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Naval Surface Warfare CenterCarderock DivisionWest Bethesda, MD 20817-5700

NSWCCD–TR–63—97/25 September 1997

Survivability, Structures and Materials DirectorateTechnical Report

Shipboard Solid Waste Management

Equipment Guide

byCharles M KellyWilliam K. Upton IIIAnthony BudzichowskiNaval Surface Warfare Center, Carderock Division

Distribution authorized to U.S. Government agencies andtheir contractors; administrative/operational use; September 1997.

Other requests for this document shall be forwarded tothe Naval Sea Systems Command (SEA 03L)

Naval Surface Warfare CenterCarderock DivisionWest Bethesda, MD 20817-5700

NSWCCD–TR–63—97/25 September 1997

Survivability, Structures and Materials DirectorateTechnical Report

Shipboard Solid Waste ManagementEquipment Guide

byCharles M Kelly

William K. Upton IIIAnthony Budzichowski

Naval Surface Warfare Center, Carderock Division

Distribution authorized to U.S. Government agencies andtheir contractors; administrative/operational use; September 1997.

Other requests for this document shall be forwarded tothe Naval Sea Systems Command (SEA 03L)

REPORT DOCUMENTATION PAGE Form ApprovedOMB No. 0704-0188

Public reporting burden for this collection of information is estimated to average 1 hour per response, including the time for reviewing instructions, searching existingdata sources, gathering and maintaining the data needed, and completing and reviewing the collection of information. Send comments regarding this burden estimateor any other aspect of this collection information, including suggestions for reducing this burden, to Washington Headquarters Services, Directorate for InformationOperations and Reports, 1215 Jefferson Davis Highway, Suite 1204, Arlington VA 22202-4302, and to the Office of Management and Budget, Paperwork ReductionProject (0704-0188), Washington, DC 20503.1. AGENCY USE ONLY (Leave Blank) 2. REPORT DATE

SEPTEMBER 1997

3. REPORT TYPE AND DATESCOVERED

FINAL4. TITLE AND SUBTITLE

SHIPBOARD SOLID WASTE MANAGEMENT EQUIPMENT GUIDE

5. FUNDING NUMBERS

6. AUTHOR(S)

Charles M. Kelly William K. Upton III Anthony Budzichowski

7. PERFORMING ORGANIZATION NAME(S) AND ADDRESS(ES) Naval Surface Warfare Center Carderock Division West Bethesda, MD 20817-5700

8. PERFORMINGORGANIZATION

REPORT NUMBER

NSWCCD-TR-63-97/25

8. SPONSORING/MONITORING AGENCY NAME(S) AND ADDRESS(ES) Naval Sea Systems Command Code 03L1 Arlington, VA 22242-5160

10. SPONSORING/MONITORINGAGENCY REPORT NUMBER

NSWCCD-TR-63-97/25

9. SUPPLEMENTARY NOTES

12a. DISTRIBUTION/AVAILABILITY STATEMENT

Distribution authorized to U.S. Government agencies and theircontractors; administrative/operational use; September 1997. Otherrequests for this document shall be forwarded to the Naval Sea SystemsCommand (SEA 03L).

12b. DISTRIBUTION CODE

ABSTRACT (Maximum 200 words)

This guide contains ship information that is needed to effectively operate and maintain the recently-installed Plastic WasteProcessors, Metal/Glass Shredders, and Large and Small Pulpers. The guide provides valuable “lessons learned” based on substantialFleet feedback on operating/maintenance experience acquired aboard various ship classes. Useful reference material is included; suchas equipment capabilities, anticipated waste generation rates and timing, numbers for APLs and Tech Manuals, AEL and GUCLinformation, supply sources, training material descriptions and availability, and manning requirements. A section is provided to helpin developing a formal ship instruction for a Solid Waste Management Plan; a sample ship instruction is included. Operator andmaintainer training and qualifications are explained; sample JQR’s are included. Appropriate points-of-contact are also provided ifadditional information is needed beyond that provided.

14. SUBJECT TERMS 15. NUMBER OF PAGES

111Solid Waste Management Equipment, Plastics Waste Processors, Solid WasteShredders, Large Pulpers, Small Pulpers

16. PRICE CODE

17. SECURITY CLASSIFICATIONOF REPORT

Unclassified

18. SECURITY CLASSIFICATIONOF THIS PAGE

Unclassified

19. SECURITY CLASSIFICATIONOF ABSTRACT

Unclassified

20. LIMITATION OF ABSTRACT

Same as Report

NSN 7540-01-280-5500 Standard Form 298 (Rev. 2-89)

Prescribed by ANSI Std. Z39-18

NSWCCD–TR–CR—97/25 v

Abstract

This guide contains ship information that is needed to effectively operate andmaintain the recently-installed Plastic Waste Processors, Metal/Glass Shredders, andLarge and Small Pulpers. The guide provides valuable “lessons learned” based onsubstantial Fleet feedback on operating/maintenance experience acquired aboard variousship classes. Useful reference material is included; such as equipment capabilities,anticipated waste generation rates and timing, numbers for APLs and Tech Manuals,AEL and GUCL information, supply sources, training material descriptions andavailability, and manning requirements. A section is provided to help in developing aformal ship instruction for a Solid Waste Management Plan; a sample ship instruction isincluded. Operator and maintainer training and qualifications are explained; sampleJQR’s are included. Appropriate points-of-contact are also provided if additionalinformation is needed beyond that provided.

