BK_Draft_Attachment_B-3_PPD_BK_System_20160406.pdf

Attachment B-3

PPD for BK System

W911QY-16-R-0004

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Performance Purchase Description for the

Battlefield Kitchen (BK)

FSE-003

20160406

1. SCOPE. This document covers the performance, interface, and acceptance requirements for the Battlefield Kitchen. This mobile kitchen has the capability to feed up to 300 personnel three meals per day in forward field locations with a five person crew. The BK will be mounted on a towable platform with a gross weight less than

12,000 lbs. The platform will be 8 feet wide by 14 feet long by 8 feet high in its travel configuration (not including the trailer tongue). It will be expandable on three sides and vertically for operation. The Battlefield Kitchen will utilize the Modular Appliances and

Modular Burner as covered under a separate specifications.

2. APPLICABLE DOCUMENTS

1.1. 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.

1.2. Government Documents.

1.2.1. 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 listed in the issue of the Department of Defense Index of Specifications and Standards (DoDISS) and supplement thereto, cited in the solicitation.

MIL-STD-1472, Human Engineering

MIL-STD-209, Interface Standard for Lifting and Tiedown Provisions

MIL-STD-913, Requirements for the Certification of Sling Loaded Military

Equipment for external Transportation by Department of Defense Helicopters

MIL-STD1791, Designing for Internal Aerial Delivery in Fixed Wing Aircraft

MIL-STD-810, Test Method Standard for Environmental Engineering Considerations and Laboratory Tests

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

MIL-C-53039, Coating, Aliphatic Polyurethane, Single Component, Chemical Agent

Resistant

FED-STD-595, Colors Used In Government Procurement

NSF/ANSI 2 – 2009, Food Equipment

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OSHA standard 29

Modular Burner Performance Purchase Description (FSE-001)

Modular Appliances, Performance Purchase Description (FSE-002)

3. REQUIREMENTS

3.1. VERIFICATION:

3.1.1. First Article: See Contract for First Article requirements.

3.2. GENERAL REQUIREMENTS

3.2.1. Meal Preparation and service: The BK shall have the capability to prepare and serve up to 300 UGRA and/or UGR H&S with enhancements or any combination in six hours or less, up to three times per day for a total of up to 900 (1200 objective) meals per day. The preparation period is four hours and the service period is two hours.

3.2.2. BK Trailer. The BK shall be mounted on the M1061A1 trailer or an approved variant.

3.2.3. Platform Expansion: The BK platform shall be expandable to provide sufficient work space for the crew in the operational configuration. As a minimum, the BK shall be expandable on three sides. One long side and the two short sides. Each expansion platform shall be 4 feet wide times the length of the side being expanded.

3.2.4. Work surfaces: The BK layout shall be designed to provide work surfaces within 48 inches to each cooking location.

3.2.5. Work Tables: The BK shall have a four work tables to be utilized inside or outside of the BK for various meal prep and meal serving functions. The table surfaces shall meet the NSF requirements for food contact. All tables shall have individually adjustable legs for use on uneven surfaces (outside).

3.2.6. Mission Oriented Protective Posture (MOPP) II: The BK shall be fully mission capable with the operators wearing MOPP II protective clothing. Operators shall be capable of performing all maintenance tasks and operator repair tasks while in MOPP II clothing.

3.2.7. Layout: The BK shall have a galley style layout parallel to the long axis of the platform. Work areas shall meet the requirements of MIL-STD-1472 to the extent possible within the limitations of the BK platform and the required equipment. Figure 1 illustrate the baseline layout. This layout was optimized based on user input and results in the most favored operational layout and is most desirable from that prospective.

Engineering considerations (packout, center of gravity, ventilation, etc.) have not been fully explored. Changes may be necessary to meet all of the requirements of this PPD.

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Figure 1. Battlefield Kitchen major component layout.

3.2.8. Basic Issue Items (BII): The BK shall be equipped with the following Basic

Issue Items in the quantities specified.

Item NSN CAGEC QTY

Slide Hammer, Ground Rod 5120-01-013-1676 1

Garbage Can 1

Chopping Board 7330-00-078-5706 1

Kit, First Aid 6545-00-656-1094 1

Fire Extinguisher 4210-01-324-5194 TBD

Colander 7330-00-266-7453 1

Measuring Cup, 4 quart 7330-00-264-5368 2

Dipper, 32 ounce 7330-00-272-2489 2

Can Opener 7330-01-245-0201 2

Egg Whip 7330-00-815-1458 2

Peeler, Potato, hand 7330-00-238-8316 3

Measuring set, spoon 7330-00-272-7876 2

Pot, Cooking, 15 gallon 7330-00-292-2307 2

Pot, Cooking, 10 gallon 7330-00-292-2306 2

Lid, Pot, Cooking 2

4 inch full size hotel pan 7310-01-528-4183 5

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2 inch full size hotel pan 5

Hotel Pan covers 5

6 inch full size hotel pan 7310-01-528-4184 6

1/2 Size Baking Sheets 36

Knife, Cooks, 10 inch 7340-00-488-7950 3

Knife, Steak, Scimitar 7340-00-197-1274 2

Knife, Boning, 10 inch 7340-01-197-1271 2

Knife, Paring, 3.25 inch 7340-00-488-7939 3

IFC Insert 6" deep 18

IFC Insert 1/3 hotel pan lid 18

Ice Cream Scoop, size 6 7330-00-197-1280 4

Spoon, Food Service, 21 inch 7340-00-223-7800 4

Skimmer, Kitchen 7330-00-680-2635 1

Tongs, food service, 12 inch 7330-00-616-0997 4

Food Turner 7330-00-256-2158 3

Ladle, Kitchen, 8 ounce 7330-00-248-1153 3

Fork, Food Preparation, 21 inch 7340-00-233-7792 2

Fork, Food Preparation, 15 inch 7340-00-223-7791 2

Spoon, Food Service, Slotted 7340-00-205-1421 8

Spoon, Food Service, 15 inch 7340-00-240-7080 8

Beverage Dispenser 500LCD, Coffee Beige 157 4

Insulated Food Container UPCSS160, Coffee Beige 157 6

Storage Can, Water, 5 Gallon 7240-00-089-3827 2

BII for Green Battlefield Kitchen

Storage Can, Fuel, 5 gallon 7240-01-337-5269 4

BII for Tan Battlefield Kitchen

Storage Can, Fuel, 5 Gallon 7240-01-337-5268 4

3.2.9. Components of the End Item (COEI): The BK will be equipped with the following COEI in the quantities specified. Note: This list shall be updated to reflect the actual items and quantities in the final production item BK.

