Water Mist Pipe Repair Kit

OUSD (R&E) CRITICAL TECHNOLOGY AREA(S): Sustainment OBJECTIVE: Develop a methodology for a high integrity repair of the DDG 1000 High Pressure Water Mist Fire Fighting System while deployed underway. DESCRIPTION: Current piping system repairs are done through building pipe sections onboard, welding, or soft patches with sealant materials. Temporary piping repairs must be reliable, effective, and quickly implemented allowing for continued operations. While one can expect there is enough good pipe wall for the mastic and patch to adhere, the challenge is knowing the integrity of the pipe wall surrounding the leak in order to have confidence in the quality of a pipe repair method in a high energy system. Even a successful hydro of such a patch doesn't guarantee that the patch won't give way when next exposed to operating pressure. Recently, a ship could not get underway due to water mist pipe header and branch line leaks that reduced system pressure in machinery spaces. The machinery spaces were shut down and created redline impacts for getting underway due to the level of defined risk. Ships Force and support activities have utilized epoxy and soft patches, with long cure times, and limited success. Regional maintenance centers evaluated the repairs and provided guidance for acceptable operations. However, further repairs were required which led to a one-month delay in test and trials. Current piping system repairs are done through building pipe sections onboard, welding, or soft patches with sealant materials. A new repair methodology must be quickly implemented to allow for continued operations and testing. The repair method should be suitable for emergent underway repair for a variety of fluid types and system pressures with primary concern being the DDG 1000 High Pressure Water mist firefighting system. PHASE I: Develop a concept for an improved method for underway repair of the DDG 1000 High Pressure Water Mist Firefighting System. Demonstrate the feasibility of the concept in meeting Navy needs and establish that the concept can be developed into a useful product for the Navy. Feasibility will be established via computer modeling or other means deemed appropriate. The Phase I Option, if exercised, will include the initial design specifications and capabilities description to build a prototype solution in Phase II. PHASE II: Develop a prototype to be tested to demonstrate its core functionality. Test the prototype at a Land Based Test Facility to ensure its suitability to shipboard use. The results of these tests will be used to refine the prototypes into a design that will meet Navy requirements. Prepare a Phase III manufacturing and development plan to transition the CKMS to Navy use. PHASE III DUAL USE APPLICATIONS: Support the Navy in transitioning the repair system to Navy use. As High-Pressure Water Mist systems become more prevalent across the fleet and industry, quick high integrity repair methods will be needed. Transition the product through sole source justification and utilizing Logistics outfitting and provisioning of approved products, technical manuals, and maintenance documentation through the program offices and fleet type commanders. Major industrial systems incorporating engines, generators, and turbines will benefit from capabilities developed under this SBIR topic. REFERENCES: 1. Navy design specifications SWBS 505, and SWBS 555. KEYWORDS: Pipe Repair; Water Mist; High Pressure; Temporary Repair; Damage Control; Fire Fighting