BK_Draft_Attachment_B-2_PPD_Burner_20160406.pdf

Attachment B-1

PPD for Modular Burner

W911QY-16-R-0004

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Performance Purchase Description for the

Modular Burner for Field Feeding

FSE-001

DRAFT

20160406

1. SCOPE. This document covers the physical, performance, interface, and acceptance requirements of the Modular Appliance Burner for future Army field kitchens. This burner will be used in Army field feeding kitchens as well as independent operation in dismounted appliances. This effort is in the developmental stage and as such, some requirements and characteristics are not yet fully defined. This document will be updated to include more detailed technical data as the project matures. It is the intention of the government to replace this document with a government owned and maintained technical data package concurrent with Full Rate Production decision.

2. APPLICABLE DOCUMENTS

2.1. GENERAL. The documents listed in this section are required to meet the requirements specified in sections 3 and 4 of this specification. This section does not include documents cited in other sections of this specification 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 cited in sections 3 and 4 of this specification, whether or not they are listed in section 2.

2.2. GOVERNMENT DOCUMENTS

2.2.1. Specifications, standards, and handbooks and technical data. 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 listed in the issue of the Department of Defense Index of Specifications and Standards

(DoDISS) and supplement thereto, cited in the solicitation.

Human Factors Engineering, MIL-STD-1472

NSF/ANSI 2 – 2009, Food Equipment

DA Pam 385-16, System safety

MIL-STD-882E for environmental safety and occupational Health.

Modular Burner Performance Purchase Description (FSE-002)

Battlefield Kitchen Performance Purchase Description (FSE-003)

Appendix A, Drawing, MB2, 3 sheets

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Appendix B, Drawing, MB2 Interface

3. REQUIREMENTS

3.1. FIRST ARTICLE: When specified in section 6.2, a sample shall be subjected to a first article inspection and test as specified in section 4.2.

3.2. GENERAL REQUIREMENTS. The modular burner as defined by this document is intended as the primary heat source of the modular appliances (PPD-FSE-002), and in turn, the modular appliances will be used to create the appliance suite for the Battlefield

Kitchen (PPD-FSE-003). As all three of these items are still in the developmental phase, many of the technical requirements are interdependent. Some performance requirements have not yet been defined outside of the BK system in order to maximize design latitude during the remainder of the developmental process. These requirements shall be evaluated as part of the Battlefield Kitchen System as noted in section 4.

3.2.1. Firing Rate. The modular burner shall have a firing rate sufficient to allow the modular appliances to meet all of their requirements. The firing rate shall be no less than

52,000 BTU/hr and no greater than 62,000 BTU/hr.

3.2.2. Fuel compatibility. The modular appliances shall be capable of meeting all requirements while operating on JP-8, Jet A, Jet A-1, and F-34.

3.2.3. Burner exchange. The burner shall be capable of being quickly and easily swapped between modular appliances in less than 10 minutes after a cool down period of not more than 1 minute using only a flat blade screwdriver.

3.3. INTERFACE REQUIREMENTS.

3.3.1. Burner – Appliance Physical Interface. The burner and appliances are still in development and as such, alterations to the current design may be acceptable, however;

the physical interfaces of the burner and appliance shall not be altered without prior approval of the government. The Government Furnished Equipment (GFE) griddle shall be the standard test fixture for the burner physical interface. The current government design burner meets this physical interface requirement. Drawings of the current burner are provided in appendices A and B.

3.3.2. Electrical cable interface. The burner shall interface with the modular appliance

(See Performance Purchase Description FSE-002) electrical system for all necessary power and controls.

3.3.3. Electrical power compatibility. The burner shall be capable of operating on 120

VAC, single phase, 50/60 Hz power with a steady state power draw no greater than 90 watts.

3.3.4. Fuel system interface with appliance. The modular burner shall be capable of interfacing physically and functionally with the modular appliances (See PPD FSE-002).

The modular burner shall have a recirculating fuel system with double shut-off, quick disconnect fittings.

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3.3.5. Electronic interface and controls. The burner controller shall be designed to accept control signals from, and send control signals to, the modular appliances as required for proper operation.

3.3.6. Flame size and shape. The size and shape of the flame shall be such that it does not cause degradation, either short term or long term, of the modular appliances.

3.4. ENVIRONMENTAL REQUIREMENTS. The modular burner shall be capable of meeting the same environmental requirements as the modular appliances (reference FSE-

002) when installed in any modular appliance. Specifically: temperature range, wind, rain, and blowing sand and dust, salt fog, and humidity. The modular burner shall not fail nor cause a failure of the modular appliance when operated in the modular appliance.

3.5. LIFE CYCLE REQUIREMENTS

3.5.1. Reliability and Maintainability. As much as practical, the burner shall be maintainable and repairable by the operator. A minimum number of tools shall be required to maintain/repair the appliances at the operator level.

