Document jyYoNroMwDvXp2Ykby6GJXev2

PLAINTIFF'S | EXHIBIT 1 _WV^5876 PLAINTIFFS# m. EXHiBrrjii %mmm IKCH`POUND KIL-I-2781F 21 August 1991 SUPERSEDING MXL-I-2781E 7 October 1275 (see 6.10) MILITARY SPECIFICATION INSULATION, PIPE, THERMAL This specification is approved for use by ell Departoents and Agencies of the Department: of Defense. 1. SCOPE 1.1 Scoop This specification establishes the requirements for preformed thermal insulation for use on pipes et surface temperatures up to 1200 degrees Fahrenheit (*F)< 2. APPLICABLE DOCUMENTS 2.1 Covernraent documents. 2.1.1 Saeclflcqpions, 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 (DoDXSS) and supplement thereto, cited in the solicitation (sec 6.2). SPECIFICATIONS FEDERAL m-?-no Fibreboard; Corrugated and Solid, Sheet Stock (Container Grade), and Cut Shapes MILITARY MIL-C-2861 MXL-L-imO Cement, insulation, high Temperature Lumber and Plywood, Fire-Retardant Treated. Beneficial comments (recommendations, additions, deletions) and any pertinent data which may be of use in improving this document should be addressed to*. Commander, Naval Sea Systems Commend, SEA 55Z3, Department of the Navy, Washington, DC 20362-S10I by using the selfaddressed Standardization Document Improvement Proposal (DD Fora 1426) appearing at the end of this document or by letter. ____ ________ AHSC N/A uniimited. FSC 5640 Approved for public release; distribution is WV-05876 Kit-3-278IF STANDARDS FEDERAL FED-STD* 313 Material. Safety Data Transportation Data and Disposal Data for Hazardous Materials Furnished to Government Activities. MILITARY MIL*STD-1623 MIL-STD-2073-1 Fire Performance Requirements and Approved Specifications for Interior Finish Haterials and Furnishings (Naval Shipboard Use). DOD Materiel Procedures For Development And Application of Packaging Requirements. (Unless otherwise indicated, copies of federal and military specifi cations and standards are available from the Standardization Documents Order Desk, Bldg. 4D, 700 Robbins Avenue, Philadelphia, Pa 19111-5094). 2-2 Non-Government publications. The following documents fora a part of this document to the extent specified herein. Unless otherwise specified, the issues of the documents which are DoD adopted are those listed in the issue of DoDISS cited in the solicitation. Unless otherwise specified, the issues of the documents not listed in the DoDISS are the issues of the documents cited in Che solicitation (see 6.2). AMERICAH SOCIETY FOR TESTING AND MATERIALS (ASTK) C 302 Standard Test Method for Density of Preformed Pipe-Covering-Type Thermal Insulation, . C 335 Standard Test Method for Steady-State Heat Transfer Properties of Horizontal Pipe C 356 Insulation, Standard Test Method for Linear Heat Shrinkage of Preformed High-Temperacure Thermal Insulation Subjected to Soaking Heat. C 411 Standard Test Method for Hoc-Surface Performance of High-Temperature Thermal Insulation. C 421 Standard Tost Method for Tumbling Friability of Preformed Block-Type Thermal Insulation. C 446 Standard Test Method For Breaking toed and Calculated Modulus of Rupture of Preformed Insulation for Pipes. C 449 Standard Specification for Mineral Fiber Hydraulic-Setting Thermal Insulating and Finishing Cement, C 585 Standard Practice for Inner and Outer Diameters of Rigid Thermal Insulation for Nominal Sizes of Pipe and Tubing (NFS System). D 3951 Standard Practice for Commercial Packaging. (DOD adopted) (Application for copies should be addressed to the American Society for Testing and Materials, 1916 Race Street, Philadelphia, PA 19103.) 2 MIL-I-2781F 2.3 ftydar of precede^. In the event of a conflict between the text of this document end the references cited herein (except for related associated detail specifications, specification sheets, or KS standards), the text of this document takes .precedence. Nothing in this document, however, supersedes applicable laws and regulations unless a specific exemption has been obtained. 3. REQUIREMENTS 3.1 Qualification. The thermal pipe insulation furnished under this specification shall be products which are authorized by the qualifying activity for listing an the applicable qualified products list at the time of award of contract (see 4,3 and 6.4). 