N102-161 TITLE: Flexible Electronic Cooling Water (ECW) Piping Interfaces

TECHNOLOGY AREAS: Ground/Sea Vehicles, Materials/Processes

ACQUISITION PROGRAM: PMS 502, CGX Program, ACAT 1

OBJECTIVE: Explore the development of alternatives to traditional ECW piping system interfaces through the application of novel interface concepts and the use of advanced material solutions to minimize maintenance and life cycle costs, time required and level of effort associated with movement and rearrangement of these shipboard piping systems.

DESCRIPTION: A significant cost component of maintenance and life-cycle costs for hull, mechanical and electrical systems is the need for hot-work when a piece of equipment is moved or rearranged within a space onboard Navy ships. When equipment is moved, associated piping is typically rerouted. This requires new, welded or brazed pipe connections, the installation of new pipe hangers and the cutting, grinding and repainting associated with removal of the existing pipe hangers. The overall process is both time consuming and can be expensive. In addition, this work often requires a full Ship Alteration (SHIPALT), which includes a two year planning period, followed by a three to six month change-out and since it must be accomplished in a shipyard, the availability of the ship is directly affected.

This topic seeks to explore the development of innovative, non-traditional concepts to enable flexibility in the installation, relocation or re-routing of ECW piping runs in an attempt to reduce labor and material costs typically associated with these types of changes. Total escalated life-cycle cost of a conventional ECW System is estimated at over $4 Million. Across multiple compartments within one ship and considering entire classes of ships, the cost savings could be significant. Proposed concepts will be required to meet existing Navy shock qualifications for piping (see references). Meeting these shock requirements represents the most significant challenge associated with designing a shipboard, flexible piping solution.

Proposed concepts should eliminate the need for hot work (welding, brazing, cutting and grinding) while meeting all referenced shipboard standards and requirements (see references below). In addition, concepts should eliminate the need for a SHIPALT by removing the need for hot work (welding, brazing, cutting and grinding) and causing minimal disruption to the ship. The concepts should allow this work to be performed via Equipment Alteration (Machinery Alterations, Field Changes, etc), which do not require the extensive planning and change-out period associated with and are less expensive than SHIPALTs. In addition, by performing piping change-outs via Equipment Alteration vice SHIPALTs, the ship�s availability is increased since it does not have to return to a shipyard for this work to be performed. Proposed concepts should focus on electronic cooling water piping applications. Current shipboard pipe sizes range from a 2 inch main to a � inch supply line. The temperature range for this piping is from 40 to 105 degrees Fahrenheit and the pressure range is from 10 to 150 lb/sq. in. If successful, there is a possibility that the proposed flexible piping solution could be used for potable water piping in the future.

PHASE I: Demonstrate the feasibility of the development of innovative, non-traditional approaches to eliminate the need for welding and/or hot work and meet current Navy standards and requirements. Establish performance goals of the approach. Provide a Phase II development approach and schedule that contains discrete milestones for product development.

PHASE II: Develop a prototype of the proposed Phase I concept(s). In a laboratory environment, validate the performance goals identified in Phase I. Provide manpower, cost-savings and performance metrics. Prepare an implementation and test plan that contains discrete milestones for product development for the purposes of obtaining necessary certifications for shipyard and/or manufacturing sector implementation.

PHASE III: Utilizing the concept(s) developed during Phase I and Phase II, work with Navy and industry to approve and certify the proposed concept for use in Navy applications and then transition this technology to existing and future surface combatant systems.

PRIVATE SECTOR COMMERCIAL POTENTIAL/DUAL-USE APPLICATIONS: The commercial shipping industry may find the same cost reduction benefits in the use of these piping interfaces.

REFERENCES:
The following references are available through ASSIST (https://assist.daps.dla.mil/quicksearch/):
1. MIL-S-901: Grade "A" Shock Testing

2. MIL-STD-167-1: Mechanical Vibrations of Shipboard Equipment

3. MIL-STD-2142: Magnetic Silencing Characteristics

4. MIL-STD-1399-300: Interface Standard for Shipboard Systems, Electric Power Alternating Current (Metric)

5. MIL-STD-1310G: Navy Standard for Grounding

6. MIL-E-16400: General Specification for Electronic, Interior Communication and Navigation Equipment, Naval Ship and Shore

7. MIL-W-21965: General Specification for Water Cooling of Shipboard Electronic Equipment

8. MIL-H-24520: Hose and Hose Assembly for Water Cooling of Electronic Equipment

9. MIL-STD-438: Schedule of Piping, Valves, Fittings and Associated Piping Components for Submarine Service

10. MIL-STD-777: Schedule of Piping Valves, Fittings and Associated Piping Components for Surface Ships

11. Removed at the request of TPOC (4/26/10)

12. Removed at the request of TPOC (4/26/10)

13. Removed at the request of TPOC (4/26/10)

14. Removed at the request of TPOC (4/26/10)

KEYWORDS: electronic cooling water systems; piping; fittings; interfaces; arrangements; open systems;

** TOPIC AUTHOR (TPOC) **

DoD Notice:   Between April 21 and May 19, 2010, you may talk directly with the Topic Authors to ask technical questions about the topics. For reasons of competitive fairness, direct communication between proposers and topic authors is not allowed starting May 19, 2010, when DoD begins accepting proposals for this solicitation.

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