3.5.2. Ground Transit. The Modular Burner shall meet the transit requirements of the

Battlefield Kitchen when mounted in the modular appliance and transported within the

Battlefield Kitchen.

3.5.3. Remove and Replace Cycles. The burner shall be capable of withstanding 20 cycles consisting of removing the burner then replacing it in a modular appliance without failure of the burner tube seal or any other component.

3.6. SAFETY REQUIREMENTS

3.6.1. Health Hazards. The Modular Burner shall be designed to minimize danger of hazards to the operators and maintainers. Damage to safeguards shall be easily noticeable by operators and maintainers.

4. VERIFICATION

4.1. VERIFICATION ALTERNATIVE. Alternative test methods, techniques, or equipment, including; application of statistical process control, tool control, or cost effective sampling procedures may be proposed by the contractor. Acceptable alternative verification approach, including the use of sample testing shall be identified in the contract.

Table I. Requirement and Verification Methods

Requirements and Verification Methods

Requirement Title Verification

3.2 GENERAL REQUIREMENTS 4.2

3.2.1 Firing Rate 4.2.1

3.2.2 Fuel Compatibility 4.2.2

3.2.3 Burner exchange 4.2.3

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3.3. INTERFACE REQUIREMENTS 4.3

3.3.1 Physical Interface with Appliance 4.3.1

3.3.2 Electrical Interface with Appliance 4.3.2

3.3.3 Electrical Power Compatibility 4.3.3

3.3.4 Fuel System Interface with Appliance 4.3.4

3.3.5 Electronic Interface and Controls 4.3.5

3.3.6 Flame Size and Shape 4.3.6

3.4 ENVIRONMENTAL REQUIREMENTS 4.4

3.5 LIFE CYCLE REQUIREMENTS 4.5

3.5.1 Reliability and Maintainability 4.5.1

3.5.2 Transit 4.5.2

3.5.2 Swap Cycles 4.5.3

3.6 SAFETY REQUIREMENTS 4.6

3.6.1 Health Hazards 4.6.1

4.2. GENERAL REQUIREMENTS

4.2.1. Firing Rate. The firing rate shall be verified while operating in a modular appliance. The burner shall be operated at 100% duty cycle for 60 minutes. The weight of the fuel shall be taken at the beginning and the end of the test. The fuel energy shall be assumed to be 18,000 Btu/lb. The firing rate shall be determined by multiplying the weight of the fuel consumed in 60 minutes by 18,000 Btu/hr. A calculated value outside the range of 52,000 to 62,000 shall constitute a failure.

4.2.2. Fuel Compatibility. This requirement shall be evaluated in conjunction with the

Battlefield Kitchen Reliability Testing. During Battlefield Kitchen testing, the primary fuel will be JP-8. At the discretion of the Government, any fuel listed in section 3 may be substituted during any test so long as the environment conditions of the test are within the specifications of the fuel. Any degradation of performance, failure or damage to the burner or any burner component as a result of the use of an alternate fuel shall constitute a failure.

4.2.3. Burner Exchange. This requirement shall be evaluated in conjunction with the

Battlefield Kitchen Reliability Test and the evaluation of swap cycles (4.5.3). During the battlefield kitchen testing, each burner of a battlefield kitchen shall be removed and installed 20 times during the course of the testing. The burners shall be rotated through different appliances. Each burner in the BK system shall be operated in a minimum of four different appliances to verify interchangeability. If the appliance has been operating.

A cool down period of 1 minute shall be allowed. A removal and installation shall include the disconnection of all fuel and electrical connections, physically removing the burner from the appliance, the installation of the burner, and the reconnection of all fuel and electrical connections. The time required to exchange the burner shall be recorded.

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The average of all exchanges shall be calculated. An average exchange time in excess of

10 minutes shall constitute a failure. Inability to remove the burner (as a result of heat deformation or any other reason) after 1 minute of cooling shall constitute a failure.

4.3. INTERFACE REQUIREMENTS

4.3.1. Physical Interface with Appliance. The burner shall be installed in the GFE appliance to test the physical interfaces, to include function of mounting hardware and combustion chamber seals. Failure to physically interface with the GFE modular appliance shall be cause for failure. Electrical and fuel interface shall not be tested with the GFE burner. The physical interface shall also be evaluated during the Battlefield

Kitchen evaluation. Failure to fully interface and function with the modular appliance suite in the Battlefield Kitchen developmental prototype shall constitute a failure.

4.3.2. Electrical Interface with Appliance. This requirement shall be evaluated in conjunction with the Battlefield Kitchen reliability evaluation and the Burner Exchange evaluation (4.2.3). Failure of the burner to operate as a result of improper interface shall constitute a failure.

4.3.3. Electrical Power Compatibility. This requirement shall be evaluated in conjunction with the Battlefield Kitchen reliability evaluation. Failure of the burner to properly operate or failure to meet any performance requirement while powered with a

120VAC, 50 or 60 Hertz as a result voltage compatibility shall constitute a failure.

