Attachment_0001_-_ATPD-2418_-_dated_23_Feb_16.docx
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- Expeditionary Water Packaging System (EWPS)
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- W56HZV15R0225
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INCH-POUND
ATPD 2418
23 FEB 2016
PURCHASE DESCRIPTION
EXPEDITIONARY WATER PACKAGING SYSTEM (EWPS)
This specification is approved for use by the U.S. Army Tank Automotive Research, Development and Engineering Center (TARDEC), Research, Development and Engineering Command (RDECOM), Department of the Army, and is available for use by all Departments and Agencies of the Department of Defense.
| 1. | SCOPE | 9 |
| 1.1. | Scope | 9 |
| 2. | APPLICABLE DOCUMENTS | 9 |
| 2.1. | General | 9 |
| 2.2. | Government Documents | 9 |
| 2.2.1. | Specifications, Standards, and Handbooks | 9 |
| 2.2.2. | Other Government Documents, Drawings, and Publications | 11 |
| 2.3. | Non-Government Publications | 12 |
| 2.4. | Order of precedence | 15 |
| 3. | REQUIREMENTS | 15 |
| 3.1. | Description | 15 |
| 3.2. | Testing | 16 |
| 3.3. | Design and Operation Requirements | 16 |
| 3.3.1. | Set-up/tear-down | 16 |
| 3.3.2. | Operation and Maintenance | 16 |
| 3.3.3. | ISO Shelter | 17 |
| 3.3.3.1. | ISO Shelter Dimensions and Characteristics | 17 |
| 3.3.3.2. | CSC certification | 17 |
| 3.3.3.3. | Shelter Certification | 17 |
| 3.3.3.4. | Shelter Marking | 17 |
| 3.3.3.5. | Forklift compatibility | 17 |
| 3.3.3.6. | Prime mover compatibility | 18 |
| 3.3.3.7. | Weight/Center of Gravity (CG) | 18 |
| 3.3.4. | Power Requirements | 18 |
| 3.3.5. | Compressed Air System | 18 |
| 3.3.5.1. | Air System Piping | 18 |
| 3.3.6. | ECU System | 18 |
| 3.3.6.1. | Clean Room Requirements | 19 |
| 3.3.7. | Water Storage | 19 |
| 3.3.8. | Water Testing Laboratory | 19 |
| 3.3.8.1. | Water Testing Equipment | 19 |
| 3.3.8.2. | Refrigerator | 19 |
| 3.3.8.3. | Incubator | 19 |
| 3.3.8.4. | Laminar Flow Hood | 20 |
| 3.3.8.5. | Autoclave | 20 |
| 3.3.8.6. | Cabinetry | 20 |
| 3.3.8.7. | Power | 20 |
| 3.3.8.8. | Seating | 20 |
| 3.3.9. | Water Treatment System | 21 |
| 3.3.9.1. | Piping system | 21 |
| 3.3.9.2. | Cam and groove fittings | 21 |
| 3.3.9.3. | Pump | 21 |
| 3.3.9.4. | Inline Heater | 21 |
| 3.3.9.5. | Flowmeter | 21 |
| 3.3.9.6. | Temperature Gauge | 21 |
| 3.3.9.7. | Pressure Gauges and Transmitters | 22 |
| 3.3.9.8. | Carbon Block Filter | 22 |
| 3.3.9.9. | Calcium Hypochlorite Injection System | 22 |
| 3.3.9.10. | Sterile Filter | 22 |
| 3.3.9.11. | Valves | 22 |
| 3.3.9.12. | Pressure Regulator | 22 |
| 3.3.9.13. | Clean in Place System | 23 |
| 3.3.10. | Bottling System | 23 |
| 3.3.10.1. | Bottling Room Access | 23 |
| 3.3.10.2. | Preforms | 24 |
| 3.3.10.3. | Preform Hopper | 24 |
| 3.3.10.4. | Blow Molder | 24 |
| 3.3.10.5. | Filler/Capper | 24 |
| 3.3.10.6. | Cap Hopper | 24 |
| 3.3.10.7. | Caps | 25 |
| 3.3.10.8. | Ultraviolet Treatment of Bottles and Caps | 25 |
| 3.3.10.9. | Bottle Marking | 25 |
| 3.3.10.10. | Bottle Accumulation | 25 |
| 3.3.10.11. | Bottled Water Production Rate | 25 |
| 3.3.10.12. | Production Efficiency | 25 |
| 3.3.10.13. | Bottled Water Quality | 26 |
| 3.3.10.14. | Filled Bottle Durability | 26 |
| 3.3.11. | Palletization | 26 |
| 3.3.12. | Cleaning | 26 |
| 3.3.13. | Chemical stowage | 26 |
| 3.3.14. | Electrical | 26 |
| 3.3.14.1. | Control Panel | 27 |
| 3.3.14.2. | Lighting | 27 |
| 3.3.15. | Fire Extinguisher | 27 |
| 3.3.16. | Service and Storage Life | 27 |
| 3.4. | Transportability | 27 |
| 3.4.1. | Tie-down Provisions | 27 |
| 3.4.2. | Transportation Configurations | 28 |
| 3.4.2.1. | Air transport, Military Aircraft | 28 |
| 3.4.2.2. | Rail Transportability | 28 |
| 3.4.2.3. | Highway Transport | 28 |
| 3.4.2.4. | Marine Transport/Sealift | 28 |
| 3.5. | Ownership and Support Requirements | 28 |
| 3.5.1. | Lubricants and Coolants | 28 |
| 3.5.2. | Safety and Health | 28 |
| 3.5.2.1. | Electrical Wiring | 28 |
| 3.5.2.2. | Pressurized Lines | 29 |
| 3.5.2.3. | High Temperature | 29 |
| 3.5.2.4. | Rotating Machinery | 29 |
| 3.5.2.5. | Warnings | 29 |
| 3.5.2.6. | Mechanical Hazards | 29 |
| 3.5.2.7. | Noise Limits | 29 |
| 3.5.2.8. | Chemical Hazards | 29 |
| 3.5.2.9. | Environmental hazard prevention | 29 |
| 3.5.3. | Human factors engineering (HFE) | 29 |
| 3.5.4. | Durability | 30 |
| 3.5.5. | Reliability | 30 |
| 3.5.6. | Maintainability | 30 |
| 3.5.7. | Materiel/Operational Availability (Ao) | 30 |
| 3.5.8. | Servicing, operation and maintenance | 30 |
| 3.6. | Environmental requirements | 30 |
| 3.6.1. | Hazardous Material Restrictions. | 30 |
| 3.6.2. | Disposal. | 31 |
| 3.6.3. | Temperature | 31 |
| 3.6.4. | Sand | 31 |
| 3.6.5. | Dust | 31 |
| 3.6.6. | Humidity | 31 |
| 3.6.7. | Solar radiation | 31 |
| 3.6.8. | Rain | 32 |
| 3.6.9. | Salt Fog | 32 |
| 3.6.10. | Altitude | 32 |
| 3.6.11. | Ozone | 32 |
| 3.7. | Materials | 32 |
| 3.7.1. | Materials in Contact with Potable Water | 32 |
| 3.7.1.1. | Stainless Steel Piping and Fittings in Contact With Potable Water | 32 |
| 3.7.1.2. | Filter Vessels | 32 |
| 3.7.1.3. | Hose Assemblies | 33 |
| 3.7.1.4. | Other Non-metallic Components | 33 |
| 3.7.2. | Surfaces within the EWPS Bottling Room | 33 |
| 3.7.3. | Resistance to Fungus | 33 |
| 3.7.4. | Hazardous Materials | 33 |
| 3.7.4.1. | Ozone Depleting Substances | 33 |
| 3.7.4.2. | Lead | 33 |