NSWCCD–TR–CR—97/25 vii

Contents

page

Standard Form 298........................................................................................iii

Abstract............................................................................................................v

Technical Documentation References.............................................................x

Administrative Information.............................................................................xi

Acknowledgments ...........................................................................................xi

Purpose ............................................................................................................1

Now What Do I Do?....................................................................................1

Development of Ship Instruction ................................................................1

Background......................................................................................................2

Current Legislation......................................................................................2

What You Can Discharge and Where .........................................................3

PRIME and Other Helpful Programs ..........................................................3

PRIME and WRAPS ...............................................................................3

CHRIMP..................................................................................................4

Pollution Prevention (P2) Afloat.............................................................4

Solid Waste Generation Rates & Peak Times.................................................5

Equipment Installation Timetable ...................................................................6

Equipment Descriptions ..................................................................................8

Plastics Waste Processor and Heat Sealer...................................................8

Metal/Glass Shredder ..................................................................................10

Large Pulper ................................................................................................12

Small Pulper ................................................................................................13

Waste Handling Procedures ............................................................................14

Source Separation - Enforcement/Inspection..............................................14

Traffic Flow.................................................................................................14

Staging Requirements..................................................................................15

Sample solid Waste Staging Calculation ................................................16

Plastics.................................................................................................16

Metal & Glass......................................................................................16

Food Waste, Paper, and Cardboard .....................................................17

Unprocessed/Processed Solid Waste Staging Requirements ..................17

On-Board Storage (Plastic Disks) ..............................................................18

Transfers to Shore and Replenishment Ships (Plastic Disks) ....................18

Pierside Disposal (Plastic Disks) ................................................................19

Safety and Health Issues..................................................................................20

NSWCCD–TR–CR—97/25viii

page

Plastics Waste Processor, Odor Barrier Bags, and Heat Sealer ..................20

Metal/Glass Shredder ......................................................................................21

Pulpers .........................................................................................................21

Equipment Spaces .......................................................................................22

Storage Areas (Plastic Disks) ......................................................................22

Equipment Operation & Processing Experiences ...........................................23

Plastics Waste Processor .............................................................................23

Lessons Learned ......................................................................................23

What to Process .......................................................................................23

What NOT to Process..............................................................................24

Metal/Glass Shredder .................................................................................24

Lessons Learned ......................................................................................24

What to Shred..........................................................................................24

What NOT to Shred.................................................................................24

Pulpers (Large & Small) .............................................................................25

Lessons Learned ......................................................................................25

What to Pulp............................................................................................26

What NOT to Pulp...................................................................................26

Lessons Learned Applicable to All Solid Waste Management Equipment 27

Manning...........................................................................................................28

Supervision..................................................................................................28

Operators .....................................................................................................28

Enforcement ................................................................................................28

Maintainers..................................................................................................29

Crew Training..................................................................................................30

Training Concepts .......................................................................................30

Training Course Materials - Interactive Course Ware (ICW).....................30

Large Pulper or Small Pulper ICW (Module formats are the same).......30

Operator Training Module...................................................................30

Maintainer Module ..............................................................................31

Module 1..............................................................................................31

Module 2 - Troubleshooting and Maintenance ...................................31

PWP and SWS.........................................................................................31

Operator Module .................................................................................31

Maintenance Module...........................................................................31

Training Hardware (Computer) Requirements ...........................................32

Job Qualification Requirements ..................................................................32

NSWCCD–TR–CR—97/25 ix

page

Logistics and Maintenance Support ................................................................33

Technical Data.............................................................................................33

Planned and Scheduled Maintenance..........................................................33

Spare Parts ...................................................................................................35

Consumable Items and Special Tools .........................................................36

Consumable Items Usage Rates ..................................................................37

PWP.........................................................................................................37

SWS.........................................................................................................37

Figures

1. Plastics Waste Processor (CMU and CLCU).............................................8

2. Metal/Glass Shredder.................................................................................10

3. Large Pulper...............................................................................................12

4. Small Pulper ...............................................................................................13

Tables

1. Shipboard Solid Waste Generation Data...................................................5

2. Planned Equipment Installations...............................................................6

3. Solid Waste Staging Requirements ...........................................................15

4. Solid Waste Equipment Design Mission Requirements ...........................15

5. Processed Solid Waste Volume Reductions..............................................16

6. Solid Waste Management Equipment MRCs............................................33

7. Estimate of PWP Consumable Items Used in a Six Month

Deployment for Several Ship Classes.......................................................37

8. Estimate of SWS Consumable Items Used in a Six Month

Deployment for Several Ship Classes.......................................................38

Appendix A: Developing A Ship Instruction for Solid Waste

Management Plan ...................................................................39

Appendix B: Job Qualification Requirements (JQR) Samples ....................68

Appendix C: Training Materials & Environmental Resources……………87

Appendix D: Sample Trash Disposal Room Log.........................................90

Appendix E: Program Points of Contact ......................................................93

Abbreviations ..................................................................................................95

NSWCCD–TR–CR—97/25x

Technical Documentation References

1. Report to Congress, U.S. Navy Compliance with the Marine Plastics Pollution Research and ControlAct of 1987, Department of the Navy, January 1992.

2. U.S. Navy Shipboard Solid and Plastics Waste Management Program Plan, Naval Sea SystemsCommand (NAVSEA 03L-Environmental Engineering Group), April 1993.

3. Report to Congress, U.S. Navy Ship Solid Waste Management Plan for MARPOL Annex V SpecialAreas, Department of the Navy, November 1996.

4. OPNAVINST 5090.1B, Environmental and Natural Resources Program Manual, (OPNAV-45),December 1994.

5. OPNAVINST 5510.1H, Department of the Navy Information and Personnel Security ProgramRegulation.

6. Operation and Maintenance, Organizational and Intermediate for the Plastics Processor (CMU andCLCU), S9593-C4-MMM-010, 30 September 1995.

7. Operation and Maintenance, Organizational and Intermediate for the Shredder, Solid Waste, S9593-C5-MMM-010, 30 September 1995.

8. Operation and Maintenance, Organizational and Intermediate for the Large Pulper, S9593-C2-MMM-010, 1997.

9. Operation and Maintenance, Organizational and Intermediate for the Small Pulper, S9593-C3-MMM-010, 1997.

10. Shipboard Solid Waste Processing Equipment Basic Ship Installation Integration Package, Naval SeaSystems Command (NAVSEA 03L-Environmental Engineering & Auxiliary Systems Group), RevisionE, 30 April 1997, S9593-C6-IIN-010, 0910-LP-012-4560.

11. N45-NTSP-X-10-96-01 Environmental and Natural Resources Program Navy TrainingSystems Plan (CNO N45).

12. NTP-S-30-9508 Plastic Waste Processor Navy Training Plan (NAVSEA 03L1).

13. NTP-S-30-9603 Solid Waste Equipment Navy Training Plan (NAVSEA 03L1).

14. OPNAVINST 1540.55, Shipboard Training Enhancement Program (STEP).

NSWCCD–TR–CR—97/25 xi

Administrative InformationThis report was prepared in support of the Naval Sea Systems Command

(NAVSEA) Environmental Engineering Group, NAVSEA 03L. It was performed underJob Order Number 1-6340-549.

