Crane Division, Naval Surface Warfare Center, Code 1162 Bldg 2521, 300 Highway 361, Crane, Indiana 47522-5001

A -- ABRASIVE WATERJET SYSTEM FOR CUTTING THROUGHT THE CASING OF MUNITION ITEMS CONTAINING ENERGETIC MATERIAL, RANGING IN SIZE BETWEEN 20MM TO 120MM FIXED AMMUNITION ITEMS. SOL N00164-99-R-0136 DUE 083099 POC Ms. Ellen Jarosz, Contract Specialist, 812-854-5315, FAX 813-854-3464 (Mr. S. Bingham, Contracting Officer) WEB: Click here to review Crane Division Acquisition Department, http://www.crane.navy.mil. E-MAIL: Click here to contact the Contract Specialist via, jarosz_e@crane.navy.mil. The Crane Division, Naval Surface Warfare Center, in support of the U.S, Army Defense Ammunition Center, Joint Demilitarization Technology Program, is soliciting research proposals using a Broad Agency Announcement (BAA). The BAA is for the demonstration and optimization of an abrasive waterjet system for cutting through the casing of munition items containing energetic material, ranging in size between 20mm to 8" fixed ammunition items. This state-of-the-art system should be capable of remote operation, with hardware and software that is capable of programming the lance for specific cutting operations, and monitoring the water pressure, flow rate and abrasive flow rate during operation, while containing all overspray, residue and the munition item during operation. The system shall be designed and constructed in accordance with DoD safety standards and Federal, State and local environmental regulations for operations within an explosive environment. Disposition of any residual material will be handledin accordance with safety and environmental regulations. The waterjet system shall be validated by prototype testing at the Contractor's site. Sufficient numbers of engineering test samples shall be processed in order to validate the acceptability of the system to effectively and efficiently cut through the steel casings of obsolete munition items. The result of the proposed effort will be to cost effectively field an abrasive waterjet system for the cutting of munition items with low technical and minimal safety risk. This is planned as a 4 phase effort as follows: Phase I -- consists of optimizing the cutting parameters for a 20,000 psi slurry jet and a 50,000 psi conventional abrasive waterjet system. The cutting target should be steel, of specification ASTM A576/A108/A109/A331/A107, or equivalent, with the following parameters being optimized as a minimum: Pressure, Water flow rate, Abrasive type/size, Abrasive flow rate, Nozzle diameter, Nozzle geometry, and Nozzle material. These parameters shouldbe studied with the target both above and below the water in the catch tank. The contractor shall demonstrate the capability of being able to recycle and reuse the spent abrasive while removing all kerf material from the abrasive prior to reuse. Deliverables for this effort will consist of: 1) test procedures for the testing program to be carried out, 2) schematics and engineering drawings for the test equipment, drawings shall contain as a minimum item name, materials of manufacture and dimensions, 3) raw data from the test program provided in a standardized format, 4) analysis of the data which will include an estimation of the cost of each cut, to a defined level of quality, based on costing provided as GFI, 5) recommendations from the analysis on the optimal cutting conditions for specified cutting operations. Phase II -- Based on the results of the phase I test program, an abrasive waterjet prototype system shall be constructed and tested at the Contractor site. The system shall consist of an abrasive injection system, hardware/software for monitoring and programming of the system, a high pressure pump, an abrasive collection and recycling system to include removal and treatment of residual explosives, and a system for holding and rotating the shells defined as the target. This system will include automatic shutdown capability when limits of pressure have exceeded the rating level of the components within the system. After proveout of the prototype system, the Contractor shall ship and install the system at a designated DoD site. The installation, system operation and training period shall be no less than 10 working days. The contractor shall prepare a comprehensive documentation package to include engineering drawings, equipment specifications, standardized procedures including test protocol, training manuals, operation and maintenance manuals, safety documentation and SOP's. Phase III -- The contractor will investigate recycle and treatment of the water used in the cutting process. This effort will include quantification and qualification of all products of the waterjet stream and the procurement of a water treatment system that will remove the impurities from the recycled water such that the water can be recycled or discharged. The deliverables for this effort will include as a minimum: 1) Data and analysis from the process stream collected under the Phase II effort, 2) Specifications of the equipment to be purchased for treatment of the water, 3) SOP's for system operation along with operational and maintenance manuals. Phase IV -- Based on the results of the Phase II effort, the Contractor will investigate the use of cutting mediums other than water for carrying the abrasive to the target. The main thrust of this effort will be enhancement of the efficiency of the cutting operation along with a more efficient and/or less costly method of treatment the chosen medium. The cutting medium(s) chosen for the testing will be such that they will not have an adverse effect on any energetic material found within the munition items. The total program is planned as a 24 month effort. It is anticipated that a minimum of $700K will be awarded under the BAA. Requests for a complete BAA package may be addressed to Ms. Ellen Jarosz, telephone 812-854-5315, fax 812-854-3465; mailing address is: Ms. Ellen Jarosz, Contract Specialist, Code 1162NZ Bldg. 64, NSWC Crane, 300 Highway 361 Crane, IN, 47522-5001; or send a request via e-mail to jarosz_e@crane.navy.mil. (e-mail is preferred). The BAA package will be posted on the NSWC web site at http://www.crane.navy.mil. It is anticipated that proposals will be required on or about 30 August 1999. All responsible sources may submit a proposal which shall be considered. See Numbered Note 26. (Mr. S. Bingham, Contracting Officer) Posted 07/13/99 (W-SN353425). (0194)

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