| 3.7.5. | Deterioration Prevention and Control | 33 |
| 3.7.6. | Corrosion Control Performance | 33 |
| 3.7.7. | Shelter External Corrosion During Service Life | 34 |
| 3.7.8. | Shelter Internal Corrosion During Service Life | 34 |
| 3.7.9. | Dissimilar Metals | 34 |
| 3.7.10. | Recycled, Recovered or Environmentally Preferable Materials | 34 |
| 3.7.11. | Thermal and Sound-Insulating Material | 34 |
| 3.8. | Treatment and Painting | 34 |
| 3.8.1. | External Surfaces | 34 |
| 3.8.2. | Other Surfaces | 35 |
| 3.9. | Construction/Welding | 35 |
| 3.10. | Manuals and Special Instructions | 35 |
| 3.11. | Tools, Special Tools and Test Equipment. | 35 |
| 3.12. | Basic Issue Items (BII) | 35 |
| 3.13. | Identification, marketing and information | 36 |
| 3.13.1. | Data plates | 36 |
| 3.14. | Load and packaging plans and instructions | 36 |
| 4. | VERIFICATION | 36 |
| 4.1. | Classification of Tests, Inspection, and General Criteria | 36 |
| 4.1.1. | First Article Test (FAT) | 36 |
| 4.1.1.1. | Production Verification Testing (PVT) | 36 |
| 4.1.1.2. | Post-Test Operational Check (PTOC) | 36 |
| 4.1.2. | Acceptance Inspection and Test (AI&T) | 37 |
| 4.1.3. | Certificates of Conformance (CoC) | 37 |
| 4.1.4. | Pre-FAT Inspection/Confidence Test | 37 |
| 4.2. | Test Water | 37 |
| 4.3. | Design and Operation Requirements | 41 |
| 4.3.1. | Set-up/tear-down | 41 |
| 4.3.2. | Operation | 41 |
| 4.3.3. | ISO Shelter | 41 |
| 4.3.3.1. | ISO Shelter Dimensions and Characteristics | 41 |
| 4.3.3.2. | CSC Certification | 41 |
| 4.3.3.3. | Shelter Certification | 41 |
| 4.3.3.4. | Shelter Marking | 41 |
| 4.3.3.5. | Forklift Compatibility | 41 |
| 4.3.3.6. | Prime Mover Compatibility | 41 |
| 4.3.3.7. | Weight/Center of Gravity (CG) | 41 |
| 4.3.4. | Power Requirements | 42 |
| 4.3.5. | Compressed Air System | 42 |
| 4.3.6. | ECU System | 42 |
| 4.3.6.1. | Clean Room Requirements | 42 |
| 4.3.7. | Water Storage | 42 |
| 4.3.8. | Water Testing Laboratory | 42 |
| 4.3.8.1. | Water Testing Equipment | 42 |
| 4.3.8.2. | Refrigerator | 42 |
| 4.3.8.3. | Incubator | 43 |
| 4.3.8.4. | Laminar Flow Hood | 43 |
| 4.3.8.5. | Autoclave | 43 |
| 4.3.8.6. | Cabinetry | 43 |
| 4.3.8.7. | Power | 43 |
| 4.3.8.8. | Seating | 43 |
| 4.3.9. | Water Treatment System | 43 |
| 4.3.9.1. | Piping System | 43 |
| 4.3.9.2. | Cam and groove fittings | 43 |
| 4.3.9.3. | Pump | 44 |
| 4.3.9.4. | Inline Heater | 44 |
| 4.3.9.5. | Flowmeter | 44 |
| 4.3.9.6. | Temperature Gauge | 44 |
| 4.3.9.7. | Pressure Gauges and Transmitters | 44 |
| 4.3.9.8. | Carbon Block Filter | 44 |
| 4.3.9.9. | Calcium Hypochlorite Injection System | 44 |
| 4.3.9.10. | Sterile Filter | 44 |
| 4.3.9.11. | Valves | 45 |
| 4.3.9.12. | Pressure Regulator | 45 |
| 4.3.9.13. | Clean-in-Place System | 45 |
| 4.3.10. | Bottling System | 45 |
| 4.3.10.1. | Bottling Room Access | 45 |
| 4.3.10.2. | Preforms | 45 |
| 4.3.10.3. | Preform Hopper | 45 |
| 4.3.10.4. | Blow Molder | 45 |
| 4.3.10.5. | Filler/Capper | 45 |
| 4.3.10.6. | Cap Hopper | 46 |
| 4.3.10.7. | Caps | 46 |
| 4.3.10.8. | Ultraviolet Treatment of Bottles and Caps | 46 |
| 4.3.10.9. | Bottle Marking | 46 |
| 4.3.10.10. | Bottled Water Production Rate | 46 |
| 4.3.10.11. | Production Efficiency | 46 |
| 4.3.10.12. | Bottled Water Quality | 46 |
| 4.3.10.13. | Filled Bottle Durability | 46 |
| 4.3.11. | Palletization | 47 |
| 4.3.12. | Cleaning | 47 |
| 4.3.13. | Chemical Stowage | 47 |
| 4.3.14. | Electrical | 47 |
| 4.3.14.1. | Control Panel | 47 |
| 4.3.14.2. | Lighting | 47 |
| 4.3.15. | Fire extinguisher | 47 |
| 4.3.16. | Service and storage life | 47 |
| 4.4. | Transportability | 47 |
| 4.4.1. | Tie-down Provisions | 47 |
| 4.4.2. | Transportation Configurations | 48 |
| 4.4.2.1. | Air transport, Military Aircraft | 48 |
| 4.4.2.2. | Rail Transportability | 48 |
| 4.4.2.3. | Highway Transport | 48 |
| 4.4.2.4. | Marine Transport/Sealift | 48 |
| 4.5. | Ownership and Support Requirements | 48 |
| 4.5.1. | Lubricants and Coolants | 48 |
| 4.5.2. | Safety and Health | 48 |
| 4.5.2.1. | Electrical Wiring | 49 |
| 4.5.2.2. | Pressurized Lines | 49 |
| 4.5.2.3. | High Temperature | 49 |
| 4.5.2.4. | Rotating machinery | 49 |
| 4.5.2.5. | Warnings | 49 |
| 4.5.2.6. | Mechanical Hazards | 49 |
| 4.5.2.7. | Noise Limits | 49 |
| 4.5.2.8. | Chemical Hazards | 49 |
| 4.5.2.9. | Environmental Hazard Prevention | 49 |
| 4.5.3. | Human Factors Engineering (HFE) | 50 |
| 4.5.4. | Durability | 50 |
| 4.5.5. | Reliability | 50 |
| 4.5.6. | Maintainability | 50 |
| 4.5.7. | Materiel/Operational Availability (Ao) | 50 |
| 4.5.8. | Servicing Operation and Maintenance | 50 |
| 4.6. | Environmental Requirements | 50 |
| 4.6.1. | Temperature | 51 |
| 4.6.1.1. | High temperature | 51 |
| 4.6.1.2. | Low temperature | 51 |
| 4.6.2. | Sand | 51 |
| 4.6.3. | Dust | 51 |
| 4.6.4. | Humidity | 51 |
| 4.6.5. | Solar Radiation | 51 |
| 4.6.6. | Rain | 51 |
| 4.6.7. | Salt Fog | 51 |
| 4.6.8. | Altitude | 52 |
| 4.6.9. | Ozone | 52 |
| 4.7. | Materials | 52 |
| 4.7.1. | Materials in Contact with Potable Water | 52 |
| 4.7.1.1. | Stainless Steel Piping and Fittings | 52 |
| 4.7.1.2. | Filler Vessels | 52 |
| 4.7.1.3. | Hose Assemblies | 52 |
| 4.7.1.4. | Other Non-Metallic Components | 52 |
| 4.7.2. | Surfaces within the EWPS Bottling Room | 52 |
| 4.7.3. | Resistance to Fungus | 52 |
| 4.7.4. | Hazardous Materials | 53 |