AcknowledgmentsWe would like to thank the individuals who reviewed this document for omissions

and errors; in particular, Mr. Peter McGraw and Mr. Richard Schaeffer. We would alsolike to thank Mr. Stephen Baylin of ManTech Advanced Technology Systems, for histechnical input and assistance in bringing our ideas and thoughts together in forming thisdocument. Finally, we would like to thank the many officers and enlisted personnelfrom the Fleet, particularly those from USS GEORGE WASHINGTON (CVN 73) , USSTHEODORE ROOSEVELT (CVN 71), USS VANDEGRIFT (FFG 48), USS WASP(LHD 1), USS KEARSARGE (LHD 3), USS CORONADO (AGF 1), and USSSTETHEM (DDG 63) for their assistance and support during equipment at-sea testingand in the preparation of the sample ship instruction and JQRs found in this document.

NSWCCD–TR–63—97/25 1

Purpose

Now What Do I Do?

You are most likely reading this because your ship either has been or will soon beoutfitted with some combination of new solid waste management equipment. The worldis changing. Things that we would do routinely in the past may not even be allowableany more. You most likely find a recycling container in your home today while tenyears ago recycling of any kind was rare. Trash used to go off the fantail routinely - bagafter bag after bag, left to float until some force of nature came along to sink them. Asoften as not, those remnants of life at-sea would end up on somebody’s shoreline, oreven worse would cause the death of some unsuspecting sea creature. You are gettingthe equipment needed to protect the environment and resources of the sea, so now whathappens? Well, the first thing that’s needed is a cohesive game plan that addresses theflow of shipboard solid waste from start to finish, cradle to grave. This Guide has beenprepared to assist you by explaining what your new equipment will do and describing theduties and responsibilities of everyone onboard to operate it effectively. You will needto implement and enforce new procedures such as “source separation” that willmaximize processing efficiency, and also minimize both labor expenditures and theundesirable circumstances associated with the collection and disposal of solid waste.These new procedures may seem painful at first, but they will ultimately save you a lotof time and effort. This Guide will also assist you in the preparation and development ofa required Ship Instruction that will give you this cohesive game plan.

Development of Ship Instruction

All of your solid waste management equipment is new, in that none of it evenexisted just a few years ago. All of the equipment has been extensively ship-tested,accumulating a substantial number of operating hours. This Guide is intended todisseminate the valuable information that was generated during these evaluations, so thatnobody has to “re-invent the wheel.” Your Ship Instruction will have to address all ofthe elements of solid waste management, and will have to address the responsibilities ofall crew members involved with its operation and maintenance. The guidance onpreparing a Ship Instruction is found in Appendix A. Also, we have included a sampleShip Instruction (Solid Waste Management Plan - SWMP) to demonstrate the procedure.The sample SWMP is not intended to be used as is; it needs to be tailored to yourindividual ship. However, you should find that it meets your needs fairly closely. If so,you might start by using the SWMP as is, and then modify it as experience is gained, andyou see what your specific needs will be. Even if you are not responsible for generatingthis instruction, remember that its contents are very likely to determine how easy ordifficult your particular job in this area will be. You will be much better off byproviding your input to this Plan while it is being developed, rather than just beinggoverned by it after the fact.

NSWCCD–TR–CR—97/252

Background

Current Legislation

The U.S. Navy Solid and Plastics Waste Program was initiated to develop astrategy for Fleet-wide compliance with the pertinent parts of the InternationalConvention for the Prevention of Pollution from Ships (MARPOL). MARPOLrequirements address various types of pollution from ships and are delineated in severalannexes. Annex V to the Convention pertains to shipboard solid waste disposal while atsea. It prescribes three types of requirements:

• Distance-from-shore restrictions for solid waste discharge.

• Prohibition of discharging plastics waste into the seas.

• Designation of special sea areas where enhanced efforts are required tominimize pollution from ships. Special areas that are now in effect are the Baltic Sea,the North Sea and the Antarctic Area. Other special areas that have been designated butare not yet in effect (due to inadequate waste handling facilities) are: The Persian Gulf,Red Sea, Black Sea, Mediterranean Sea, Caribbean Sea and the Gulf of Mexico.

The MARPOL Convention does not apply to naval warships. MARPOL does,however, require members to ensure that their warships operate under the requirementsof the convention as is reasonable and practicable. The United States became party toMARPOL Annex V in 1987, with an amendment to the Act to Prevent Pollution fromShips (APPS). Under APPS, Congress mandated full compliance for U.S. Navy ships by1994. Congress later acknowledged that full compliance for Navy ships would not betechnically feasible by the initial deadlines while maintaining the desired operationalcapabilities in the U.S. Fleet1,2. Amendments to APPS in 1993 modified the originallegislation by implementing a total ban on discharging plastics waste anywhere at seaafter 31 December 1998. Also, this amendment required the Navy to achieve zerodischarge of all solid waste in MARPOL Special Areas after 31 December 2000 with adecision based on a plan3 for compliance by all Navy ships submitted to Congress inNovember 1996. That plan concluded that zero-discharge of all solid waste isimpractical. The Navy’s preferred method for operations in MARPOL Special Areas,considering such factors as cost, ship habitability, and environmental effects, was toinstall metal/glass shredders and solid waste pulpers on all Navy ships the size offrigates and larger.

Congress effectively approved the Compliance Plan through the National DefenseAuthorization Act for Fiscal Year 1997. This legislation required compliance with non-plastic solid waste discharge restrictions in “special areas” by December 2000 andallowed the use of Navy developed metal/glass shredders and solid waste pulpers.Congress accepted the Navy’s proposal with the proviso that what ships do in SpecialAreas will be the same as what is done everywhere at sea. The bottom line is: no plasticsoverboard, and shreddable metal and glass to be shredded and bagged before beingdischarged overboard. Pulpables such as food waste, paper, and cardboard can be pulped(ground up) and discharged as a slurry overboard. There are still restrictions aboutdischarging near the shoreline as explained below.


What You Can Discharge and Where

NOTE: The National Defense Authorization Act for Fiscal Year 1997, Section 324,allows the U.S. Navy to discharge solid wastes as indicated below, howeverOPNAVINST 5090.1B4 has not yet been revised to incorporate these changes.