4.3.4. Fuel System Interface with Appliance. This requirement shall be evaluated in conjunction with the Battlefield Kitchen reliability evaluation and the Burner Exchange evaluation (4.2.3). Failure of the burner to operate as a result of improper interface shall constitute a failure.

4.3.5. Electronic Interface and Controls. This requirement shall be evaluated in conjunction with the Battlefield Kitchen reliability evaluation. Failure of the burner to operate as a result of improper interface shall constitute a failure.

4.3.6. Flame Size and Shape. This requirement shall be evaluated in conjunction with the Battlefield Kitchen reliability evaluation. Failure of the burner to operate properly or damage to any modular appliance as a result of the flame size or shape shall constitute a failure. Whether the failure is charged to the burner or the appliance shall be determined based on the details of the failure and shall be determined based on failure analysis.

4.4. ENVIRONMENTAL REQUIREMENTS. This requirement shall be evaluated in conjunction with the Battlefield Kitchen reliability and the modular appliances evaluation. The burner shall be subjected to all of the environmental requirements of the

Battlefield Kitchen and the Modular Appliances while installed in a modular appliance.

Failure of the Burner as a result of any required environmental condition shall constitute a failure. Inability of the Battlefield Kitchen or the Modular Appliances to meet an environmental requirement as result of the burner’s inability to meet the environmental requirement shall constitute a failure.

4.5. LIFE CYCLE REQUIREMENTS

4.5.1. Reliability and Maintainability. This requirement shall be evaluated in conjunction with the Battlefield Kitchen reliability evaluation. The burner shall be

P a g e 6 | 9 evaluated for RAM as a component of the Battlefield Kitchen system. Reliability failures of the burner shall be scored against the Battlefield Kitchen system.

4.5.2. Transit. The ability of the burner to meet transit requirements shall be evaluated as part of the Battlefield kitchen transit evaluation. Failure of the burner as a result of any required transit requirement of the Battlefield Kitchen shall constitute a failure. Failure of the Battlefield Kitchen or any Modular appliance as a result of the burner failure caused by a transit test shall constitute a failure.

4.5.3. Swap Cycles. This requirement shall be evaluated in conjunction with the

Battlefield Kitchen Reliability Test. During the battlefield kitchen testing, each burner of a battlefield kitchen shall be removed and installed 20 times during the course of the testing. A failure of the sealing system or any component associated with the removal and installation of the Burner shall constitute a failure. The time required to exchange the burner shall be recorded. The average of all exchanges shall be calculated. An average exchange time in excess of 10 minutes shall constitute a failure.

4.6. SAFETY REQUIREMENTS

4.6.1. Health Hazards. This shall be evaluated during the course of the Battlefield

Kitchen evaluation. The burner shall be included in the Battlefield Kitchen System

Safety Assessment Report and the System Safety Hazard Analysis Report. Hazards associated with the burner shall be charged to the overall safety of the kitchen.

5. PACKAGING

5.1. Packaging. For acquisition purposes, the packaging requirements shall be as specified in the contract or purchase order (see 6.2). When actual packaging of materiel is to be performed by DoD personnel, these personnel need to contact the responsible packaging activity to ascertain requisite packaging requirements. Packaging requirements are maintained by the Inventory Control Point’s packaging activity within the Military Department or Defense Agency, or within the Military Department's System

Command. Packaging data retrieval is available from the managing Military

Department's or Defense Agency's automated packaging files, CD ROM products, or by contacting the responsible packaging activity.

6. NOTES: This section contains information of a general or explanatory nature that may be helpful, but is not mandatory.

6.1. Intended use. This document was created for the combined development and production of the Battlefield Kitchen System. For this effort, the development and production shall include the development and production of the modular appliances as well as the modular burner. Many of the features and performance specifications will be further defined during the developmental phase of this first contract. This document is not intended to be used in follow on contracts without prior modification of the content.

The modification should include updates and clarifications based on the outcome of the first production effort.

6.2. General information. The modular burner is intended to be the primary heat source of the Modular Appliances. It is required to interface with the modular appliance in that it must connect to the modular appliances fuel and electrical connectors, it must fit the

P a g e 7 | 9 appliance combustion chamber and it must communicate with the modular appliance control system. As this component, as well as the modular appliances are still under development, some requirements are circular in nature, e.g. the burner must interface with the appliance, and the appliance PPD may state that the appliance must interface with the burner. These interfaces have recommended solutions that are defined in the solid models of these components; however, improvements to these interfaces will be considered. These interface requirements shall be fixed at such time that the design details of the burner and appliances are fixed. This will occur at the critical design review of the burner and appliances.

6.3. Acquisition requirements: Acquisition Documents must specify the following:

6.3.1. Title of this specification: PPD for Modular Burner, FSE-001

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Appendix A – Burner Assembly Drawings

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Appendix B – Burner Interface Drawing