| 4.7.4.1. | Ozone Depleting Substances | 53 |
| 4.7.4.2. | Lead | 53 |
| 4.7.5. | Deterioration Prevention and Control | 53 |
| 4.7.6. | Corrosion Control Performance | 53 |
| 4.7.7. | Shelter External Corrosion during Service Life | 53 |
| 4.7.8. | Shelter Internal Corrosion during Service Life | 53 |
| 4.7.9. | Dissimilar Metals | 53 |
| 4.7.10. | Recycled, Recovered, or Environmentally Preferable Materials | 54 |
| 4.7.11. | Thermal and Sound-Insulating Materials | 54 |
| 4.8. | Treatment and Painting | 54 |
| 4.8.1. | External surfaces | 54 |
| 4.8.2. | Other surfaces | 54 |
| 4.9. | Construction/Welding | 54 |
| 4.9.1. | Quality of construction and welding | 54 |
| 4.10. | Manuals and Special Instructions | 54 |
| 4.11. | Tools, Special Tools, and Test Equipment | 55 |
| 4.12. | Basic Issue Items (BII) | 55 |
| 4.13. | Identification, Marketing, and Information | 55 |
| 4.13.1. | Data plates | 55 |
| 4.13.2. | Markings | 55 |
| 4.14. | Load and Packaging Plans and Instructions | 55 |
| 5. | PACKAGING | 55 |
| 5.1. | Packaging | 55 |
| APPENDIX A | 57 | |
| APPENDIX B | 58 | |
| APPENDIX C | 59 | |
| APPENDIX D | 61 |
SCOPE
Scope This purchase description (PD) establishes the requirements (Section 3.0) and verification (Section 4.0) methods for the Expeditionary Water Packaging System (EWPS): a shelterized system that produces one-liter plastic bottles of potable water for Soldiers’ consumption at forward operating bases (FOBs). The EWPS shall be capable of blow-molding polyethylene terephthalate (PET) plastic preforms followed by the filling, capping, and labeling of the one-liter PET bottles. The EWPS shall have a minimum hourly production rate of 900 1-L bottles of potable water. The EWPS shall be configured within a single 1C (20’x8’x8’) ISO shelter, transportable by a Heavy Expanded Mobility Tactical Truck (HEMTT) Load Handling System (LHS) truck or a Palletized Load System (PLS) truck/trailer. A second ISO 1C shelter is for the Basic Issue Items (BII), other Components of the End Item (COEI), a Government furnished generator of 60kW capacity, and a laboratory area for record-keeping and water quality monitoring.
The EWPS will have minimal BII since the EWPS is operated and maintained by contracted personnel. The EWPS has an extremely high demand of supplies in order to produce pallets of bottled water. Contracted personnel will be responsible for all necessary support equipment and supplies for the operation and maintenance of the EWPS site, such as, personnel protective equipment (PPE), consumables, tools, water quality monitoring equipment and supplies, palletizing and other post packaging equipment and supplies, material handling equipment (MHE), general office equipment and supplies, and any additional shelters.
APPLICABLE DOCUMENTS
General The documents listed in this section are specified in sections 3, 4, or 5 of the PD. This section does not include documents cited in other sections of this PD 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, 4, or 5 of this PD, whether or not they are listed. Unless specified otherwise, only document versions that are current at the time of contract award shall apply to the procurement.
Government Documents
Specifications, Standards, and Handbooks The following specifications, standards and handbooks form part of this PD to the extent specified herein. Unless otherwise specified, the issue of these documents shall be those cited in the solicitation or contract (see 6.2).
FEDERAL STANDARDS
| FED-STD-595/33446 |
| Tan 686 |
DEPARTMENT OF DEFENSE STANDARDS
| MIL-STD-130 |
| Identification Marking for U.S. Military Property |
| 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-1366 |
| Transportability Criteria |
| MIL-STD-1472 |
| Human Engineering |
| MIL-STD-1474 |
| Noise Limits |
| MIL-STD-1916 |
| DoD: Preferred Methods for Acceptance of Product |
| MIL-STD-3006 |
| Sanitation Requirements for Food Establishments |
| MIL-STD-40051-2 |
| Preparation of Digital Technical Information for Page-Based Technical Manuals |
| MIL-STD-46855 |
| Human Engineering Requirements for Military Systems, Equipment, and Facilities |
FEDERAL SPECIFICATIONS
| TT-C-490 |
| Chemical Conversion Coatings and Pretreatments for Metallic Substrates (Base for Organic Coatings) |
COMMERCIAL ITEM DESCRIPTIONS
| A-A-393 |
| Extinguisher, Fire, Dry Chemical (Hand Portable) |
| A-A-50271 |
| Plate, Identification |
| A-A-59326 |
| Coupling Halves, Quick Disconnect, Cam Locking Type |
DEPARTMENT OF DEFENSE SPECIFICATIONS
| MIL-PRF-10924 |
| Grease, Automotive and Artillery |
| MIL-DTL-12468 |
| Decontaminating Agent, STB |
| MIL-D-16791 |
| Detergents, General Purpose (Liquid, Nonionic) |
| MIL-DTL-53072 |
| Chemical Agent Resistant Coating (CARC) System Application Procedures and Quality Control Inspection |
| MIL-DTL-64159 |
| Camouflage Coating, Water Dispersible Aliphatic Polyurethane, Chemical Agent Resistant |
DEPARTMENT OF DEFENSE HANDBOOKS
| MIL-HDBK-454 |
| General Guidelines for Electronic Equipment |
| MIL-HDBK-1791 |
| Designing for Internal Aerial Delivery in Fixed Wing Aircraft |
| MIL-HDBK-3006 |
| Guidelines for Auditing Food Establishments |
(Copies of DoD documents are available online at https://assist. dla.mil/quicksearch/ or from the Standardization Document Order Desk, 700 Robbins Avenue, Building 4D, Philadelphia, PA 19111-5094.)