Plastics

Once equipped with an operable Plastics Waste Processor, surface ships areprohibited from discharging plastics into the sea. After 1998, those ships without plasticprocessing capability or who have non-operating Plastics Waste Processors shall retainall plastics waste on board or retrograde it to other ships. Exceptions to these retentionrequirements are allowed only when necessary for the purpose of securing the safety ofthe ship or the health of ship’s force.

Pulped Paper, Cardboard, and Food Waste

Can be discharged beyond 3 nautical miles from either U.S. or foreign shorelines,including special areas.

Metal and Glass

Shreddable metal and glass (you don’t need or want to shred “durable” items like adesk, an I-beam, or a glass ash tray) can be shredded and discharged once the ship isbeyond 12 nautical miles from any shoreline.

PRIME and Other Helpful Programs

There are a number of other programs within the Navy that are intended to clean upthe environment while making life at sea less difficult. Some of these programs arelisted below, along with pertinent points-of-contact.

PRIME and WRAPS

To reduce plastics in the supply system, the Navy established the Plastics Removalin the Marine Environment (PRIME) Program in 1990. PRIME has caused DODprocurements to minimize plastic packaging materials, plastic end item substitution, toinvoke conservation and recycling policies; resulting in a substantial reduction in theamount of plastic that enters the ship’s waste stream. The Naval Supply SystemsCommand (NAVSUP) recently established the Waste Reduction Afloat Protects the Sea(WRAPS) Program, focused on the reduction of all materials that generate solid waste.The current POC for this program is Ms. Vickie Edgar, Naval Inventory Control Point(NAVICP), Code 054A, Mechanicsburg PA, DSN 430-5623, Commercial (717) 790-5623.


CHRIMP

Hazardous materials on Navy ships are managed in accordance with the NavyConsolidated Hazardous Materials Reutilization Inventory Management Program(CHRIMP), using the software package HICS (Hazardous Material Inventory ControlSystem). Under CHRIMP, hazardous materials are taken to sea, used and brought backto shore for proper disposal. It has established a chain of authorized ownership for eachuse of hazardous material from the time it is procured to the time it is used or disposed.The current POC for this program is Mr. Paul Murphy, Navy Supply Systems Command(NAVSUP), Code 4242, Mechanicsburg PA, DSN 430-6849, Commercial (717) 790-6849.

Pollution Prevention (P2) Afloat

The objective of the P2 Afloat program is to develop a process for the Fleet toincorporate pollution prevention practices in its operation and maintenance procedures.This process will identify equipment and material changes to effectively reduce theshipboard hazardous waste stream at the source. Teams of pollution prevention expertsare identifying suitable technologies, alternate materials, and management initiatives thatcan be demonstrated aboard selected ships during their deployments. A P2 AfloatGuidance Document is being developed to identify applicable equipment, materialand/or process changes by ship class. The current POC for this program is Mr. DrewJackson, NSWCCD 632, Carderock MD, DSN 287-5243, Commercial (301) 227-5243.


Solid Waste Generation Rates and Peak Times

A number of shipboard surveys have been completed on a variety of ship classeswhich classify and quantify solid waste generation rates while at sea. Table 1 should beused for estimating processing requirements, staging area needs, labor assignments, etc.

Table 1. Shipboard Solid Waste Generation Data2

Stream Generation Rate(lb./person/day)

Generation Volume(cu.ft./person/day)

Unprocessed WasteDensity (lb./cu.ft.)

Garbage-food wastes 1.21 0.027 45.0Paper/Cardboard 1.11 0.185 6.0Metal/Glass 0.54 0.046 11.8Plastics 0.20 0.154 1.3

Total: 3.06 0.412 ---

Peak in-feed times for all of the solid waste equipment will generally center aroundmealtimes, since the majority of waste going into any of the machines is a result of foodpreparation or consumption. UNREP evolutions will also result in large generation ratesover short periods of time. Since all of the equipment needs to be shut downperiodically for cleaning and/or adjustment, efforts should be made to be sure these shut-down periods do not coincide with these expected periods of high loading.

3.06 lbs/da y/man

Food40%

Plastics (clean)3%

Plastics (food)3%

Metal/Glass18%

Paper/Cardbd36%

0.412 ft3/day/man

Paper/Cardbd43%

Metal/Glass12%

Plastics (food)19%

Plastics (clean)19%

Food7%

By Weight By Volume


Equipment Installation Timetable

Plastics Waste Processors (PWPs) are being installed throughout the Fleet on a schedule thathad 50% of them installed by 1 July 1997, with all installations to be completed by 31 December1998. The installation of Metal/Glass Shredders, and Large and Small Pulpers on frigate andlarger class ships will begin in mid-1998, and will continue through 31 December 2000. Table 2summarizes by ship class the equipment installations being performed.

Table 2. Planned Equipment Installations

SHIPCLASS

CREWSIZE

Installations Planned (Quantity)

Metal/GlassShredder

LargePulper

SmallPulper

Plastics Waste Processor

PlasticsShredder

CMU CLCU HeatSealer

AGF-3 554 1 1 0 1 3 2 1AGF-11 831 1 1 0 1 3 2 1AO-177* 2791 1 1 0 1 3 2 1AOE-1 719 1 1 0 1 3 2 1AOE-6 630 1 1 0 1 3 2 1ARS-50 90 1 0 1 0 1 1 1AS-39 1771 1 1 0 1 4 2 1CG-47 409 1 1 0 1 2 1 1

CGN-36* 604 1 1 0 1 3 2 1CV-63** 5624 2 2 1 2 11 6 2CV-64* 5624 2 2 1 2 11 6 2CV-67 5786 2 2 1 2 11 6 2

CVN-65 5815 2 2 1 2 11 6 2CVN-68 6286 2 2 1 3 14 8 3/4DD-963 396 1 1 0 1 2 1 1DDG-51Flt I&II

303 1 1 0 1 2 1 1

DDG-68Flt IIA

303 1 1 0 1 2 1 1

DDG-993 303 1 1 0 1 2 1 1FFG-7 220 0 0 1 0 2 1 1LCC-19 1516 1 1 0 1 3 2 1LHA-1 2922 1 1 0 1 6 3 1LHD-1 3151 1 1 0 1 6 3 1LPD-4 1487 1 1 0 1 3 2 1LPD-17

LX1300 1 1 0 1 3 2 1

LSD-36 794 1 1 0 1 3 2 1LSD-41 852 1 1 0 1 3 2 1LSD-49 852 1 1 0 1 3 2 1MCM-1 72 0 0 0 0 0 0 1MCS-12 1746 1 1 0 1 3 2 1MHC-51 50 0 0 0 0 0 0 1

*AO-177, CGN-36, and CV-64 are currently not scheduled to get Pulpers or MGS due to decommissioning plans.**CV-63 equipment suite is under review pending decommissioning decision.