Item Name NSN CAGEC QTY

Prep table 4

Drain Hose Assembly 1

Convection Oven 2

Heater Tank 1

Griddle 2

Stove Top 1*

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Tilt Skillet 1*

Refrigerator 1

Hand Wash Cabinet 1

Modular Burner 7

Weapon rack 1

Stair rails 4

Knife block 1

Prep sink 1

Stairs 4

Water supply hose for sinks 1

3 kW Generator 1

Movable Lights TBD

Exhaust fan box TBD

Intake fan box TBD

Ventilation Plenum TDB

*The Battlefield Kitchen will have either two Stove Tops, Two Tilt Skillets, or one of each. The exact appliance distribution will be determined during the developmental phase of the contract.

3.2.10. NSF. The BK system and components shall meet the requirement of

NSF/ANSI 2.

3.3. SYSTEMS

3.3.1. Fuel system: The BK shall have a fuel systems to provide fuel for the modular appliances. The fuel system shall utilize the army standard 5 gallon fuel can, NSN 7240-

01-337-5269, as the fuel containers. The system shall consist of the fuel storage containers, fuel lines and fitting and fuel can adapters to connect the fuel lines to the fuel cans. The fuel can adapters shall be designed in such a way as to allow filling of the fuel cans without removing the fuel can adapters or disconnecting fuel lines or interrupting the supply of fuel to the modular appliances. The BK shall have a 3 to 1 ratio of burners to fuel containers. Maximum lift from the bottom of the fuel can to the level of the kitchen floor (bottom of the appliance base) shall be no more than the 18 inches. Fuel shall be automatically drawn from the fuel cans and distributed to the appliances in a continuous process.

3.3.2. Water System:

3.3.2.1. Potable water system: The BK shall be capable of drawing potable water from external water storage vessels through a standard hose bib. The primary water storage vessels will be the 400 gallon water trailer (water buffalo), NSN 2330-01-108-

7367. The BK water system shall use a 50 foot water hose designed for potable water to transport water from the storage vessel to the BK. The connection on the BK can be through an intermediate water system or directly to the hand wash sink. The requirements for maximum lift are provided in the PPD for the modular appliance sink.

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3.3.2.2. Waste Water system. The BK shall have a waste water system to transport waste water from the BK to the Food Sanitation Center (FSC), NSN 7360-01-277-2558.

The waste water system shall consist of all components beginning at the outlet of the

Modular Hand Wash Cabinet and terminating at the connection to the Food Sanitation

Center. The waste water system will be gravity feed and no pumping will be required of the BK system. The transfer hose from the BK to the FSC shall be 50 feet in length and

1.25 inch nominal diameter.

3.3.3. Ventilation System:

3.3.3.1. Main Exhaust System: The ventilation system shall have an exhaust system to expel products of combustion and cooking effluent generated by the modular appliances at the source (each appliance). The main exhaust system shall have a minimum capacity of 150 cubic feet per linear foot of vent hood in addition to the air flow necessary to vent the modular ovens.

3.3.3.2. Make-up air: The ventilation system shall have a make-up air system capable of introducing fresh, filtered air at a rate at least 10% greater than the exhaust system. Make up air shall be filtered to remove sand and dust to an acceptable level, see

3.7.4. The make-up air system shall be capable of tempering the make-up air in cold conditions. There shall be a user operable control to allow the operator to select the level of tempering. The heat of the exhaust air may be used to temper the makeup air.

3.3.3.3. Heater Tank exhaust: The ventilation system shall include the necessary components to expel the combustion exhaust gases from the Heater Tank. This system may be independent of the other ventilation system components.

3.3.4. Lighting System:

3.3.4.1. White Light: The BK shall have lighting system shall provide a minimum of

50 foot-candles on all working surfaces and cooking areas in accordance with the requirements of MIL-STD-1472 for Assembly, General, Medium.

3.3.4.2. Blackout Light: The BK shall have blackout lighting for night time operations. The blackout lights shall be red light (greater than 620 nm). Under blackout lighting conditions, the BK shall not be visible due to leakage of the BK lighting to the naked eye at a distance of 100 m.

3.3.5. Modular Appliances Interface: The BK shall have interface provisions for the modular appliances. Interfaces shall include electrical, fuel, ventilation, and lock down in both travel and operational configuration.

3.3.5.1. Appliance Suite: Unless otherwise specified in the contract, the BK shall contain and have following Modular appliances suite as defined in the PPD for Modular

Appliances FSC-001:

Two Modular ovens (P/N TBD)

Two Modular Griddles with vent hood (P/N TBD)

One Tilt Skillet with vent hood (P/N TBD)

One Stove Top module with vent hood (P/N TBD)

One Heater Tank line (P/N TBD)

One Modular Refrigerator (P/N TBD)

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One Modular Hand Wash Sink (P/N TBD)

3.3.6. Electrical System:

3.3.6.1. Internal Power. The BK electrical power shall be provided by the Standard

Army 3 kW TQG, NSN 6115-01-285-3012, or its successor, as specified in the contract.

The generator shall be part of the BK system and shall be transported on board the BK trailer.