3.2 Material. The thermal pipe insulation shall consist of heatresisting compounds suitable for the temperature conditions and the purpose intended. 3.2.1 Prohibited fibers. Neither asbestos nor ceramic (refractory) fibers nor aaterisIs containing any of these fibers shall be used in the insulation (see 3.5). 3.3 Form end dimensions. 3.3.1 Form and length. Thermal pipe insulation in nominal pipe sizes up to and including 10 inches shall be furnished in sections 3 feet long, split in half lengthwise. Pipe insulation for nominal pipe sizes larger than 10 inches may be furnished in serai-cylindrical sections or es curved segments, 3 feet in length. Each section or segment shall be true to shape end round ness and shall fit standard iron pipe sizes. A tolerance of plus or minus 1/4 inch in length will be permitted (see 4.5.2.1). 3.3.2 Inner diarneter- The inner diameter of the pipe insulation shall bo as specified in AST# C 585 (see 4.5-2.2). The inner diameter of pipe insulation listed in ASTH C 585 approximates the outer diameter of iron pipe sizes. The insulation can be applied either to a pipe or es a second layer to a smaller size of pipe insulation. 3.3.3 Thickness^ Pipe insulation shall be furnished in Che thicknesses listed in ASTM C 585 as specified (see 6.2). A tolerance of pLus 1/8-inch or minus 1/16-ineh in actual thicknesses specified in ASTM C 585 will be per mitted (see 4.5.2.3). 3.4 ffiyaical requirements. Pipe insulation shall confers to the requirements specified in table I. 3 HiL-uznir Table HI- Physical requirements. Characteristics Density average, ib/ft3 maximum Thermal conductivity (average), Btu/hr. ft.2 deg T at mean temperature of: 200T 300F 400*F 500* F 600*F 70G*F Weight loss by tumbling, loss in weight (average) percent max. After first 10 minutes After second 10 minutes Modulus of rupture (average), lb/in2 minimum Changes under soaking heat for 6 hours at 1200*F, Linear shrinkage (average) percent, max. Test A.5.3 4,5.4 4 5.5 4.5.8 4.5.7 Physical Requirements 15.0 0.42 0.45 0.50 0.60 0.45 0.70 20 40 If 2.0 V Three Claes density (pounds per cubic foot <lbs/fc3>) of che sample tested. 3.5 Simulative service. Thermal pipe insulation shall not warp, crack oc show other visible changes. Minor surface cracks chat do not propagate more chan l/6-inch Internally from che hoc face surface of che pipe insulation shall be disregarded (see 4-5,9). ^3,6 Fire resistance unfi araoke dcngi-rv. The finished insulation shall conform co che fire resistance and smoke density requirements sec forth in K1L-STD*i623 (see 4.5.S). 3.7 Compatibility. The insulation material shall be compatible with thermal insulation cement conforming co ASTh C 449 and with high temperature thermal insulating cement conforming to MIL-C-2861, Without the application of a primer, the cements shall readily adhere co the insulation segments and form a smooch, protective surface. Drying time for each cement after application shall not exceed 2 hours (see 4,5-10). 3.8 Appearance and workmanship. Insulation shall be free of defects in appearance and workmanship (see 4-5.2.4). 4 KH.-X-2781F 3.9 Material aafotv dara sheet fHSPSV. The contracting activity shall be provided a material safety data sheet at the time of contract award. The HSDS shall be provided in accordance with the requirements of FED-STD-313. The MSDS shall be included with each shipment of the material covered by this specification (see 6.5). 3.10 Recovered materials. Unless otherwise specified herein, all material incorporated in the products covered by this specification shall be nev and may be fabricated using materials produced from recovered materials to the maximum extent practicable with jeopardizing the intended use. The term recovered materlaIs" means macerials which have been collected or recovered from solid wosee and reprocessed Co become a source of raw materials, as opposed to virgin raw materials. None of the above shell be interpreted to mean that the use of used products is allowed under this specification unless otherwise specifically specified. 3.11 Tnxicitv. The material shall have no adverse effect on the health of personnel.when used for its intended purpose (see 6.1 and 6.6). Questions pertinent to this effect shall be referred by the contracting activity to the Bureau of Medicine and Surgery (BUKED) who will act as an advisor to the contracting activity. 