Other Government Documents, Drawings, and Publications
U.S. ARMY REGULATIONS
| AR 70-38 |
| Research, Development, Test, and Evaluation of Materiel for Extreme Climatic Conditions |
| AR 70-75 |
| Survivability of Army Personnel and Materiel |
| AR 750-1 |
| Army Material Maintenance Policy and Retail Maintenance Operations |
| AR 350-1 |
| Army Training and Leader Development |
U.S. ARMY PAMPHLETS
| DA Pam 611-21 |
| Military Occupational Classification and Structure |
| DA Pam 750-8 |
| The Army Maintenance Management System (TAMMS) User’s Manual |
U.S. ARMY FIELD MANUALS
| FM 3-5 |
| NBC Decontamination |
| FM 10-52 |
| Water Supply in Theaters of Operations |
| FM 3-11.4 |
| Multiservice Tactics, Techniques, and Procedures for Nuclear, Biological, And Chemical (NBC) Protection |
| FM 3-11.5 |
| Multiservice Tactics, Techniques, and Procedures for Chemical, Biological, Radiological, and Nuclear Decontamination |
U.S. ARMY TECHNICAL BULLETINS
| TB MED 577 |
| Sanitary Control and Surveillance of Field Water Supplies |
(Copies of U.S. Army pamphlets, regulations, technical manuals, field manuals, and technical bulletins are available from http://www.usapa.army.mil or U.S. Army Tank-Automotive and Armaments Command, RDTA-DP MS 110, Warren, MI 48397-5000.)
U.S. ARMY TEST AND EVALUATION COMMAND
| TOP 6-2-335 |
| U.S. Army TECOM Test Operations Procedures (TOP) for Test, Measurement, and Diagnostic Equipment (System Particular) |
(Copies of this document is available through DTIC www.dtic.mil/.)
U.S. ARMY PURCHASE DESCRIPTIONS
| ATPD 2304 |
| Off-Road family of Vehicles (11 Ton to 16.5 Ton Payloads) and Heavy Expanded Mobility Tactical Truck (HEMTT) Extended Service Program (ESP) |
| ATPD 2203 |
| Enhanced Container Handling Unit (E-CHU) |
| ATPD 2344 |
| Tank, Collapsible, Self-supporting, Drinking Water Storage, 3000 US Gallons |
(Copies of these documents are available from usarmy.detroit.rdecom.mail.tardec-standardization@mail.mil.)
U.S. ARMY DRAWINGS
| Appendix A |
| EWPS, Piping and Instrumentation Diagram |
| Appendix B |
| EWPS, Shelter Layout Diagram |
| Appendix C |
| EWPS, Thresholds and Objectives |
| Appendix D |
| EWPS, Functional Block Diagram |
U.S. ARMY PUBLICATIONS
Capability Production Document (CPD) for Expeditionary Water Packaging System (EWPS)
CODE OF FEDERAL REGULATIONS (CFR)
| 21CFR 129 |
| Processing and Bottling of Bottled Drinking Water |
| 21CFR165.110 |
| Bottled Water |
| 21CFR173-189 |
| Food and Drugs (covers additives both direct and indirect such as contact surfaces) |
| 29CFR1910 |
| Occupational Safety and Health Standards (OSHA) |
| 40CFR136, 141 and 143 |
| Health and Safety |
| 49 CFR |
| Department of Transportation |
Non-Government Publications The following documents form 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 (see 6.2).
3-A SANITARY STANDARDS INC
| 3-A 02-10 |
| Centrifugal and Positive Rotary Pumps |
| 3-A 10-04 |
| Filters Using Single Service Filter Media |
| 3-A 28-04 |
| Flowmeters |
| 3-A 33-02 |
| Metal Tubing |
| 3-A 59-00 |
| Automatic Positive Displacement Samplers for Fluid Products |
| 3-A 63-02 |
| Hose Assemblies |
| 3-A 63-03 |
| Sanitary Fittings |
| 3-A 64-00 |
| Pressure Reducing and Backpressure Regulating Valves |
| 3-A 68-00 |
| Ball Valves |
(Copies of 3-A documents are available from www.3-A.org or 3-A Sanitary Standards Inc, 6888 Elm St Suite 2D, Mclean VA, 22101.)
AMERICAN NATIONAL STANDARDS INSTITUTE, INC (ANSI)
| ANSI/NSF Standard 14 |
| Plastic Piping System Components and Related Materials (DoD Adopted) |
| ANSI/NSF Standard 60 |
| Drinking Water Treatment Chemicals – Health Effects (DoD Adopted) |
| ANSI/NSF Standard 61 |
| Drinking Water System Components – Health Effects (DoD Adopted) |
(Copies of NSF documents are available from www.nsf.org or NSF International, P.O. Box 130140, 789 N. Dixboro Road, Ann Arbor, MI 48113-0140; Copies of ANSI documents are available from www.ansi.org or ANSI Customer Service Department, 25 W. 43rd Street, 4th Floor, New York, NY 10036.)
AMERICAN SOCIETY OF MECHANICAL ENGINEERS (ASME)
| ASME/ANSI B31.3 |
| Process Piping |
| ASME/ANSI B46.1 |
| Surface Texture (Surface Roughness, Waviness, and Lay) |
| ASME BPVC Section VIII-1 |
| ASME Boiler and Pressure Vessel Code – Rules for Construction of Pressure Vessels |
| ASME BPE |
| Bioprocessing Equipment |
AMERICAN WELDING SOCIETY (AWS)
| AWS D18.1/D18.1M |
| Specification for Welding of Austenitic Stainless Steel Tube and Pipe Systems in Sanitary (Hygienic) Applications |
| AWS D18.3/D18.3M |
| Specification for Welding of Tanks, Vessels, and Other Equipment in Sanitary (Hygienic) Applications |
(Copies of these documents are available from www.aws.org or American Welding Society, 550 N.W. LeJeune Road, Miami, FL 33126.)
ASTM INTERNATIONAL
| ASTM E84 |
| Standard Test Method for Surface Burning Characteristics of Building Materials |
| ASTM A240/A240M |
| Standard Specification for Steel, Stainless, Plate, Sheet and Strip for Pressure Vessels, Heat-Resisting Chromium and Chromium-Nickel |
| ASTM A270/A270M |
| Standard Specification for Seamless and Welded Austensic and Ferritic/Austentic Stainless Steel Sanitary Tubing |
| ASTM A380/A380M |
| Standard Practice for Cleaning, Descaling and Passivation of Stainless Steel Pats, Equipment, and Systems |
| ASTM A967/A967M |
| Standard Specification for Chemical Passivation Treatments for Stainless Steel Parts |
| ASTM D1171 |
| Standard Test Method for Rubber Deterioration |
| ASTM F838 |
| Determining Bacterial Retention of Membrane Filters Utilized for Liquid Filtration |
(Copies of these documents are available from www.astm.org or ASTM International, P.O. Box C700, West Conshohocken, PA 19428-2959.)