3.3.6.2. External Power. The BK shall be capable of operating from external tactical and commercial power sources (foreign and domestic). The BK shall have an input connector compatible with Cable, pigtail, 4ft, 40/60 amp, NSN 6150-01-256-6301.

3.3.6.3. Foreign power. All components within the BK shall be capable of operating on 50 or 60 Hz, 120 VAC power supplies.

3.3.6.4. Sanitation Center Interface. The BK shall be equipped with an auxiliary outlet compatible with a standard 5-15P connector to provide power to the Food

Sanitation Center. The auxiliary outlet shall be designed for a maximum 15 amp power draw. The FSC power requirement is 780 watts. The auxiliary connector for the Food

Sanitation Center shall be accessible from the BK exterior. The cable connected to the outlet shall not interfere with BK internal operations.

3.3.7. Meal Holding and Serving System:

3.3.7.1. Hot Hold: The BK shall have hot hold capacity with the minimum capacity equivalent to the capacity of one modular oven to include sheet pans and serving pans.

Hot hold capacity shall be maximized within the space constraints of the BK. Holding cabinets shall be compatible with full sized hotel pans and ½ sized sheet pans. See 6.2 for additional information.

3.3.7.2. On-board Meal Service: The BK layout shall accommodate a serving line such that customers can be served within the shelter of the BK kitchen. The serving line shall be segregated from the meal preparation and cooking area. The serving line shall consist of the modular Heater Tank and at least one table. The serving line shall have a sneeze guard to protect the food during meal service. The serving line shall provide a walk space a minimum of 36 inches wide with no more than one 90 degree turn for customers.

3.3.7.3. Remote Serving. The BK shall have a means to pass food that is loaded into the Insulated Food Containers (IFC) from the kitchen to personnel outside the BK at ground level without carrying the containers down the stairs. This pass through shall also be available to load items onto the BK without carrying them up the stairs.

3.4. TRANSPORTABILITY

3.4.1. Transportability Configuration: All equipment necessary for the BK to perform its cooking function and meet the terms of this specification shall be storable within the

BK in its transportation configuration. The BK shall meet all the terms of transportability without damage to the BK, its systems or components. The BK shall meet the requirement for being towed on U.S. and European roadways without special

P a g e 8 | 25 considerations. The maximum width of the Battlefield Kitchen in transportation configuration shall be 8 feet.

3.4.1.1. Generator deployment. The generator shall be transported within the envelope of the BK but shall be located external to the BK envelop for operations. The generator shall not require lifting by the crew for normal deployment or packout.

3.4.2. System deployment and pack out: Once the BK platform is level, it shall take no more than 30 minutes for its crew consisting of four soldiers and one supervisor to have the kitchen ready to start meal preparation. Once all cooking equipment has reached a safe temperature, it shall take no more than 30 minutes to prepare the BK for travel.

3.4.3. Overland Transit: The prime mover of the BK is the Light Medium Tactical

Vehicle (LMTV) which has a rated tow capacity of 12,000 pounds. In its travel configuration, the BK shall be capable of being towed over highway, gravel road, and cross country terrain by the LMTV and other vehicles capable of towing the BK weight and pintle configuration. The BK shall not exceed 96% of the rated tow capacity of the

LMTV.

3.4.4. Internal Air transit: The BK shall be air transportable on C-130 and larger fixed wing aircraft. Air transport must be without restrictions or special clearances. The BK shall not require shoring during loading or unloading procedure. Maximum height of the

BK in transportation configuration shall be 96 inches.

3.4.5. External Air Transit: The BK shall be sling load transportable by current and future Joint Service Aircraft capable of lifting the BKs weight.

3.4.6. Rail Transit: The BK shall have appropriate tie down provisions and shall be capable of being transported by rail.

3.5. ENVIRONMENTAL

3.5.1. Temperature Range: The BK shall be capable of performing all functions throughout the ambient temperature range of -25°F to 125°F.

3.5.1.1. Low Temperature. The BK shall have an integral system to heat the BK kitchen environment to a minimum average temperature of 50°F during operation with ambient temperatures as low as 20°F. In addition to the integral system, supplemental heating interfaces shall be provided to allow for heating of the BK using an external heater for temperatures down to -25°F. The BK shall be capable of withstanding storage temperatures as low as -60°F. After returning from low temperature storage to the BK operating range (above -25°F), the system shall be fully operational without permanent set or loss of resiliency of components, discoloring, cracking, or bulging of any component.

3.5.1.2. High Temperature. In ambient temperatures above 70°F, the average temperature inside the BK shall not exceed 10°F higher than ambient during normal cooking operations. The BK shall be capable of withstanding storage temperatures as high as 160ºF. After returning from high temperature storage to the BK operating range

(below +125°F), the system shall be fully operational without permanent set or loss of resiliency of components, discoloring, cracking, or bulging of any component.

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3.5.2. Altitude: The BK shall meet all the terms of this specification while operating at altitudes up to 8,000 feet above sea level.

3.5.3. Blowing Rain: The BK shall be fully mission capable when exposed to rain at a rate of 4 inches/hour and a wind speed of 40 mph.

3.5.4. Steady and Gusting Wind: The BK in its operational configuration shall be designed to withstand steady winds of 55 mph and gusting winds to 65 mph without damage.

3.5.5. Snow loading: The BK shall be designed to withstand snow loading of 10 pounds per square foot in operational configuration and 40 pounds per square foot in transportation configuration.

3.5.6. Fungus: The BK shall be designed to resist fungus growth in all environmental conditions.

3.5.7. Corrosion: The BK shall be designed to resist corrosion. The BK shall be designed to meet the requirement of MIL-STD-872, salt fog test.

3.5.8. Humidity: The BK shall be capable of operating in humidity conditions from

5% to 100%, AR-70-38, 15 September 1979, with no more than 20% degradation to basic capabilities.