For those small ships and craft not receiving Plastics Waste Processors, use of odorbarrier bags for food contaminated plastics waste is recommended (see Enclosure 2 inAppendix A).

All installations to date have been scheduled based on ship availability. Fordetailed scheduling information, refer to Appendix E for the appropriate point of contact.


Equipment Descriptions

Plastics Waste Processor and Heat Sealer

Figure 1. Plastics Waste Processor (CMU and CLCU)

The Plastics Waste Processor (PWP) system consists of four components designedto shred, compact and process shipboard plastics waste into a 20-inch diameter, 1-3 inchthick compressed disk. These components are a Plastics Shredder, Compress Melt Unit(CMU), Closed Loop Cooling Unit (CLCU) and a Heat Sealer. The Plastics Shreddermay not be installed on smaller ship installations. It is almost identical to theMetal/Glass Shredder (see below), but is designated for shredding plastics only and vice-versa. The operator loads waste plastic onto the shredder sorting tray to perform a finalsort to remove any items that should not be processed in the shredder. The operator thencloses the sorting tray door, which allows the waste plastic to fall into the shreddingchamber. The operator then pushes the RUN button, which starts the shredder’s 5-hp


electric motor. The motor, through a reduction gear box, turns two counter-rotatingshafts, fitted with hardened steel cutting blades. One Plastics Shredder will service from1-6 CMUs. The shredded plastic is discharged into a plastic bag-lined collection binlocated under the cutting blades. After shredding, the plastic is put into a CMU whichcompacts the plastic with a mechanical ram and heats the compacted disk to surfacetemperatures above 300°F to soften the plastic, dry food wastes on the surface of thedisk, and "fuse" the shredded plastic into a dimensionally stable disk. Processing heatwill be removed from the CMUs by a CLCU that uses either sea water or chilled waterfor cooling. One CLCU can supply cooling to either one or two CMUs simultaneously,Figure 1.

The compacted disk results in a plastic volume reduction of about 30 to 1. Allprocessed plastic disks should be placed in "odor barrier" bags (OBBs) and sealed by aHeat Sealer (HS). This is primarily necessary to contain odors that might result from anyremaining food contamination, and need not be implemented if processing non-food-contaminated plastic waste. The OBB-sealed disks can be stored aboard ship forprolonged periods (60 days or more) without any health or sanitation problems as long asthe OBB is not torn. More than one disk can be placed inside an OBB, so long as it canbe properly sealed. A single CMU completes a cycle (makes a disk) in approximately 40minutes. The amount of plastic that can be loaded per cycle is approximately 10 pounds,but the actual quantity is totally dependent on the operator. The CMU will complete acycle with no plastic in it about as quickly as it can with 25 pounds of plastic. Therefore,the process rate is dependent on how much plastic the operator can load into a CMU.

The PWP installation for most ship classes consists of one shredder, three CMUs,two CLCUs and one HS. The units can be installed next to each other or separated fromone another. Large ship classes (LHD 1, CVN 68) will receive multiple PWP or PWPcomponent configurations. Small ship classes (ARS 50, MHC 51, MCM 1, PC 1) willnot receive an entire PWP installation. For these classes, the total volume ofunprocessed plastics to be stored on board is less than the required volume forinstallation and operation of an entire PWP. Therefore, only a single CMU (with CLCU)and/or HS will be installed. It is possible that when using unshredded plastic, theprocessing rate of a CMU may be somewhat reduced. However, since the quantity ofplastics generated is substantially less than on other ship classes, the daily processingtime will also be substantially less. The processed plastics volume reduction remains atabout 30 to 1.


Metal/Glass Shredder

Figure 2. Metal/Glass Shredder

The Metal/Glass Shredder (MGS), Figure 2, is a simple, easy-to-use, ruggedmachine. It is used to shred metal and glass wastes (mostly tin cans) to reduce volumeand ensure a sinkable form. It is nearly identical to the Plastics Shredder except that ithas combs between the cutter blades to assist in the shredding, and it shreds for 30seconds after the operator pushes the RUN push-button versus 60 seconds for the PS. A3 to 1 volume reduction between processed and unprocessed metal and glass can beexpected for the MGS. The shredded metal and glass is collected in a removable plasticbin and placed into burlap bags for handling and overboard discharge.

(In this document, a shredder may be referred to as an MGS [processes metal andglass only], a PS [shreds plastics waste only], or it may be referred to as an SWS [SolidWaste Shredder]. SWS is a generic acronym that refers to either the Metal/GlassShredder or a Plastics Shredder, since they both have much in common, but are not

NSWCCD–TR–63—97/25 11

identical. A Metal/Glass Shredder should never be used to process plastics, and vice-versa mainly to avoid the possibility of discharging plastic in the metal/glass shredmixture.)


Large Pulper

Figure 3. Large Pulper

Shipboard pulpers process food waste, cardboard and paper. They are alsoapproved for destroying Confidential and Secret material in accordance withOPNAVINST 5510.1H5 - “Department of the Navy Information and Personnel SecurityProgram Regulation” because all pulped material must pass through ¼” diameter holesin the pulpers’ internal sizing rings. They pulp these items into a non-floating slurry thatis pumped overboard. The large pulper, Figure 3, will be capable of processing about 75percent by weight and/or volume of all the shipboard solid waste streams. The operatorsorts waste on the built-in feed tray to remove non-pulpables such as metal, glass, andplastic. The operator then pushes the pulpable waste into the large mixing tank. Seawater at 100 gallons per minute is mixed with the waste. A 20-hp motor rotates a two-bladed impeller at high speed past five stationary cutters. The impeller pulps the wasteand generates a vortex to mix the sea water and waste. The large pulper is designed toresist damage if trash sorting errors occur and metal, glass, or other non-pulpablematerial is put into the machine. Metal and glass debris is carried to and collected in a"junk box" which is emptied manually. Plastics accidentally placed in the machine ispartially shredded and retained within the pulping chamber for manual removal.