GENERAL MOTORS CORPORATION (GM)
| GMW 14872 |
| Cyclic Corrosion Laboratory Test |
(Copies are available from Global Engineering Documents, An HIS GROUP Company, 15 Inverness Way East, Englewood, Colorado 80112.)
INTERNATIONAL ORGANIZATION FOR STANDARDIZATION (ISO)
| ISO 668 |
| Series 1 Freight Shelters – Classification External Dimensions and Ratings |
| ISO 1161 AMD1 |
| Specifications for Corner Fittings for Series 1 Freight Shelters |
| ISO 1496-1 |
| Series 1 Freight Containers – Specification and Testing (DoD Adopted) |
| ISO 6346 AMD3 |
| Freight Containers – Coding, Identification, and Marking |
(Copies of these documents are available from www.iso.org or American National Standards Institute, 11 West 42nd Street, New York, N.Y. 10036.)
INTERNATIONAL SOCIETY OF BEVERAGE TECHNOLOGISTS
| ISBT DWG NO. 3784253-18 |
| Carbonated Soft Drink, Finish No. PCO-1881-1 |
(Copies of this drawing can be obtained from the International Society of Beverage Technologists website at http://www.threadspecs.com/threadspecs-downloads.asp. )
NATIONAL ELECTRICAL MANUFACTURERS ASSOCIATION (NEMA)
| NEMA 250 |
| Enclosures for Electrical Equipment, 1000 Volts Maximum (DoD Adopted) |
(Copies of this document are available from www.nema.org or National Electrical Manufacturers Association, 1300 North 17th Street, Suite 1752, Rosslyn, VA 22209.)
NATIONAL FIRE PROTECTION ASSOCIATION (NFPA)
| NFPA 70 |
| National Electric Code |
(Copies of this document are available from www.nfpa.org or National Fire Protection Association, 1 Batterymarch Park, Quincy, MA 02269.)
SOCIETY OF AUTOMOTIVE ENGINEERS (SAE)
| SAE J534 |
| Lubrication Fittings (DoD Adopted) |
(Copies of this document are available from www.sae.org or SAE Customer Service, 400 Commonwealth Drive, Warrendale, PA 15096-0001.)
UNDERWRITERS LABORATORIES INC (UL)
| UL 250 |
| Standard for Safety, Household refrigerators and Freezers |
| UL 471 |
| Standard for Safety, Commercial Refrigerators and Freezers |
| UL 1995 |
| Standard for Safety, Heating and Cooling Equipment |
| UL 61010-1 |
| Safety Requirements for Electrical Equipment for Measurements Control and Laboratory Use |
(Copies of this document are available from www.ul.com or Underwriters Laboratories Inc, 2600 N.W. Lake Rd., Camas, WA 98607-8542 Telephone: 1.877.UL.HELPS (1.877.854.3577).
Order of precedence Unless otherwise noted herein or in the contract, 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.
REQUIREMENTS
As written in this PD, minimum acceptable performance threshold requirements are indicated with the word “shall” throughout the text. Objective capabilities that are not mandatory are indicated with the words “should”, “desired”, or “desirable” (equivalent to objective or “O” in Capabilities Production Document (CPD)).
Description For the purpose of this PD, the EWPS consists of two ISO 1C shelters, one that produces one-liter plastic bottles filled with potable water and one for the laboratory, storage of BII, and COEI. A functional block diagram of the EWPS is included in Appendix D. All processes except those highlighted in orange are components required as part of the EWPS. A piping and instrumentation diagram (P&ID) of the water treatment and conveyance system that is required as part of the EWPS is shown in Appendix A. A sample of a layout diagram showing the components within each ISO shelter is included in Appendix B.
The Expeditionary Water Packaging System (EWPS) packages water that has already been certified as potable by the U.S. Army Public Health Command (USAPHC) in accordance with the requirements contained in Technical Bulletin Medical (TB MED) 577 In Accordance With (IAW) doctrine for the Joint Services and North Atlantic Treaty Organization (NATO). The certified potable water delivered to the EWPS site is stored in one of three standard 3,000 gallon collapsible water storage tanks (ATPD 2344) or other applicable potable water storage equipment and a 3,000 gallon cleaning waste tank supplied as (GFE) for the EWPS. One tank is used for operation while the other two tanks of water are held for testing and verification of water quality. All appropriate valves, hoses, and fittings for accepting, distributing water to the EWPS and for cleaning shall be provided by the Contractor. Water is drawn from the operation tank by a pump and is then dechlorinated by carbon block filtration. A small amount of chlorine or minerals can then be added if required, and then the water is purified using a sanitary filter system (0.2 micron sterile filter) prior to entering the filling system. Polyethylene terephthalate (PET) preforms and high density polyethylene (HDPE) caps are loaded into hoppers that supply them to the blow molder and capper respectively. PET preforms are conveyed from the hopper into the heating oven and then to the blow molder where they are formed into bottles. Bottles are then filled with water and capped. Bottles leaving the filler/capper are then marked (imprinted without a label) before exiting the EWPS shelter on a conveyor. Once bottles exit the EWPS shelter, they are stored for post packaging. It is the responsibility of the Contractor operating the system to provide any post packaging equipment to palletize the filled bottles. The minimum production rate of 1-liter filled bottles is 900 bottles per hour. Power for the system is supplied by Government Furnished Equipment (GFE) Advanced Medium Mobile Power Source (AMMPS) generator of 60 kW, /240 VAC, wye-connected, 3 phase or off commercial grid power of 60 Hz, 480/277 – 416/240 VAC, wye-connected, 3 phase. The EWPS will have a detachable interactive training capability to meet adequate training requirements in a simulated setting without the need to actually operate the system. This will enhance operator proficiency and increase operational readiness.
The EWPS water treatment system, preform and cap hoppers, blow molder and filler/capper, compressor, chiller, and the Environmental Control Unit (ECU) shall be permanently mounted and operate within a single 1C (20’L X 8’W X 8.0’H) ISO shelter. The shelter shall be transportable by a HEMTT-LHS truck, PLS truck or PLS trailer using the Enhanced Container Handling Unit (E-CHU, ATPD 2203) for loading and unloading.
The second ISO 1C shelter is for a Government furnished generator with a 60 kW power output, an ECU, and a laboratory area for record-keeping and water quality testing. The second shelter shall also be transportable by a HEMTT-LHS truck or a PLS truck/trailer using the Enhanced Container Handling Unit (E-CHU, ATPD 2203) for loading and unloading.
Basic Issue Items (BII) and Components of the End Item (COEI) can be stored for transport in either or both shelters.
Testing The EWPS shall be subjected to first article test, comprising of a Production Verification Test (PVT) operated by Contracted personnel, in accordance with (IAW) section 4 of this PD.