3.5.9. Conducted Emissions: The BK shall meet the conducted emissions requirements of MIL-STD-461: CE102, figure CE102-1 limit, 10 kHz to 10 MHz, power leads conducted emissions

3.5.10. Radiated Emissions: The BK shall meet the radiated emissions requirements of MIL-STD-461: RE102, figure RE102-4, 2 MHz to 1 GHz, case and cables radiated emissions.

3.6. OWNERSHIP AND LOGISTICS

3.6.1. Reliability: The BK shall have a Mean Time Between Hardware Essential

Function Failure (MTBEFF) of not less than 390 hours. The BK shall have a Mean Time

Between System Abort of 660 hours.

3.6.2. Maintainability: The BK shall have a mean time to repair of no greater than 1 hour. And the field level maintenance ratio shall not exceed 0.025 maintenance man hours per operating hour.

3.6.3. Operator Maintenance Tools: All tools necessary to perform operator maintenance shall be provided with the BK. There shall be a storage location within the

BK to house the operator maintenance tool kit. This storage are shall be securable with a padlock that has a minimum hasp diameter of ¼ inch.

3.6.4. Cleanability: The BK and its components, shall be cleaned with commonly available cleaning supplies and water. Procedures for cleaning the kitchen shall be provided and detailed in the operator’s manual, using commonly available cleaning supplies.

3.6.5. Labels:

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3.6.5.1. Use Placard. The BK shall have replaceable, durable placards to aid and instruct the operators in the set up and pack out of the BK equipment. These placards shall be located in an easily accessible and visible location while setting up and packing out the BK. They shall indicate the correct positions of all the BK components in the transportation and operational configurations.

3.6.5.2. Data plate: The BK shall have a data plate located on the solid wall of the

BK easily readable from someone standing at ground level. The data plate shall contain the following information:

Contract Number

Name of Manufacturer

Date of Manufacture

UID number

UID barcode

Part number

NSN

System Weight

3.6.6. Colors. The BK shall be either green 383, # 34904 or tan, #33446 as per FED-

STD-595. When the Battlefield Kitchen is set up in transportation and operation configuration, all visible surfaces shall be matching color. The color or each individual

Battlefield Kitchen shall be specified in the delivery order. All metal surfaces shall be prepared, primed, and painted with non-toxic CARC complying with MIL-C-53039. The

5 gallon fuel containers shall also be color coordinated with the kitchen in accordance with 3.2.8. Basic Issue Items.

3.7. SAFETY:

3.7.1. Health Hazards. The BK system shall be designed to minimize danger of hazards to the operators and maintainers. Damage to safeguards shall be easily noticeable by operators and maintainers. Health Hazards shall be limited 3D, 3E, or 4B through 4E or any hazard with an F probability accordance with the Risk Assessment matrix in MIL-STD-882E.

3.7.2. Noise: Noise exposure to operators shall not exceed 80 decibels (dBA) during normal operations.

3.7.3. Surface Temperatures. As much as practical for a kitchen, surfaces shall be designed to prevent burns to operators. Proper warning labels shall be used to mitigate hazard.

3.7.4. Sand and Dust infiltration: Sand and dust inside the BK work environment shall not exceed 50 Million Particles per Cubic Feet or 15 Milligram per Cubic Meter as set forth in OSHA standard 29 CRF.

3.7.5. Camouflage systems: The BK shall be capable of being camouflaged using standard army camouflage systems. Camouflage will not be part of the BK.

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3.7.6. Ballistic Protection (Optional). The BK shall be capable of having ballistic protection installed during static operation. The BK will not be required to transport ballistic protection.

3.8. COMPLEXING KITCHENS: The BK shall be designed to allow two or more BKs to be coupled together. The coupling can be either back to back or front to back. There shall be a means for personnel to move between BKs that are coupled without exiting the kitchen complex.

3.9. DISMOUNTED OPERATION: The BK components shall be designed in such a way that they may be easily removed from the BK platform and reconfigured at a remote location (e.g. inside a hard shelter or other structure). As much as practical, equipment organic to the BK shall be used for dismounted operation with a minimum of additional equipment. Additional equipment required for dismounted operation shall be part of the

BK system as Additionally Authorized Items (AAI), see 3.9.1. The dismounted equipment shall be configurable as follows: 1) Dismounted as a complete suite, 2) One-half suite (two vent hooded appliances, one oven and the Heater Tank), or 3) any single appliance. The dismounted ventilation system shall be capable of exhausting all exhaust

(cooking and combustion) from the appliances through a flexible 6 inch duct a minimum of 10 feet as measured from the exhaust exit (window or other exhaust point of the room) to the closest appliance in the suite chain.

3.9.1. Additional Components. Any component that is part of the dismounted system but not required for mounted operation is not required to be transported within the BK and shall be part of a separate dismounted kit. Equipment or components necessary for dismounted operation that are not part of the basic BK system shall be included in the

TM as Additional Authorized Items (AAI). These items will not be part of the BK packout.

3.9.2. Lifting Requirements. For the purposes of downloading BK items for operation, all equipment on the BK shall meet the lifting requirements of MI-STD-1472 for 5th through 95th percentile personnel for four, two, or one man portability (male and female population). The exceptions to this are limited to the oven module, generator, and heater tank. The oven, generator, and heater tank shall meet the requirements of 4 man

(male population) lift.

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.