4. QUALITY ASSURANCE PROVISIONS 4.1 Responsibility for inspection. Unless otherwise specified in the contract or purchase order, the contractor ia responsible for the performance of all inspection requirements (examinations and tests) as specified herein. Except as otherwise specified in the contract or purchase order, the con tractor may use his or any other facilities suitable for the performance of the inspection requirements specified heroin, unless disapproved by the Government, The Government reserves the right to perform any of the Inspec tions set forth in the specifications where such inspections are deemed necessary ro ensure supplies end services confer/a to prescribed requirements, 4.1.1 Responsibility for comnllance. All items shall meet all require ments of sections 3 and 5. The inspection sec forth in this specification shall become a part of the contractor's overall Inspection system or quality program. The absence of any inspection r-equiresents in the specification shall not relieve the contractor of the responsibility of ensuring that all products or supplies submitted co the Government for acceptance comply with all requirements of the contract. Sampling inspection, as part of the manu facturing operations, ia an acceptable practice to ascertain conformance to requirements, however, this does not authorize submission of known defective material, cither indicated or actual, nor does it commit the Government to accept defective materiel. 4,2 Classification of Inspections. The inspection requirements specified herein are classified as follows: (a) Qualification inspection (see 4.3). (b) Quality conformance Inspection (see 4.4). 5 KXL-1-2781F *2.1 Inspection conditions. Unless otherwise specified (see 6,2), ell inspections shall be performed in accordance with the conditions specified herein. 4.3 OualiflcBtigp inspection. Qualification inspection shall consist of the examinations and tests listed in table II. Qualification tests shall be conducted at a laboratory satisfactory to the Naval Sea Systems Command. Table II. Qualification inspection. Inspection Material Dimensions DensLey Thermal conductivity Weight loss by tumbling Modulus of rupture Changes under soaking heat- <6 brs. at 1200F), linear shrinkage Fire resistance and smoke density Simulative performance Compatibility Material safety data sheet Appearance and workmanship Requirement 3.2 & 3.2.1 3.3 3.4 3.4 3.4 3,4 3.4 3.6 3.5 3,7 3.9 3.8 Test method Certification end visual 4.5.2 4.5,3 4,5.4 4.5,5 4.5.6 4,5.7 4.5.8 4.5.9 4.5,10 ** 4.5.2,4 4.3.1 Qualification sample. Three samples for qualification tests shall be selected and subjected to the tests of 4.5.2, 4.5.3, 4.5.5, and 4,5.7; and one sample for the tests of 4.5.4, 4.5,8, 4.5.9 and 4.5.10. 4.3.2 Retention of qualification. The contractor shall conduct qualification examinations end tests every 3 years and shall submit the results to the Naval Sea Systems Command (see 6.4). 4.4 Quality conformance Inspection. Quality conformance inspection shall consist of the examinations end "testes listed in ^sble III (see 4.3). 6 HIL-I-2781F Table in. Dualitv conformance,-*nsoecCion. Inspection Requirement Material Dimensions Density Thermal conductivity Weight loss by tumbling Modulus of rupture Changes under soaking heat- (6 hrs. at 1200F), linear shrinkage Fire resistance and smoke density Simulative performance Compatibility Material safety data sheet Appearance and workmanship Packatinc 3.2 & 3.2.1 3.3 3.4 3.4 3.4 3.4 3.4 3.6 3.5 3.7 3.9 3.8 5.1 thru 5.4 Test method Certification and visual 4.5.2 4.5.3 4.5.4 *.5.5 4.5.6 4.5.7 4.5.8 4.5.96.5.10 4.5.2.4 ... 4.4.1 Lot. For purposes of Inspection sampling, a lot is defined as all insulation sections o one site produced in the same facility, under the sane conditions and from the same materials. 