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Small Pulper

Figure 4. Small Pulper

The small pulper, Figure 4, has been developed for use on small ships (like FFGs)which cannot easily accommodate the large pulper or for use in concert with largepulpers on large ships. The small pulper is a reduced-size, geometrically similar versionof the large pulper. A 7.5-hp motor rotates a two-bladed impeller at high speed past fivestationary cutters. The impeller pulps the waste and generates a vortex to mix the seawater and waste. Like the large pulper, the small pulper will process paper, food waste,and cardboard. Like the large pulper, it can be used to destroy pulpable Confidential andSecret documents. However, large items, including large cardboard boxes or pieces ofcardboard, will have to be torn or cut before they can be fed into the small pulper's feedchute.


Waste Handling Procedures

Source Separation - Enforcement/Inspection

This new solid waste management equipment has been installed as the result ofrecent environmental legislation. The successful shipboard implementation of thisequipment depends to a large part on how easy the process is on all concerned. If asailor has to waste a lot of time in line to get rid of a bag of trash, other duties may getmissed. To make the process as efficient and as fast as possible, you need to eliminatethe possibility of anyone having to separate trash in the processing area. The incomingbags need to be properly “typed” so that the operators can quickly and confidently placethe contents into their respective processors without worrying about what is in the bagthat is going to foul up their machine. The only way to accomplish this routinely is toimplement and enforce “source separation”. Most spaces need to have three trashcontainers on-site, one for plastics only, one for metal & glass, and one for pulpables.They don’t necessarily need to be emptied and replaced on a daily basis. Experience hasshown that once this procedure has been established, it becomes “second nature,” andsource separation is performed automatically with little or no thought involved (so longas the appropriate containers are available for disposal). It seems easier to implementsource separation on a smaller ship, since crew members are more likely to know eachother, and ignoring source separation will only make more work for someone youalready know. On a larger ship, like a CVN, the job becomes slightly more difficult. Onone such ship, one or two Master-at-Arms (MAAs) were stationed at the entrance to thesolid waste processing spaces. Their duty was to make sure that nobody just came in anddropped a bag of trash off without having it inspected by one of them first. All bagswere required to be marked on the outside with the work center’s identification name incase it needed to be returned because of improper source separation. During mealtimes,lines tended to form, people would become antsy, wanting to be somewhere else (SeeTraffic Flow). Without the MAAs, there would have been long lines of bags, with nopeople attached, making it impossible to enforce source separation. With the MAAsthere, anybody bringing in an unsorted bag of waste would be told to go back to theirwork center and sort it properly. This often resulted in an argument, which the MAAsnever seemed to lose.

Traffic Flow

It’s nice if you have a large space that has an entrance at one end, and a useable exitat the other, but it’s not very likely that you do. Most of the processing areas have onlyone entrance that can be effectively used for traffic flow. Scheduling procedures need tobe established to minimize the problems inherent in two-way trash-carrying traffic in aconfined area. If possible, set up drop-off times by Division/Work Center. The worstthing that can happen is for incoming traffic to get frustrated by a long wait, drop off atrash bag, and leave. Inevitably, the bag will not have been properly segregated, and willhave to be re-sorted prior to processing. This uses up a lot of space in an alreadycramped area, adds to the operator’s burden, frustrates other sailors waiting with trashbags, and causes more drop-and-runs. Lines are going to form, no matter how well youplan ahead. These lines need to be far enough out of the way to not impede other shipoperations (you don’t want long lines of trash-carriers in a narrow passageway, for

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example), but not so far away from supervision that you get a problem with the drop-and-runs. The smaller the ship, the harder this gets.

Staging Requirements

You generally won’t have to worry about staging area requirements, since this isnormally addressed and taken care of during equipment installation. Staging areas aredefined as locations aboard ship where the solid waste stream can be stored both prior toand after processing. Most ships should have space for one half day of staging forunprocessed plastic, metal and glass, food waste, paper, and cardboard. However, thereare sure to be numerous cases where future needs in other areas will require areconfiguration of the ship that impacts on the solid waste staging availability. Parts ofthe ship installation manual for solid waste equipment (Ref. 5) has been reproducedbelow to provide a feel for what should be provided in the way of staging. The stagingrequirements for each solid waste stream are defined below in Table 3.

Table 3 . Solid Waste Staging Requirements

Solid Waste Stream Unprocessed ProcessedPlastics 1 day’s staging* 1 solid waste mission duration (see Table 4)Metal/Glass 1 day’s staging* 1 day’s staging (normally only needed when

too close to shore)Paper/Cardboard/Garbage 1 day’s staging* N/A

*Due to space constraints, usually less than one full day of staging was achieved.

Table 4 provides (for each ship class) the solid waste equipment design missions asdefined in the U.S. Navy Shipboard Solid and Plastics Waste Management ProgramPlan, reference (2). A solid waste mission duration is an estimate of a nominal at-seaperiod, representative of the intervals between port calls during peacetime operationswhere processed plastics waste disks can be off-loaded and industrial support can beobtained if required. It was chosen to strike a reasonable balance between providingreliable solid waste processing capability for each ship class, while helping to reduce thecost and ship impacts for both back-fitting equipment and new ship constructioninstallations.

Table 4. Solid Waste Equipment Design Mission Durations

Ship Class Solid Waste Equipment DesignMission Duration Estimated (Days)

PC 5MCM, MHC 15CV, CVN 60All Others 30

The amount of solid waste generated in one day by a particular ship class iscalculated using the generation rates shown in Table 1. Staging areas for one half day ofunprocessed waste are required, and should have been provided for during installation.


The solid waste staging volumes required for processed waste are calculated using thestaging requirements and mission data shown above, and the volume reductionscontained in Table 5. Sample calculations are provided below.