Design and Operation Requirements The design and operation requirements section follows the functional block diagram in Appendix D. Starting with requirements for setup and operation, it then addresses each of the functional areas on the diagram. Miscellaneous requirements not referenced on the functional block diagram are included in paragraphs 3.3.1 to 3.14.
Set-up/tear-down The setup and teardown time of the EWPS shall not exceed 48 hours for each individual task, with four Contracted personnel. The four person Contracted personnel may consist of operators and maintainers. Setup time starts with both EWPS shelters setting on the ground and fully packed. Setup time ends when the system is in operation producing bottles ready for palletization. Teardown time begins when notification is given to an operating EWPS that is producing bottles ready for palletization. Teardown time ends when the two shelters are ready for pickup by the transport vehicle.
Operation and Maintenance Each EWPS shall be operated and maintained by no more than four contracted personnel per 10-hour shift. The four Contracted personnel may consist of supervisors, operators and maintainers. The Contracted personnel will perform the receipt of all raw material, fuel, and water including the offloading of consumables and supplies from trucks using Material Handling Equipment (MHE). Contracted personnel will operate and maintain the EWPS including the 60 kW Government furnished generator and the GFE water tanks. Contracted personnel will supply the necessary equipment and consumables for palletizing filled bottles and load onto trucks using MHE. Contracted personnel will perform all water quality measurements, maintain water quality records, keep maintenance records on all equipment, keep records of Clean In Place (CIP) and system sanitizations, maintain an inventory of consumables to keep the plant running 20 hrs per day, and keep records of distributed pallets of water.
ISO Shelter’ The EWPS consists of two ISO 1C shelters.
The first ISO shelter (Shelter 1) shall contain the functional components shown in Appendix B: The water treatment system, preform and cap hoppers, blow molder, chiller, filler/capper, air compressor, and an Environmental Control Unit (ECU) all of which shall be permanently mounted and operate within Shelter 1. Preforms and caps are placed into hoppers with the operator positioned outside the shelter. Filled bottles exit the shelter on a conveyor and are temporarily stored. Bulkheads separate the bottling room from the water treatment system, compressor and ECU. Operators only enter the bottling room for PMCS, startup, shutdown, and routine corrective maintenance. The system shall provide an area for the operator to sanitize their hands and don foot covers and gloves prior to entering the bottling room, load caps and preforms through the access panels into the hoppers, and palletize bottles. A vestibule, such as an expandable shelter, may be attached to the outside of the ISO shelter to provide this area.
The second ISO shelter (Shelter 2) shall contain the following functional components three 3,000 gallon collapsible water storage tanks, a 3,000 gallon waste water tank, additional BII and COEI, a Government furnished generator of 60 kW capacity, an ECU, and a laboratory/office area for record-keeping and water quality testing.
ISO Shelter Dimensions and Characteristics Each EWPS shelter shall have external dimensions and permissible tolerances that conform to Table 2 of ISO 668 for 1C shelters and corner fittings that conform to ISO 1161. It shall be able to accommodate nine stacked, fully loaded ISO 1C shelters above it, and also stackable on top of an ISO 1C shelter. The EWPS shall be capable of being lifted from the four top corner fittings, as well as at the four bottom corner fittings. It shall be capable of withstanding longitudinal external restraint, have two sets of fork lift pockets, and have rigidity in the transverse and longitudinal directions IAW ISO 1496-1.
CSC certification Each EWPS shelter shall be Conventions for Safe Containers (CSC) certified by an approved authority, designated as such by the United States Coast Guard, in accordance with 49CFR450-453.
Shelter Certification The EWPS shelters shall obtain a Shelter Transportability Certification or waiver from Director US Army Soldier Systems Center (Natick), Kansas Street, Natick MA 01760. Natick-certified shelters shall meet the requirements of ASTM E1925 and ASTM E1976.
Shelter Marking Each EWPS shelter shall be marked with ISO identification coding numbers provided by the Government. The markings shall be in accordance with ISO 6346, and include the owners code, equipment category identifier, serial number, check digit, size code, and type code.
Forklift compatibility The EWPS shelters shall include two sets of forklift pockets IAW ISO 1496-1, Annex C.
Prime mover compatibility The EWPS shelters shall be compatible with the E-CHU as defined in ATPD 2203. The EWPS shall be capable of being loaded and unloaded using the E-CHU from the PLS (M1074 and M1075) and HEMTT LHS trucks (M1120) and trailers (M1076). The loading and unloading shall be accomplished using only the E-CHU.
Weight/Center of Gravity (CG) The weight of each EWPS shelter with installed equipment, including the GFE generator and 3K tanks, and all of its COEI and BII shall be less than 24,000 lbs. The location of the CG of the complete system shall be marked on the shipping plate of each shelter. The CG of each EWPS shelter when attached to the E-CHU, at gross weight, with all components stowed for transport, shall be located no greater than 44 inches above the corner casting bottoms, 110 +0/-6 inches rearward of the front end of the E-CHU, and within 2.5 inches of the longitudinal centerline.
Power Requirements The complete EWPS system shall be powered by one Government Furnished Advanced Medium Mobile Power Source (AMMPS) generator of 60 kW capacity. The EWPS shall include at least 100 feet of power cable so that the AMMPS can be removed from the shelter and setup 100 feet away from Shelter 1. The generator will be operated at 60 Hz, 416/240 VAC, wye-connected, 3 phase. The EWPS shall also be capable of operating off commercial power 60 Hz, 480/277 VAC, wye-connected, 3 phase. All components in Shelter 2 shall be capable of operating from a separate 60 Hz, 120 VAC power source.
Compressed Air System The compressed air system provides air for blowing bottles, pneumatic controls, and utility air for general use. The compressor shall be permanently mounted in shelter 1 and separated from the bottling room by an insulated, sealed bulkhead. The duty cycle of the compressor shall be less than 75%. The treatment system for all compressed air shall produce air having an ISO 8573-1 purity class of class 1 for particulates, class 3 for dewpoint, and class 1 for total oil. The final filter shall be a sterile filter capable of removing a 107 cfu/cm2 Brevundimonas diminutas challenge. Each sterile filter cartridge shall have undergone integrity testing as part of the manufacturing process. The sterile filter shall be mounted in a 3-A approved filter vessel with sanitary clamp connections. The sterile filter vessel internal surfaces shall have a roughness of less than 20 µ-inches Ra. External surfaces of the vessel shall have a roughness of less than 35 µ-inches Ra. All stainless steel surfaces on the sterile filter vessel shall be cleaned and passivated using one of the methods in ASTM A380. Any refrigerant included with the compressed air dryer shall be non-flammable and non-toxic, consistent with ASHRAE 34, Class A1, and shall be EPA-approved.
Air System Piping The EWPS air system piping shall be constructed of UNS S31600 and UNS S31603 stainless steel. All stainless steel assemblies that have been welded shall be cleaned and passivated using one of the methods in ASTM A380. The air piping configuration shall allow easy access to all components for inspection, maintenance, repair and operation. Frequently replaced or adjusted items such as air filters, pressure regulators, or valves shall be readily accessible for the operator without having to step over or crawl behind or around other components. The piping system shall be designed to prevent contact or cross contamination between water and other operating fluids.
