity as specified herein. If liquid-cooled, the engine shall operate with antifreeze IAW A-A-52624;

cooling system overflow reservoir shall be included for liquid-cooled engines, to prevent coolant discharge into the environment (see 3.5.3).

h. Engine rotating and moving parts guard, providing reliable, quick, and easy access for maintenance, and requiring no tools for removal or installation.

i. Oil dipstick conforming to SAE J 614.

3.3.4.6 Electrical system. The starting, charging and lighting systems, and all electrical components of the assembly shall be nominal 24 VDC. A temperature-compensated, integral charging system, wiring, and battery(s) shall be supplied to provide starting, lighting, and additional electrical power as needed to (a) recharge the battery(s) in not more than 30 minutes of continuous operation after the system has been started three times at -25F, and (b) start the system at -25F three times within approximately a 1-hour period with a minimum of 15 minutes between starts after a 5 minute run period.

3.3.4.6.1 Batteries. All batteries shall be US Army approved IAW MIL-PRF-32143.

Batteries shall be readily accessible for service and inspection and shall be of sufficient quantity and type to comply with the starting, lighting, normal and surge electrical loads, reserve electrical power capacity, and maintenance requirements.

3.3.4.6.2 Battery cables. The positive cable(s) shall have a non-conductive red sleeve at both ends. The negative cable(s) shall have a black non-conductive sleeve on both ends. A battery terminal non-conductive protective cover shall be provided on each battery terminal connector (red for positive and black for negative). The battery cables shall be marked to indicate polarity.

3.3.4.6.3 Battery box. A vented battery box shall be provided to retain/protect the batteries during operation and transport. The box shall allow for easy installation and removal of the batteries. The box shall protect the batteries from external environmental conditions and shall provide for venting of battery gases at or near the top of the box. The box shall be resistant to battery electrolyte. Means shall be provided to allow drainage out of the bottom of the box, regardless of incline. An external power disconnect shall be provided on the outside of the battery box, to disconnect battery power from the assembly without opening the battery box and without disconnecting batteries directly.

3.3.4.7 Control and Instrument panels. A control panel and an instrument panel shall be provided for the pump assembly. The control and instrument panels shall be covered by a latching door(s) with automatically engaging hold-open devices. The panels shall each contain a switch that automatically turns off the lights when the panel door is closed. All panel face components shall be labeled and legible by the operator.

3.3.4.7.1 Control panel. The control panel shall be of modular design and meet the requirements for NEMA 250 Type 4 X enclosures. The control panel shall be replaceable in under 30 minutes using no special tools (see 6.6.5). The control panel shall include the following as a minimum:

a. Power ON/OFF toggle circuit breaker and indicator light.

b. Assembly OFF/RUN-STANDBY/START toggle switch and indicator light.

c. Glow plug, or other pre-heat device, power toggle switch (momentary) and indicator light.

d. Control Mode selector switch (3 position; MANUAL/LOCAL/REMOTE).

e. RAISE/HOLD/LOWER toggle switch (return to center).

f. Engine shutdown indicator(s).

g. Battle short bypass toggle switch and indicator light.

h. Voltmeter.

i. Ammeter.

j. EMERGENCY STOP pushbutton, readily accessible in case of emergency, even if control panel door is closed.

3.3.4.7.1.1 Control panel components. The control panel face components in 3.3.4.7.1 shall be sealed against the environmental effects of 3.6.3 (Sand) through 3.6.8 (Salt fog).

Components located in the control panel shall only be electrical components. Discrete visual indicators shall be of the light emitting diode (LED) type in lieu of incandescent bulbs. All switching components shall be hermetically sealed.

3.3.4.7.1.2 Engine/pump protection. The engine and pump of the assembly shall be provided with automatic protections resulting in engine shutdown. A manual reset shall be required following an automatic shutdown; toggling the assembly OFF/RUN-STANDBY toggle switch is acceptable. All alarm and shutdown circuits shall be designed fail-safe; a shutdown condition, sensor failure, broken wire, blown fuse, etc. shall result in an engine shutdown.

Engine/pump protections shall include the following shutdown conditions as a minimum:

a. Engine over speed (exceeding 110% of maximum engine rated speed).

b. High engine temperature.

c. High fuel supply temperature (exceeding 175 degrees F).

d. Low engine oil pressure.

e. Excessive discharge pressure (exceeding 110% of rated discharge pressure, see

3.3.3.2 and 3.3.4.1)

3.3.4.7.1.3 Shutdown annunciation. Shutdown annunciation shall be provided for the engine/pump protections of 3.3.4.7.1.2. A unique indication shall be provided for each shutdown condition and each sensor failure. A diagnostic or start-up check shall be provided allowing the operator to verify that the shutdown indicator(s) is(are) functional.

3.3.4.7.1.4 Emergency shutdown capability. The pump assembly shall be equipped with a reliable, fail-safe, remote emergency shutdown capability. Operator shall have the ability to shut down the engine/pump beyond a 15 foot perimeter of the pump assembly. The remote emergency shutdown shall be capable of secure mounting on the ground rod (see 3.5.5.2), to be readily available for use and not resting on the ground surface. Electrical shunt, or bypass, shall also be provided for applications where the remote shutdown capability is not used or desired.

3.3.4.7.1.5 Command and control module (C2M) communications. The pump assembly shall communicate with the C2M of the E2FDS system. The data communicated shall include system operating status, errors, warnings, etc, and reception of operating condition inputs.

3.3.4.7.1.5.1 Receive, pressure set-point. The pump assembly shall receive its operating pressure set-point from the C2M, and return acknowledgment of set-point back to the C2M. The operating set-point includes zero pressure condition, or no operation, upon which the pump assembly returns to STANDBY status.

3.3.4.7.1.5.2 Receive and transmit, status report. The pump assembly shall receive command from the C2M to provide assembly status report. The pump assembly shall transmit status report to the C2M, including at a minimum: pump assembly ID, oil pressure, fuel level and fuel tank temperature (only in fuel system per 3.3.4.9), engine temperature, engine speed, suction and discharge pressure, voltmeter reading, ammeter reading, operation mode (MANUAL, LOCAL, REMOTE; RUN or STANDBY), and pending or upcoming maintenance service.

3.3.4.7.1.5.3 Receive and transmit, maintenance report. The pump assembly shall maintain a stored history of its maintenance service, and hours of operation. The pump assembly shall receive command from the C2M to provide assembly maintenance history report. The pump assembly shall transmit the most recent maintenance history first, selectable back to the entire stored maintenance history.

3.3.4.7.1.5.4 Transmit, condition status. The pump assembly shall transmit its overall operating condition status regularly, along with its pump assembly ID, to verify communications, and shall transmit its overall operating condition immediately whenever the condition changes.

The condition status includes at a minimum: pump assembly ID, operation mode (MANUAL, LOCAL, REMOTE; RUN or STANDBY), operating condition (green, yellow, or red). Green operating condition indicates all sensors and operating conditions are within normal design operation parameters. Yellow operating condition indicates pending or upcoming maintenance service, or sensor(s) outside of normal operating conditions or tolerances, but pump assembly is still functional and operating.