4.2. VERIFICATION METHODS.

Requirement Title Verification

3.2 GENERAL REQUIREMENTS 4.3

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3.2.1 Meal Preparation 4.3.1

3.2.2 BK Trailer 4.3.2

3.2.3 Platform Expansion 4.3.3

3.2.4 Work Surfaces 4.3.4

3.2.5 Work Tables 4.3.5

3.2.6 MOPP II 4.3.6

3.2.7 Layout 4.3.7

3.2.8 Basic Issue Items 4.3.8

3.2.9 Components of the End Item 4.3.9

3.2.10 NSF 4.3.10

3.3 SYSTEMS 4.4

3.3.1. Fuel System 4.4.1

3.3.2 Water System 4.4.2

3.3.2.1 Potable Water System 4.4.2.1

3.3.2.2 Waste Water System 4.4.2.2

3.3.3 Ventilation System 4.4.3

3.3.3.1 Main Exhaust System 4.4.3.1

3.3.3.2 Make-up Air 4.4.3.3

3.3.3.3 Heater Tank Exhaust 4.4.3.4

3.3.4 Lighting System 4.4.4

3.3.4.1 White Light 4.4.4.1

3.3.4.2 Blackout Light 4.4.4.2

3.3.5 Modular Appliance Interface 4.4.5

3.3.5.1 Modular Appliance Suite 4.4.5.1

3.3.6 Electrical System 4.4.6

3.3.6.1 Internal Power 4.4.6.1

3.3.6.2 External Power 4.4.6.2

3.3.6.3 Foreign Power 4.4.6.3

3.3.6.4 Food Sanitation Center Interface 4.4.6.4

3.3.7 Meal Holding and Serving 4.4.7

3.3.7.1 Hot Hold 4.4.7.1

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3.3.7.2 On-Board Meal Service 4.4.7.2

3.3.7.3 Remote Serving 4.4.7.3

3.4 TRANSPORTABILITY 4.5

3.4.1 Transportability Configuration 4.5.1

3.4.1.1 Generator Deployment 4.5.1.1

3.4.2 System Deployment and Pack Out 4.5.2

3.4.3 Overland Transit 4.5.3

3.4.4 Internal Air Transit 4.5.4

3.4.5 External Air Transit 4.5.5

3.4.6 Rail Transit 4.5.6

3.5 ENVIRONMENTAL 4.6

3.5.1 Temperature Range 4.6.1

3.5.1.1 Low Temperature 4.6.1.1

3.5.1.2 High Temperature 4.6.1.2

3.5.2 Altitude 4.6.2

3.5.3 Blowing Rain 4.6.3

3.5.4 Steady and Gusting Wind 4.6.4

3.5.5 Snow Loading 4.6.5

3.5.6 Fungus 4.6.6

3.5.7 Corrosion 4.6.7

3.5.8 Humidity 4.6.8

3.5.9 Conducted Emissions 4.6.9

3.5.10 Radiated Emissions 4.6.10

3.6 OWNERSHIP AND LOGISTICS 4.7

3.6.1 Reliability 4.7.1

3.6.2 Maintainability 4.7.2

3.6.3 Operator Maintenance Tools 4.7.3

3.6.4 Cleanability 4.7.4

3.6.5 Labels 4.7.5

3.6.5.1 Use Placard 4.7.5.1

3.6.5.2 Data Plate 4.7.5.2

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3.6.6 Colors 4.7.6

Tan 4.7.6.1

Green 4.7.6.2

3.7 SAFETY 4.8

3.7.1 Health Hazards 4.8.1

3.7.2 Noise 4.8.2

3.7.3 Surface Temperatures 4.8.3

3.7.4 Sand and Dust Infiltration 4.8.4

3.7.5 Camouflage Systems 4.8.5

3.7.6 Ballistic Protection (optional) 4.8.6

3.8 COMPLEXING KITCHENS 4.9

3.9 DISMOUNTED OPERATION 4.10

3.9.1 Additional Components 4.10.1

3.9.2 Lifting Requirements 4.10.2

4.3. GENERAL REQUIREMENTS

4.3.1. Meal Preparation.

4.3.2. BK Trailer. Verify that the BK trailer is the M1061A1 trailer and that it is manufactured in accordance with the M1061A1 trailer technical data or an approved variant.

4.3.3. Platform Expansion. Verify that the BK can be expanded beyond its travel configuration. Verify that both eight foot sides and at least one 14 foot call can be expanded at least 4 feet. Allowances shall be made for corner support posts and the mounting of the fabric walls. The inability to sufficiently expand the BK floor space shall constitute a failure.

4.3.4. Work Surfaces. Verify that there is a work surface within 48 inches of each appliance. A work surface shall be no less than 24 inches by 24 inches of flat surface area. The distance shall be measured as the shortest distance between the two components at the work surface level (36 inches above floor level).

4.3.5. Work Tables. Verify that there are a minimum of four folding work tables as part of the BK system. Verify that each table has individually adjustable legs for use on uneven surfaces. Each leg shall be adjustable between 30 and 42 inches with a maximum of 1 inch between adjustments. Verify that the table top is compliant with NSF for a food contact surface. Less than four tables shall constitute a failure. Non-compliance with

NSF food contact surface definition for the table top shall constitute a failure.

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4.3.6. Mission Oriented Protective Posture (MOPP) II. Verify the ability to set up, strike, operate the kitchen, and perform all operator maintenance tasks with the operators wearing MOPP II gear. Inability to perform any operational or maintenance task as a result of wearing MOPP II gear shall constitute a failure.

4.3.7. Layout. Verify layout matches the final approved layout of the Battlefield

Kitchen as determined by the Critical Design Review. The layout depicted in figure 1 of section 3 shall be the baseline layout. Changes to this layout may be implemented in order to improve the overall functionality or requirements of the BK. Deviation from the approved layout shall constitute a failure.

4.3.8. Basic Issue Items. Verify all items on the Basic Issue Item list are present and in new condition. Missing, damaged, or worn items shall constitute a failure.

4.3.9. Components of the End Item. Verify that all items on the Components of the

End Items are present and in new condition. Missing, damaged, or worn items shall constitute a failure.

4.3.10. NSF. Verify that the kitchen meets the requirement for NSF/ANSI 2 by inspecting equipment based on NSF/ANSI 2 design requirements. Non-conforming components, designs, or materials shall constitute a failure.