4.6.2 Sampling for quality conformance inspection. As a minimus, the contractor shall select a sample quantity of Insulation sections from each lot in accordance with table XV and subject the sample section to the examina tions and tests listed in table III. If ones or more defects are found in any sample, the entire lot shall be rejected. The contractor has the option of screening 100 percent of the lot for the defective characteristic^), or providing a new lot which shall be inspected in accordance with the sampling plan herein. Table XV. Sampling for Quality conformance inspeerion. Lot ~SiZ9 2 to 25 26 to 50 51 to 90 91 to 150 - 151 to 280 281 to 500 501 to 1200 1201 to 3200 3201 to 10000 10001 and over Sample size 3 5 6 7 10 11 15 18 22 29 7 KIL-X-2781F 4.5 Tests. 4.5.1 Conditioning samples. Test specimens shall be conditioned bydrying to constant weight in an oven at a temperatare of 215* F to 250* F. 4.5.2 plaensiotis. 4.5.2.1 Length. Length shall be determined in accordance with ASTH C 302 (see 3.3.1). 4.5.2.2 fliantycer. Hie inner diameter of the pipe insulation shall be determined in accordance with ASTH C 585 (see 3,3.2). 4.5.2.3 Thickness. Thickness shall be determined in accordance with ASTH C 302 (see 3.3.3). 4.5.2.4 Appearance gnd workmanship. The pipe insulation shall be examined to determine chat none of the following defects exist (see 3.8): (a) Cracked or broken lengths. (b) Friable or lumpy surface, (e) Inner core of insulation not concentric with outer cylindrical surface. (d) Edges not plane. (e) longitudinal cut surfaces not plana. (f) Excessive voids. (g) Warping. <h) Form not as required. 4.5.3 pensipy. The density shall be determined in accordance with ASTK C 302 (see table X). 4.5.4 Thermal conductivity. Thermal conductivity shall be determined in accordance with ASTH C 335 (see table 1). 4.5.5 Weight loss bv tumbling. Weight loss by tumbling shell be determined in accordance with ASTH C 421 (see cable I). 4.5.6 Modulus of rupture. Modulus of rupture shall be determined in accordance with ASTH C 446 (see table X). 4.5.7 Physical-changes after heat soaking. Specimens shall be weighed and measured. The specimens shall then be placed in an electrically heated oven and subjected to 1200*F for 6 hours. The specimens shall then be removed from the oven, cooled to room temperacure, and tested to determine linear shrinkage in accordance with ASTH C 356. 4.5.8 Fire rpalspancp and smoke density. Specimens shall be tested in accordance with test methods and requirements set forth in HiL-STD-1623. 4.5.9 Simularive performance. Simulative performance shall be deter mined in accordance with A3TM C411 (see 3.5). Exposure temperature shall be 1200F. 6 HIL'I"2781F 4,5.10 Compatibility. A 6-inch section of pipe insulation, 1-1/2 inches thick, shall be uniformly surface coated while at room tempoeature, vith approximately a 1/4-inch layer of finishing cement in accordance with ASTM C 449. Drying time under ambient air temperature conditions shall be deter-ained. This teat ahall be repeated with a second pipe section using a cement in accordance with MIL-C-2661. The drying time for this cement shall also be determined. 5. PACKAGING (The packaging retirements specified herein apply only for direct Government acquisition. For the extent of applicability of the packaging requirements of referenced documents listed In section 2, see 6.8). 5-1 General. 5.1.1 Naw_f_lreretarriant requirements. (a) Treated lumber and plywood. Unless otherwise specified (see 6.2), all lumber and plywood including laminated veneer material used in shipping container end pellet construction, members, blocking, bracing, and reinforcing shall be fireretardant treated material conforming to HIL-L-19140 as follows: Levfcis A and B Type II - weather resistant. Category 1 general use. Level C Type I - non-weather resistant. Category 1 general use. (b> Fiberboard. Unless otherwise specified (see 6.2), fiberboard used in the construction of class-domestic, non weather resistant fiberboard and cleated fiberboard boxes including interior packing forms shall meet the flamespread index and the specific optic density requirements of PPP-P320. .5.,2 -Prasarvation. Not applicable. 5.3 Packing. Packing shall be level a, B, C, or commercial as specified (see 6.2). 5.3.1 General requirements for lavelp a B._anri c. Containers selected (see S.3.2) shall be of minimum weight and cube consistent vith the protection required, of uniform sise, and contain quantities of like material (see 3.3). 