Table 5 . Processed Solid Waste Volume Reductions

Plastics Processor - (plastics) 30 to 1Metal/Glass Shredder - (metal & glass) 3 to 1Large Pulper - (paper, cardboard & garbage) N/ASmall Pulper - (paper, cardboard & garbage) N/A

Sample Solid Waste Staging Calculations

As an example, for the CVN-68 the following quantities of solid waste aregenerated:

Plastics:

One Day's Staging (Unprocessed Waste):6286 person crew x 0.20 lb./person/day = 1257.2 lb./day generated1257.2lbs/day generated = 967.1 cu.ft./day plastics generated1.3 lb./cu.ft. (density)

This staging area should be divided proportionately between each plastics wasteprocessing area.

One Mission’s Disk Storage Volume Requirements:1257.2 lb./day x 60 days/mission = 75,432 lb./mission plastics generated

75,432 lb./mission generated = 1934.2 cu. ft/mission plastics generated1.3 lb./cu.ft. (density) x 30 (PWP volume reduction)

The processed plastics waste stowage area can be divided proportionately betweeneach processing location aboard ship or can be stowed in another location.

Metal & Glass:

One Day's Staging (Unprocessed Waste):6286 person crew X 0.54 lb./person/day = 3394.4 lb./day

3394.4lbs/day generated = 287.7 cu.ft./day metal & glass11.8lbs/cu.ft (density)

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One Day's Staging (Processed Waste):287.7cu.ft/day generated = 95.9 cu.ft./day metal & glass3:1 (SWS volume reduction)

Food Waste, Paper and Cardboard:

One Day's Staging (Unprocessed Waste):6286 person crew x 1.21 lb./person/day = 7606.1 lb./day food waste

7606.1lbs/day generated = 169.0 cu.ft./day food waste45.0 lb./cu.ft. (density)

6286 person crew x 1.11 lb./person/day = 6977.5 lb./day paper/cardboard

6977.5lbs/day generated = 1162.9 cu.ft./day paper/cardboard6.0 lb./cu.ft. (density)

Unprocessed/Processed Solid Waste Staging Requirements

Permanent, segregated staging bins may be provided for all unprocessed solidwaste streams and for processed metal/glass within the solid waste processing space(s).Bins are optional and may be helpful in providing storage volume. However, a ship’sconfiguration and available space may be such that the installation of permanent binsmay not be possible or desirable. If bins are used, they should be designed as follows:

• Bins should be constructed of corrosion resistant (CRES) stainless or plastic.• Bins should prevent mixing of waste streams.• To prevent sanitation problems, avoid sharp edges, sharp corners, protruding

fasteners and joints which can collect debris.• Bins should allow easy placement/removal of waste.• Bins should have a deck drain and should be designed to prevent spills from

migrating to the remainder of the compartment.• Bins should be designed so bagged waste can be stacked safely as high as overhead

clearance allows.• Bins should be located to not interfere with traffic flow within the solid waste

processing space.• For Processed Metal and Glass only: Processed waste is removed from the Solid

Waste Shredder in burlap bags. The permanent staging bin should be designed toaccommodate these bags.

• Bins should be designed to prevent standing water from collecting under any part ofthe bin, especially if hidden from view.

As an example for a small area, a 36 inch high stainless steel bin surrounded byremovable vertical battens would suffice. In this type of arrangement, all portions of thebin should be accessible by a person standing outside of the bin. For larger areas,expanded metal cages would suffice provided that all of the previously stated


requirements are met. For example, if expanded metal cages are installed, deck coamingshould be installed around the cage to prevent spills from migrating to the rest of thecompartment.

On-Board Storage (Plastic Disks)

Once waste plastic has been processed, and the plastic disks have been placed andsealed in odor-barrier bags (OBBs), the generation of odor is all but eliminated so longas the disks are stored in an area where they won’t get moved around a lot. The more thebagged disks are moved around, the more likely that the bags will be punctured,reducing their effectiveness at controlling odors. Dedicated processed plastics stowageareas are being provided as part of the plastics processor ship alteration. The areasprovided are sized to provide 30 days stowage volume except for CV/CVNs which willhave 60 days stowage volume. These stowage areas may be located in the samecompartment as the processing equipment or in a separate location. The spaces must beventilated, and have deck drains. Due to the high BTU content of plastics, compartmentsprinkling and fire extinguishers are required wherever plastics is being stored.Therefore, plastics should only be stored in the designated stowage location as defined inreference 5.

Processed plastics stowage should:

• Be located to not interfere with traffic flow within the space.• Allow the processed plastic "disks" to be stacked safely as high as overhead

clearance allows.• Allow easy placement/removal of the processed plastic "disks" to minimize the

possibility of ripping or tearing the OBB which could lead to later odor andsanitation problems.

• Be located away from the storage area for unprocessed plastic, if possible.

When unprocessed/processed solid wastes are stowed in a different space from theprocessing equipment, the same space treatments must be provided as required for theprocessing equipment.

If processed plastics are stowed in a cabinet/locker accessible only from a weatherdeck, the ventilation and fire protection requirements are waived, however, naturalventilation should be provided. Fire protection requirements shall be by local fireextinguishing methods (fire extinguishers etc.) unless the stowed plastic is near other firesensitive areas of the ship such as fueling stations. Under these circumstances, the firefighting requirements will be considered on a case basis. When stowed on weatherdecks, processed plastic shall not be located in way of ventilation intakes nor obstructaccess to fire fighting equipment or extinguishing system controls.

Transfer to Shore and Replenishment Ships (Plastic Disks)

Most ships are provided with a storage area or areas that can accommodate a 30day supply of disks (carriers have a 60 day capability). As plastic disk recyclingcapabilities and facilities become more available, holding on-station until transfer toshore becomes possible is highly recommended as long as storage areas do not becomeover-filled. Processed disks can be off-loaded during a resupply operation, so long as

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the resupply ship is willing to take the disks retrograde, no special precautions need to betaken. The disks should be carefully packed in a tri-wall to avoid puncturing the OBBs.The tri-wall should be well taped shut, so it can then be high-lined or heloed over to thereceiving ship.

Transfers to shore generally do not demand the same degree of care and attention.It is likely that the disks will be mixed in with other waste plastic, so the integrity of theOBBs is no longer an issue.

Pier Side Disposal (Plastic Disks)

Shore transfer and disposal should require no special procedures beyond notifyingthe pertinent Public Works Center that you will be off-loading “X” number of pounds ofcompressed plastics waste. The shore side facility may require the segregation of thesedisks, and handle them differently than other waste.