4.4. SYSTEMS

4.4.1. Fuel System. Verify the fuel system can provide fuel to all modular appliances.

Operate all modular appliances at their maximum heat output for 30 minutes. Verify that the fuel system provides sufficient flow to maintain burner operation. Inability to provide sufficient fuel flow shall constitute a failure. Inability to interface with the modular appliances shall constitute a failure. Verify that the fuel system fuel container is the standard 5 gallon fuel can. Verify that there is at least one fuel container for every three appliances. Non-conforming fuel containers shall constitute a failure. Insufficient fuel container to appliance ratio shall constitute a failure. Verify that the fuel containers can be filled while the modular appliances are operating. Inability to maintain uninterrupted appliance operation during fueling shall constitute a failure. Measure the required fuel lift. Measure the distance from the bottom of the fuel cans in their operational position to the surface of the BK floor. A measurement greater than 18 inches shall constitute a failure.

4.4.2. Water System.

4.4.2.1. Potable Water System. Verify compatibility with a standard hose bib by connecting the COEI water supply hose to the inlet on the Battlefield Kitchen. Operate the water system and verify that it supplies water at the required flow rate. Inability to provide water to the hand wash sink shall constitute a failure.

4.4.2.2. Waste Water System. Verify the presence of all components necessary to connect the BK drainage system to the Food Sanitation Center. Verify that the components of the waste water system interface with the Hand Wash cabinet. Verify the length and diameter of the drain hose. Missing, damaged, or worn components shall constitute a failure. Inability to connect all components into a working system shall constitute a failure. Incorrect length or diameter shall constitute a failure.

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4.4.3. Ventilation System.

4.4.3.1. Main Exhaust System. With the burners not operating, measure the airspeed and cross-section area at an appropriate location in the system. Calculate the airflow in cubic feet per minute. Verify that the calculated airflow exceeds that required in accordance with 3.3.3.1. A calculated airflow below the required rate shall constitute a failure.

4.4.3.2. Make-up Air. Measure the make-up air velocity and cross-sectional area at an appropriate location in the system. Calculate the airflow in cubic feet per minute.

Verify that the calculated airflow exceeds that required in accordance with 3.3.3.2. A calculated airflow below the required rate shall constitute a failure.

4.4.3.3. Heater Tank Exhaust. With the Heater Tank burner operating, measure the velocity and cross-sectional area of the Heater Tank exhaust at an appropriate location.

Calculate the airflow of the exhaust system. Verify that the flow rate is at least equivalent to the burner manufacturers’ recommendation. A calculated air flow less than required shall constitute a failure.

4.4.4. Lighting System.

4.4.4.1. White Light. Measure the lighting on all work surfaces, in the center of the heater tank, griddles, stove tops, tilt skillets, and in front of the ovens, one foot from the door and three feet from the ground level. All measurements shall be taken with the operator in their normal working position at that station. A measurement less than 50 foot-candles shall constitute a failure.

4.4.4.2. Blackout Light. Set up the BK in accordance with the Operator’s TM. The test area must be capable of accommodating the deployed test item with no visual obstructions within a 100 m radius.

4.4.4.2.1. Deploy markers around the circumference of the 100 m radius circle at

45 degree increments.

4.4.4.2.2. Blackout testing shall be conducted on a moonless night after astronomical twilight. Moon rise/set and astronomical twilight hours are obtained from

Naval Meteorology and Oceanography Command official website:

http://aa.usno.navy.mil/data/docs/RS_OneYear.php.

4.4.4.2.3. Energize the blackout lighting system.

4.4.4.2.4. Five observers will first be dark adapted by staying in a completely dark area until instructed by test personnel to commence testing, but no less than 30 minutes.

If observers’ sight becomes compromised from exposure to a light source they must be re-adapted for an additional 30 minutes.

4.4.4.2.5. Following dark adaptation, conduct baseline light detection test for each observer. Starting at the zero marker at 100 m, when instructed, each of the five observers shall observe low intensity light source emitted outside the test item. Light source could be blackout light from an HMMWV or any other low intensity or blackout light available.

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4.4.4.2.6. The observers will stand at different 45 degree markers. Each of the five observers will view the test item with the naked eye from that marker. Each observer trial will be under two conditions, one with the light inside the test item turned on and one with the light turned off. After each trial, the observers will rotate to the next 45 degree marker. This will be repeated until each observer has been to each position or the eight positions.

4.4.4.2.7. Test personnel will record whether they see light leakage or not at each marker for the two conditions.

4.4.4.2.8. Observance of light shall constitute a failure.

4.4.4.2.9. Measure red light wavelength of the blackout lighting. A measurement less than 620 nm shall constitute a failure.

4.4.5. Modular Appliance Interface. Verify presence and operation of all interface

(electrical, fuel, ventilation, and base lock-down). Verify lock down interfaces in both operational and travel configuration. Inability to properly interface with modular appliances that causes a loss of function or inability to meet any requirement of this document shall constitute a failure.

4.4.5.1. Modular Appliance Suite. Verify the presence in the correct quantities of modular appliances. Missing, damaged, or worn components shall constitute a failure.

4.4.6. Electrical System.

4.4.6.1. Internal Power. Verify the presence of the 3 kW TQG or successor generator and operation of the BK system on generator power. This requirement shall be further evaluated during the reliability and operational testing. Inability of the 3 kW generator to provide sufficient power for all operational scenarios shall constitute a failure.

4.4.6.2. External Power. Verify the presence of input connector compatible with

40/60 amp pigtail, NSN 6150-01-256-6301 or equivalent connector. Energize external power connector with appropriate external power. Inability for all systems to function normally for all operational scenarios shall constitute a failure.