ECU System The shelter shall be ventilated, heated, and cooled to permit personnel to work comfortably and equipment to operate within design parameters for extended periods in environmental conditions specified in 3.6. The interior dry bulb temperature shall be above 50 F (10 C) in cold environments. The interior Effective Temperature (ET) in hot environments shall be at or below 90 F (26.7 C) in the bottling room and at or below 85 °F in the water laboratory. Ventilation for the bottling room and laboratory area shall introduce external fresh air at a rate of not less than 0.18 cubic feet per minute per square foot (cfm/ft2). The ECU and associated ducts for each shelter shall be integrated into the shelter structure and shall not require any setup. The ECU’s shall be permanently mounted and separated from the bottling room or laboratory area by an insulated, sealed bulkhead. Any refrigerant used with the ECU shall be non-flammable and non-toxic, consistent with ASHRAE 34, Class A1, and shall be EPA-approved. The ECU’s shall be UL 1995 listed.
Clean Room Requirements Air filters shall be incorporated in the design to achieve an ISO 14644 clean room classification of 8 inside the bottling room and laboratory and an ISO 14644 clean room classification of 5 inside the filler/capper and the laminar flow hood in the laboratory. Clean room classifications are for “at rest” conditions as defined in ISO 14644. The design of the shelters and ECU shall over-pressurize the bottling room and the laboratory to 0.3 inches of water.
Water Storage Water delivered to the EWPS site will be placed in one of three 3,000 gallon collapsible storage tanks. The tanks will be GFE and meet the requirements of ATPD 2344 and have 2-inch male and female cam and groove connectors (AA59326). The three tanks shall be stored inside Shelter 2 for transport. Only one tank is connected at a time to the water treatment system pump. All Necessary hoses, piping, fittings, and valves to complete the EWPS site shall be defined and provided by Contractor.
Water Testing Laboratory The second EWPS shelter shall provide a laboratory area in order to refrigerate water samples, conduct water quality tests, conduct microbiological tests within a laminar flow hood, incubate microbiological test samples, maintain and store records, and store supplies for conducting the tests. The internal design and selection of components within the laboratory shall be consistent with the requirements for achieving the clean room classifications in 3.3.6.1.
Water Testing Equipment The contractor that operates the EWPS shall provide all water quality testing equipment to include turbidity (SM2130B), conductivity/total dissolved solids instruments (SM 2510B), pH (SM4500-H+ B), free available chlorine (SM 4500-Cl G), high range free available chlorine (SM 4500-Cl B), total coliform and E. coli presence/absence (IDEXX Colilert® or equivalent EPA approved method), and heterotrophic plate count (IDEXX Simplate HPC® or equivalent SM 9215B EPA approved method).
Refrigerator A refrigerator (no freezer) shall be provided with a minimum capacity of 5 cubic feet. The refrigerator shall be permanently mounted and be capable of maintaining a stable temperature between 34°F and 44°F. Shelves shall be provided to store the 1-liter water bottle samples, water quality standards, and boxes of test media for coliform and HPC testing. Surfaces inside the refrigerator shall be capable of being cleaned and sanitized utilizing any of the solutions in 3.3.9.13.1 without requiring disassembly or the use of tools. The refrigerator shall be capable of being cleaned and sanitized as described herein without suffering damage or degradation. The refrigerator shall be powered by 60 Hz, 120 VAC. Refrigerant used shall be non-flammable and non-toxic, consistent with ASHRAE 34, Class A1, and shall be EPA-approved. The refrigerator shall be UL 250 or UL 471 listed.
Incubator An incubator shall be provided for incubating coliform and HPC test samples. The incubator shall be permanently mounted. The incubator shall have a capacity of at least 1.5 cubic feet and have the capability to hold at least 2 racks. There shall be a continuous temperature display and the temperature variation shall be less than 0.5 °C at 35 °C within the incubator. Surfaces inside the incubator shall be capable of being cleaned and sanitized utilizing any of the solutions in 3.3.9.13.1 without requiring disassembly or the use of tools. The incubator shall be capable of being cleaned and sanitized as described herein without suffering damage or degradation. The incubator shall be powered by 120 VAC. The incubator shall meet standards for safety in UL 61010.
Laminar Flow Hood A countertop laminar flow hood with HEPA filter shall be provided for operators to conduct the HPC and the coliform testing. The hood shall be permanently mounted and shall be a minimum of 48” wide by 24” deep and constructed with a UNS S30400 stainless steel frame and static dissipative PVC side walls. Surfaces inside the laminar flow hood shall be capable of being cleaned and sanitized utilizing any of the solutions in 3.3.9.13.1 without requiring disassembly or the use of tools. The laminar flow hood shall be capable of being cleaned and sanitized as described herein without suffering damage or degradation. The laminar flow hood shall provide a minimum air flow of 80 feet per minute. The hood’s fan/filter unit shall be powered by 60 Hz, 120 VAC and the noise level shall be less than 50 dBA. There shall be a light mounted inside the hood and a hinged front clear shield.
Autoclave A portable autoclave shall be provided that will be used to either sterilize five 250 ml glass bottles with caps, or the air system sterile filter and its vessel. The autoclave shall be powered by 60 Hz, 120 VAC power and shall be permanently mounted. The Autoclave shall have an adjustable timer from 5 minutes to at least 1 hour and a temperature display. Sterilization temperatures shall be a minimum of 249 °F. Wetted materials shall be UNS S31600. Surfaces inside the autoclave shall be capable of being cleaned and sanitized utilizing any of the solutions in 3.3.9.13.1 without requiring disassembly or the use of tools. The autoclave shall be capable of being cleaned and sanitized as described herein without suffering damage or degradation. The autoclave shall meet standards for safety in UL 61010.
Cabinetry Cabinets, countertops and drawers shall provide adequate storage space and protection for equipment items and supplies used to conduct water quality testing. Countertops shall be sturdy and of laboratory quality to withstand repeated use, cleaning, sanitizing, and support the weight of the countertop hood, incubator and autoclave. Cabinet and countertop surfaces shall be capable of being cleaned and sanitized utilizing any of the solutions in 3.3.9.14.1 without requiring disassembly or the use of tools. The Cabinet and countertop surfaces shall be capable of being cleaned and sanitized as described herein without suffering damage or degradation. Cabinetry shall provide secure protected stowage locations for easily damaged items such as glassware and instrumentation during transportation. Cabinets shall also be provided for the storage of office supplies, and legal sized files.
Power A distribution panel shall be provided for the Shelter 2 power supply that is switchable from generator power to a separate 60 Hz, 120 VAC power source. GFI-protected, UL listed power strips shall be permanently attached to the cabinets/walls and provided throughout the laboratory for providing power to the refrigerator, incubator, laminar flow hood, autoclave and the water quality instruments.
Seating At least one seat shall be provided to provide a comfortable working height for personnel working at the countertops.