5.3.2 Levels A B. and C container^. Insulation shall be packed in exterior shipping containers for the level of packing specified (see 5.3), in accordance with exterior shipping container requirements of KIL-STD-2073-1, appendix C, and herein. Unless otherwise specified (sec 6.2), container selection and options shall be at the contractor's option. 9 HIL-I-2781F 5.3.2.1 Closure* and gross weight. 5.3.2.1.1 Closure. Container closure, reinforcing, or banding shall be In accordance with the applicable container specification or appendin thereto except chat weachar-resistant fiberboard boxes shall be closed in accordance with reached V and reinforced with non-metallic or tape banding and domestic or fire-retardant fiberboard boxes shall be closed.in accordance with method I using pressure sensitive cape. 5.3.2.1.2 Weight. Wood, plywood, and cleated type containers exceeding 200 pounds gross weight shall be modified by che addition of skids in accordance with KIL-STD-2073-1 and the applicable container specification or appendix thereto. 5.3.3 Commercial. Insulation shall be packed for shipment in accord ance with ASTH D 3951 and herein, 5.3.3.1 Container modification. Shipping containers exceeding 200 pounds gross weight shall have a rainlmua of cwof 3- by `'-.inch nominal wood skids laid flat, or a skid or sill type base which will support the material and facilitate handling by mechanical handling equipment during transportation, storage and stowage, 5.4 Markin? levels A. B. C. and commatg.jgl. In addition to any special marking required (see 6.2 and herein), shipping containers shall be marked including bar coding for shipment, stowage and storage in accordance with MILSTD-2073-1, appendix F. In addition, containers shall be marked "INSUIATION FREE OF ASBESTOS AND CERAMIC (REFRACTORY) FIBERS" (see 3.2.1). 5.5 safety data sheet. A copy of the material safety data sheet (MSDS) shall be attached to the shipping document for each destination (see 3.9). 6. NOTES (This section contains information of a general or explanatory nature that may be helpful, but is not mandatory.) 5.1 Intended use. The thermal Insulation is to provide for piping operating at surface temperatures up to 1200F. 6.2 Acquisition requirements. Acquisition documents must specify the following: (a) Title, number, and data of the specification. (b) Issue of DODISS to be cited in the solicitation, and if required, che specific issue of individual documents referenced (see 2.1.1 and 2.2). <c) Nominal iron pipe size, and nominal thickness (see 3.3.3). (d) Inspection conditions, if different (see A.2.1). (e) When fite-retsrdont material is not required (see 5.1.1(a) and (b)), <f) bevel of packing required (see 5.3). 10 yKIL-X-2781P (g) Container selection and options If ocher then the contractor's (see 5.3.2). <h> Special narking required (see 5.4). 6.3 Considerscion of data r^gufapments, The following data require ments should be considered when this specification is applied on a contact. The applicable Data I ten Description (DID's) should be reviewed in conj unction with the specific acquisition to ensure that only essential data are requested/provided and that the SID's are tailored to reflect the requirements of the specific acquisition. To insure correct contractual application of the data requirements, a Contract Date Requirements List (DD Form 1423) must be prepared to obtain the data, except where DoD FAR Supplement 27.475-1 exempts the requirements for a DO Fora 1423. Reference gargftEsnh DID number . BID Tide Suggested , Jatlorins 4.4 OI-T-2072 Reports, Test The above DID's were those cleared as of the data of this specification. The current issue of DoD 5010.12*L, Acquisition Management Systems and Data Requirements Control List (AHSDL), must be researched to ensure chat only current, cleared DID's are cited on the DD Fora 1423. 