4.4.6.3. Foreign Power. Operate the kitchen using the external power interface on

120 VAC 50 Hz power for a 4 hour period. Operate all electrical component at the maximum settings (if applicable). Place loads on appliances that will require the appliances to operate at maximum settings. Verify that all electrical components of the

BK operate properly and meet all functional requirement while operating on 50 Hz power. Inability to properly function on 50 Hz power shall constitute a failure. Damage to any electrical component as a result of operating on 50 Hz power shall constitute a failure.

4.4.6.4. Food Sanitation Center Interface. Verify presence of auxiliary electrical connector for the sanitation center. Verify that the use of the FSC in conjunction with the

BK does not cause a failure or inability to meet all functional requirements of either system.

4.4.7. Meal Holding and Serving

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4.4.7.1. Hot Hold. Verify the presence and capacity of hot hold cabinet(s). Inability to hold at least 9 half sized sheet pans on 3.25 inch and four (not simultaneously) full sized six inch deep serving pans shall constitute a failure. Verify the ability to hold hot food above 140°F for a minimum of four hours. Maintain the ambient temperature less than 80ºF. Place one, six inch deep steam table pan in the hot hold cabinet with two inches of 200°F water. Monitor water temperature for four hours. Inability to hold the water temperature above 190°F shall constitute a failure.

4.4.7.2. On-Board Meal Service. Verify the presence of the Heater Tank and at least one table. Verify that both customers and servers have access to the full length of both the Heater Tank and the Table (from opposite sides). Performance of the Heater Tank shall be verified separately. Verify the presence of sneeze guard. Verify that isle for customers is a minimum of 36 inches wide. Verify the serving line aisle has no more than one 90 degree turn within the kitchen. Inability for the server to access the full length of the table and Heater Tank shall constitute a failure. Inability for the customer to access the full length of the table and Heater Tank shall constitute a failure. Requiring the customer to make more than one 90 degree turn within the kitchen shall constitute a failure.

4.4.7.3. Remote Serving. Verify a means to place an IFC and other comparably sized items from inside the BK to outside the BK without carrying them down the stairs.

Verify the ability to pass IFCs and other comparably sized items from outside the BK to inside the BK without carrying them up the stairs. Not having a pass through of appropriate size shall constitute a failure.

4.5. TRANSPORTABILITY

4.5.1. Transportability Configuration. Verify that all components required for BK operation can be packed up within the envelope of the BK. During reliability and transit tests verify that the components of the BK do not suffer damage as a result of the pack out configuration. Inability to fit all BK components within the BK for transportation shall constitute a failure. Damage to items during transit testing shall constitute a failure.

4.5.1.1. Generator Deployment. Verify that the Generator fits within the BK envelop for transportation. Verify the Generator can be moved to its operational position with lifting by operators. Verify that in the operational configuration, there is a partition capable of suppressing noise and blocking combustion emissions from entering the kitchen. Inability to fit the generator within the BK during pack out shall constitute a failure. Inability to deploy the Generator for operation without lifting by personnel shall constitute a failure. Lack of presence of partition separating the generator from the kitchen shall constitute a failure. (Noise and air quality will be evaluated under a separate test).

4.5.2. System Deployment and Pack Out. Set up the BK on a level surface with the platform level. After training of army personnel of the appropriate Military Occupational

Specialty (MOS) in the deployment and pack out, the military personnel with set up the

BK for operation. Record the time required to set up the kitchen. Have the same crew pack out the kitchen and record the time required. A time in excess of 30 minutes to deploy or pack out the kitchen shall require a retest. A time of 30 minutes or less for

P a g e 19 | 25 either deployment or pack out shall constitute a success for that leg of the test and that leg will not require further test. Additional instruction and attempts may be repeated as necessary until it becomes obvious that the requirement will not be met.

4.5.3. Overland Transit. Verify the weight and pintle loading of the BK. A weight greater than 11,520 pounds shall constitute a failure. A pintle load outside the limits for the LMTV at the gross weight shall constitute a failure. The BK shall be configured for travel and subjected 3,000 miles of road course simulating 30% primary roads, 55% secondary roads, and 10% trail and 5% cross country travel. After every 500 miles of ground mobility testing, the BK shall be set up and inspect for damage. Verify all components are operational. After the completion of the 3,000 miles, the BK shall be set up and all equipment shall be set up and tested for operation.

4.5.4. Internal Air Transit. Verify the weight of the BK configured for transportation.

If the gross weight of the BK is greater than 10,000 pounds, the BK meets the MIL-STD-

1791 definition of a potential problem in such case, BK shall be reviewed by ATTLA to determine if air lift certification is required. If ATTLA determines certification is required, the BK shall be certified for Internal Air Transport.

4.5.5. Sling Load. Verify BK, in transportation configuration, meet the requirements of MIL-STD-209 for external air transport using a rotary wing aircraft capable of lifting

12,000 pounds minimum. The BK shall be certified for External Air Transport in accordance with MIL-STD-913.

4.5.6. Rail Transit. Verify Tie down provisions in accordance with MIL-STD-209.

Inspect BK for damage prior to test and note damage. Perform rail hump test in accordance with MIL-STD-810, Method 526. After execution of rail hump test, set up the BK and verify functionality of all components. Inspect for damage to components.

Damage to the system or component of the system as a result of the rail hump test shall constitute a failure.

4.6. ENVIRONMENTAL

4.6.1. Temperature Range.

4.6.1.1. Low Temperature. The BK shall be tested for low temperature storage (-

60ºF), operation (-25ºF), and manipulation (-25°F) in accordance with MIL-STD-810, method 502.4.

4.6.1.2. High Temperature. The BK shall be tested for high temperature storage

(160ºF), operation (125°F), and manipulation (125ºF) in accordance with MIL-STD-

810F, method 501.4.

4.6.2. Altitude. The BK shall be tested for high altitude operation (8,000 feet) in accordance with MIL-STD-810F, method 500.4.