Water Treatment System The water treatment system shall consist of the components shown in the Piping and Instrumentation Diagram in Appendix A and shall be permanently mounted in the same shelter as the bottling system. The water treatment system shall be separated from the bottling room by an insulated sealed bulkhead.
Piping system The EWPS water treatment system piping shall be constructed of UNS S31600 or UNS S31603 stainless steel. The configuration shall allow easy access to all components for inspection, maintenance, repair and operation. Frequently replaced or adjusted items such as water filters, pressure regulators, or valves shall be readily accessible for the operator and maintainer without having to step over or crawl behind or around other components. The piping system shall be designed to prevent contact or cross contamination between potable water and other operating fluids. Water system piping design shall meet the requirements of the ASME BPE. All welded stainless steel pipe assemblies shall be cleaned and passivated using one of the methods in ASTM A380.
Cam and groove fittings Unless explicitly specified otherwise, all cam and groove fittings and coupling halves, adapters, reducers, dust caps, and dust plugs required by this PD shall be in accordance with AA59326. Only UNS S31600 stainless steel fittings shall be used with all UNS S31600 stainless steel pins, rings, and locking arms.
Pump Pump P-1 shown on the P&ID shall be a UNS S31600 stainless steel or UNS S31603 stainless steel, centrifugal pump meeting the requirements of 3-A 02-10. It shall have minimum total head of 120 ft water at a flow rate of 4 gpm. The same pump shall be used to circulate sanitizing and cleaning solutions.
Inline Heater A thermostatically controlled inline heater shall be provided to heat cleaning solutions from ambient temperature up to a maximum temperature of 140 °F. Use of an immersion heater inside the CIP tank as an alternate must have prior approval by the Government. The heater must deliver a minimum of 20 kW to the circulated solution. The heater shall include over-temperature and ground fault protection and be UL 499 listed. The heater shall be constructed of UNS S31600 and S31603 stainless steel with sanitary clamp connections. Wetted internal surfaces shall have a roughness of less than 20 µ-inches Ra. External surfaces of the heater shall have a roughness of less than 35 µ-inches Ra. All surfaces shall be cleaned and passivated using one of the methods in ASTM A380.
Flowmeter An inline turbine flowmeter shall be provided to measure the discharge flow from the pump after the heater. Flow range shall be from 2 gpm to 15 gpm and shall have a local display. The meter shall have an accuracy of +/- 1% of full scale. The body of the meter shall be constructed of UNS S31600 stainless steel with sanitary clamp connections. The meter shall be 3-A 28-04 certified. At least 10 diameters of straight pipe must be provided before the meter and 5 diameters of straight pipe after the meter to assure meter accuracy.
Temperature Gauge A temperature gauge shall be provided after the heater so that the cleaning solution temperatures can be measured. The temperature range shall be 0 to 200 °F. The indicator shall have an accuracy of +/- 1% of full scale. The temperature gauge shall be constructed of UNS S31600 stainless steel with sanitary clamp connections. The gauge shall be 3-A certified. Wetted surfaces shall have a roughness of less than 20 µ-inches Ra. External surfaces of the temperature gauge shall have a roughness of less than 35 µ-inches Ra.
Pressure Gauges and Transmitters Pressure gauges and transmitters shall be provided as shown on the P&ID to determine filter changeout, pressure regulator adjustment, and protection of the pump from loss of prime or deadhead conditions. The pressure range shall be 0 to 100 psig. The indicator shall have an accuracy of +/- 2% of full scale. The pressure gauge shall be constructed of UNS S31600 stainless steel with sanitary clamp connections. The sensor shall be 3-A certified. Wetted surfaces shall have a roughness of less than 20 µ-inches Ra. External surfaces of the pressure gauge shall have a roughness of less than 35 µ-inches Ra.
Carbon Block Filter A carbon block filter shall be installed on the water filtration system which consists of double open ended cartridge filters rated at 0.5 µm. The carbon block filter shall be validated for taste and odor removal, chlorine removal, and cyst reduction per NSF 42, and NSF 53. The filters shall be capable of removing up to 3 mg/liter of free chlorine at a flow rate of 900 (T) – 1200 (O) liters per hour. A minimum of three manufacturers of the filters shall be capable of being installed inside the vessel and meeting the performance requirements. The filter vessel shall be constructed of UNS S31603 stainless steel with sanitary clamp connections. This vessel does not require 3-A approval. However, to enhance CIP efficiency, wetted surfaces shall have a roughness of less than 20 µ-inches Ra. External surfaces of the filter vessel shall have a roughness of less than 35 µ-inches Ra. All vessel surfaces shall be cleaned and passivated using one of the methods in ASTM A380.
Calcium Hypochlorite Injection System The calcium hypochlorite injection system shall consist of a tank, chemical feed pump, and accessories including a suction strainer, inlet check valve, degassing valve and discharge check valve. The system shall be capable of injecting sufficient chlorine to achieve 0.2 to 0.5 mg/liter free available chlorine in the 900 (T) – 1200 (O) liter per hour flow. The system shall not require batching of the solution more than once per day. The calcium hypochlorite that will be used in the system shall meet the requirements of ASTM E1229 and be NSF 60 certified.
Sterile Filter The sterile filter shall be 0.2 µm absolute rated polyethersulfone (PES) membrane filter, with a -222 or -226 ethylene propylene diene monomer (EPDM) O-ring configuration. The filter(s) shall have a bio-reduction claim of greater than 107 cfu per cm2 when tested IAW ASTM F838. The filter(s) shall have a minimum of 30 ft2 of overall filter area. Each filter shall have undergone integrity testing as part of the manufacturing process. The filters shall be capable of operating up to a 30 psi differential at 140 °F and shall be able to withstand the effects of the cleaning and sanitizing solutions in 3.3.9.13.1. A minimum of three manufacturers of the filters shall be capable of being installed inside the vessel and meeting the performance requirements. The filter vessel shall be constructed of UNS S31603 stainless steel with sanitary clamp connections and be 3-A certified. Wetted surfaces shall have a roughness of less than 20 µ-inches Ra. External surfaces of the filter vessel shall have a roughness of less than 35 µ-inches Ra. All vessel surfaces shall be cleaned and passivated using one of the methods in ASTM A380.
Valves All valves shown on the P&ID for the water treatment system shall be as shown quarter turn ball valves, butterfly valves, or globe style sample valves. The valves shall be constructed of UNS S31600 or UNS S31603 stainless steel and either welded in place or with sanitary clamp connections. Ball valves shall be 3-A 68-00 certified. Butterfly valves and sample valves shall be of sanitary construction. Wetted surfaces shall have a roughness of less than 20 µ-inches Ra. External surfaces of the valves shall have a roughness of less than 35 µ-inches Ra.
Pressure Regulator If a pressure regulator is required it shall regulate the downstream pressure to the filler valves. The valve shall be equipped with the ability to hold the regulator in an open position for CIP or sanitization. This feature prevents the operator from having to readjust the regulator after every sanitization. The valve shall be constructed of UNS S31600 or UNS S31603 stainless steel with sanitary clamp connections.
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