6.4 Qualification. With respect to products requiring qualification, awards will be made only for products which are, at the time of award of contract, qualified for inclusion in Qualified Products List QPL No. 2781 whether or not such produces have actually been so listed by that date. The attention of the contractors is called to these requirements, and manufac turers are urged to arrange to have the products that they propose to offer to the Federal Government tested for qualification in order chat they nay be eligible to be awarded contracts or purchase orders for the products covered by this specification. The activity responsible for the Qualified Products List is the Naval Sea Systems Command, SEA 51222. Department of the Navy, Washington, DC 20362-5101, and information pertaining to qualification of products may he obtained from that activity. Application for qualification tests must be made in accordance with "Provisions Governing Qualification SD* 6", (Copies * "Provisions Governing Qualification 5D--6" &ay -be ^obtained upon application to the Standardization Documents Order Desk, Bldg. 4D, 700 Robbins Avenue, Philadelphia, PA 19111-5054). 6.5 Material Safety Data Sheets Contracting officers will identify those activities requiring copies of completed Material Safety Data Sheets prepared in accordance with FED-STD-313. The pertinent Government mailing addresses for submission of data are listed in FED-STD-313. 6.6 Toxicity. To determine conformance to requirements of 3.11, the manufacturer of the material should disclose the formulation of his product to the Bureau of Medicine and Surgery (BUHED), M2D 242, Washington, DC 20372. The disclosure of proprietary information, which will be held in confidence by BUHED, should include: the name, formula, and approximate percentage by 11 HIL-I-2781F weight and volume of each ingredient in the product; the results of any toxi cological testing of the product; identification of its pyrolysis products; end any such other information as isay be needed to permit an accurate appraisal of any toxicity problem associated with the handling, storage, application, use, disposal, or combustion of the material. Information sub mitted should be clearly narked or identified as to its being provided in connection with qualification under MIL-1*2781. 6.7 Certification. Consideration should be given to including certi ficates of compliance with each shipment of insulation. Certificates should indicate successful completion of the individual tests of the quality conformance inspection. 6.8 Sub-contracted materials and parts. The packaging requirements of referenced documents listed in section 2 do not apply when material and pares are acquired by the contractor for incorporation into the equipment and lose their separate identity when the equipment is shipped. 6.9 Subject term (key word) listing. Conductivity, thermal Density, smoke Resistance, fire 6.10 Chnnpes fron? previous issue. Marginal notations ere not used- in this revision to identify changes with respect to cho previous issue due to the extensiveness of the changes. Custodians: Army - ME Navy - SH Air Force 84 Preparing activity: Navy - SH (Project 5640*0681) STANDARDIZATION DOCUMENT IMPROVEMENT PROPOSAL mmoxm f. The preparingeetMty r&vti completeblocks I,2, X end ft tn block ), boib the document number end revision tetter should be given. 2. the submitter ofthisform mustcomplete blocks 4,5,6, and 7. 3. 7h preparing activity must provide a reply within 30 days from receiptof the form. NOTE: this form may not be used to request espies of documents, nor to request waivers, or clarification of requirements on current contracts. Comments submitted on this form do not constitute or imply authorisation to waiveany portion ofthe referenced documents) or toamend contractu*! requirements. i'Kc6MWNDM4:c:KANGi:| 1 ' l*arj*stTV*fxw- <%**>*evL-r;i.'t *"**&. 1 rUL-i-A/OlF 2. DOCUMENT DAIS fYYMMD 21 AUGUST 1.991 a. OOCUMCMTTnU INSULATION, PIPE, THERMAL . NATUM 'OF CHANGE Pdemtty'pauprtph number nd nxbcft prcptMcO rewrite, if pontH/t. Aitich *Its shoea 5. REASON fOR UCOMMENOATION . WRAWNG ACTtVtTY J. name tecribicai Pome ot Contact tiTdtin Ms. Linda Lovell (SEA 5143) PLEASE ADDRESS ALL CORRESPONDENCE AS FOLLOWS c. ADDRESS ftnekrift Zip CM*) COMMANDER, NAVAL SEA SYSTEMS COMMAND SEA 5523, DEPARTMENT OP THE NAVY WASHINGTON, DC 20362-5101 &, TElEPHOfa Prxiwit Art* CoOt} {*> CofMrdl Q) AtTTOVOM 703-602-0146 8-332-0146 ir YOU DO KQT MCtftrt A RIPtY VTM* AS DAYS, CONTACT: Dsfernt QuaSty rri Sumfc'dkw&A Of6 S28HesbtfePfk. $*t t4M. Wt Ow** V* 2204t>36C T*J*phw <fo3>756-23*0 AUTOVON 249*21*0 DO form 1426, OCT 89 Prt*iwn MTQWu sr* obtehte. ttvm