4.6.3. Blowing Rain. The BK in its operational configuration shall be tested for blowing rain at a rate of 4 inches per hour and a wind speed of 30 mph in accordance with MIL-STD-810F, method 506.4.

4.6.4. Steady and Gusting Wind.

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4.6.4.1. Erect the BK in accordance with the TM. Position the wind machine perpendicular to the side of the shelter that will be tested at a distance appropriate to achieve the desired wind speed.

4.6.4.2. In turn, subject each of the four sides of the BK to 55 mph winds for 30 minutes. Within each 30 minute trail, increase wind speed to 65 mph for 10 seconds three times.

4.6.4.3. Repeat above procedure directed at the four corners of the BK (45 degrees to the previous fan positions).

4.6.4.4. Damage to structure or fabric as a result of the test shall constitute a failure.

4.6.5. Snow Loading. The projected area of the roof will be used to determine total load.

4.6.5.1. Operational Configuration. The roof snow load criterion of 49 kg/m2 (10 lb/ft2) is equivalent to a depth of 0.5 m (20 in.) of snow with a specific gravity of 0.1 and represents a snowfall of less than 24 hours. The projected area is anticipated to be 232 square feet resulting in a snow load weight of 2320 pounds. The BK must withstand a snow load for 12 hours.

4.6.5.2. Erect the test item in accordance with the Operator’s TM.

4.6.5.3. Measure and record the roof height at various set points to include structural and fabric sections.

4.6.5.4. Gradually apply the load to the roof area. Record any damage sustained during loading.

4.6.5.5. Measure the roof height at the set points. Allow the shelter to rest for 12 hours.

4.6.5.6. Measure the roof height at the set points.

4.6.5.7. Gradually remove the simulated snow load from the shelter.

4.6.5.8. Inspect BK: Record evidence of structural damage, seam separation, or fabric damage.

4.6.5.9. Calculate deflection at set points relative to the initial measurements.

Determine if there is permanent deformation of any frame member (final height less than initial height).

4.6.5.10. Permanent deformation of frame or roof member shall constitute a failure.

Torn seams or fabric damage shall constitute a failure.

4.6.5.11. Transportation Configuration. The BK shall be tested to 40 pounds per square foot projected roof area, a total of 4,480 pounds in its transportation configuration.

4.6.5.12. Gradually apply the load to the roof area. Record any damage sustained during loading. Allow the load to sit for 5 minutes.

4.6.5.13. Remove the load and inspect the exterior roof. Damage to roof shall constitute a failure.

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4.6.5.14. Erect the BK.

4.6.5.15. Damage that prevents erecting of BK structure shall constitute a failure.

4.6.5.16. Inspect BK interior. Damage to interior of the roof structure shall constitute a failure.

4.6.6. Fungus. Test samples of the BK fabric and other relevant materials in accordance with MIL-STD-810F, test method 508.5, 28 day duration, both US and

European species.

4.6.7. Corrosion. The BK shall be subjected to the salt fog test in it operational configuration in accordance with MIL-STD-801F, Method 509.4, standard exposure.

4.6.8. Humidity. The BK shall be subjected to the Humidity test in accordance with

MIL-STD-810F, Method 507.4 in its operational configuration. The test shall consist of ten, 24 hour cycles. After the fifth cycle, verify that all equipment is still functional.

Repeat functional verification after the tenth cycle.

4.6.9. Conducted Emissions. The BK shall be tested in accordance with MIL-STD-

461, CE-102 for conducted emissions.

4.6.10. Radiated Emissions. The BK shall be tested in accordance with MIL-STD-

461, RE 102.

4.7. OWNERSHIP AND LOGISTICS

4.7.1. Reliability. The Battlefield Kitchen (BK) shall demonstrate a minimum reliability of at least 430 hours Mean Time Between Hardware Essential Function Failure

(MTBHEFF) and a Mean Time Between Hardware System Abort (MTBHSA) of at least

730 hours. The contractor shall furnish information (e.g. test data, modeling and simulation data, accelerated life test data, reliability enhancement test data, RAM model based predictions etc.) to demonstrate the BK will meet or exceed the reliability requirement prior to commencement of Government testing. For the purposes of demonstration of these requirements, testing will be conducted (as applicable) consistent with Operational Mode Summary and Mission Profile (OMSMP). Also, demonstration of these requirements in testing shall include all components of the system with the exception of the Government furnished generator. A hardware essential function failure is defined as any contractor furnished (or modified) equipment failure that results in the loss of a mission essential function as defined in Attachment D-1 Failure Definition and

Scoring Criteria (FDSC). Examples of essential function failures (EFF) include, but are not limited to, events which causes the inability of the BK to perform a cooking method, or provide ventilation, lighting, power generation or mobility functions. A hardware system abort is any hardware EFF or combination of hardware EFFs that prevent the BK from producing a scheduled hot meal. Detailed descriptions and explanations of failure categorization are found in the attached FDSC.

4.7.2. Maintainability. Maintenance data, including time required for each scheduled and unscheduled, maintenance or repair action shall be collected during performance of the reliability test. Verify that the BK is capable of having a maintenance ratio no greater than that 0.025 maintenance hours per operational hour. A maintenance ratio greater than

0.025 shall constitute a failure.

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4.7.3. Operator Maintenance Tools. Verify that all tools necessary to perform operator maintenance actions are identified in the TM. Verify that there is a secure and lockable storage box on the BK than can hold the tools necessary to perform operator maintenance.

4.7.4. Cleanability. Verify that the BK and its components can be adequately cleaned following the instructions in the manual. Verify that the unit can be returned to service after being cleaned according to the directions in the operators’ manual.

4.7.5. Labels.

4.7.5.1. Use Placard. Verify the placard(s) contain the required information, is clearly presented, and easy to understand. Verify the font size is no less than 12.

4.7.5.2. Data Plate. Verify the data plate contains the required…