Safety and Health Issues

The following safety and health precautions supplement the specific warnings andcautions appearing in the technical manuals for the individual equipment and in thecomputer-based interactive courseware. The solid waste management equipmentemploys electrical voltages that are dangerous and may be fatal if contacted by operatingor maintenance personnel. There are electrical and mechanical devices associated withall the equipment that must be inspected and maintained in a constant state of readinessto avoid personnel injury or equipment damage.

Some components are extremely heavy. Extreme caution must be exercised whenworking with or maintaining this equipment. While every practical precaution has beenincorporated into the design of the equipment, it is not possible or practical to try todescribe every condition or hazard that might be encountered. All operating andmaintenance personnel should, at a minimum closely observe the following:

Unless under the direct supervision of a qualified trained person, no personnelshall operate or maintain solid waste management equipment for which he/she isunqualified.

Reliance on interlock circuits, switches and valves to remove electrical power, seawater and ship service air pressure from the solid waste management equipment shouldnever be assumed. Always observe the ships’ proper tag out procedures.

If a hazard condition is detected or suspected, particularly after equipmentinstallation, modification or repair, report it at once so that it can be investigated,publicized, or corrected as required.

Because of the food-contaminated nature of the waste, care should be taken to keepthe space as clean as possible. The deck in the space will usually be wet whenprocessing is underway, so care must be taken to ensure adequate footing. You alsoneed to expect that some of the incoming containers will contain oil, and that some ofthat oil will end up on the deck, making footing even worse.

Specific safety and hazard issues as they apply to each specific type of solid wastemanagement equipment are as follows:

Plastics Waste Processor, Odor Barrier Bags, and Heat Sealer

Laboratory and shipboard evaluation of the PWP and OBBs in regard to health andsafety issues have been performed by the Navy over the past seven years. Tests havebeen performed to determine the effectiveness of plastic disks and/or bags in preventingodors, to examine the biological activity caused by gas generation and indirectly, todetermine the potential of human exposure to possible health hazard sources.

Based on the results of these tests, the Bureau of Medicine and Surgery (BUMED)and the Navy Environmental Health Center (NEHC) recommended that: a) odor barrierbags containing food contaminated plastic be stored in ventilated spaces, b) personnelwho come into contact with broken or leaking bags should wash their skin with soap andwater and remove and launder their clothing if it also comes in contact, c) a wound thatcomes into contact with leaking bags should be treated as any other wound for infection,

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d) waste plastic contaminated with solid and liquid food should be scraped or drained asmuch as possible (before processing) to minimize bacterial reproduction and gasproduction, e) contents of bags should not be ingested, and f) spills from bags in storageareas should be cleaned with detergent and water and be treated with disinfectant.NEHC also recommended that PWPs be designed to achieve a core temperature withinthe plastic disk of 170° F for five minutes to ensure destruction of organisms. This coretemperature parameter was incorporated into the PWP Compress Melt Unit (CMU)design. These NEHC space and disk handling recommendations have been incorporatedinto PWP interface requirements for ship installations, technical manuals and crewtraining literature for the PWP and odor barrier bags.

There had been some concern about the health and sanitation issues pertaining tothe PWP and OBBs that are used to process and store waste plastic aboard Navy ships.Namely, the concern was over the possibility that the plastics waste disks producedcould be unsanitary to handle, that the CMUs might be difficult to keep clean and bagsmight become bloated with noxious gasses creating an unhealthy situation. While thebloating of bags containing very heavily food-contaminated plastic disks has beenobserved occasionally both during laboratory and shipboard testing of prototypeequipment, there have been no reports from any Navy ship of unhealthy conditionsstemming from properly stored plastics disks and properly cleaned CMUs, including noreports of sailors becoming ill.

The operators of CMU equipment are required to wear gloves and an apron. Theoperators of the Plastics Shredder will be required to wear protective gear whichincludes gloves, ear protection, face shield, safety shoes, and an apron.

Staging areas where unprocessed waste plastic can be stored were provided near theships’ PWPs during the equipment installation. In addition, storage areas were providedwhere bagged plastic disks can be stacked between removal battens or placed incardboard (tri-wall) containers for long term storage at sea. Space treatments for thesestaging and disk storage areas involving deck treatments, bulkhead sheathing, fireprotection and ventilation were incorporated into each ship installation to maximizesanitation and habitability concerns. Sailors must be trained to carefully handle baggeddisks to guard against tearing or ripping the bags when carrying them to and fromdesignated storage areas. Unsafe health and sanitation conditions will not occur whenPWP and odor barrier bags are operated and used properly, the way they were intended.

Metal/Glass Shredder

The Metal/Glass Shredder itself is outfitted with a number of safety devices andinterlocks designed to prevent injury to the operator. Nothing is gained by trying todefeat them, other than to increase the probability of your injury. Operators of theMetal/Glass Shredder will be required to wear protective gear which includes gloves, earprotection, face shield, safety shoes, and an apron. The shredded metal and glass hasvery sharp edges, and must be handled appropriately.

Pulpers

The operator needs to use care when lifting waste containers up to the pulper in-feed tray. They can be excessively heavy. The pulper can take it, but the operator maybe strained. Operators should not reach into the pulper chamber when the unit is


running. Although the blades are way down at the bottom, the contents of the chamberare whirling around at high speed, and may include hard items that could damage an armor kick back at the operator. Pulper operators will also be required to wear protectivegear which includes gloves, ear protection, face shield, safety shoes, and an apron.

Equipment Spaces

All of this equipment is processing waste that is contaminated with food. Thesespaces need to be set up so that they can easily be kept clean. Food waste will need to bewashed off the inside and the outside of the equipment at least on a daily basis, and thedeck needs to be as non-skid and clean as possible. If mats are used to increase footingon the decks, they need to be easy to clean, or the cure may be worse than the disease.

Storage Areas (Plastic Disks)

Storage areas should generally not have personnel inside except for the purpose ofbringing plastic disks in or taking them out. Solid waste equipment spaces can be usedto meet some of the daily storage needs, but a larger, dedicated space(s) is usuallyneeded, and is normally provided and outfitted at the time of equipment installation.These spaces need to be kept available for long term storage of plastic disks.

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Equipment Operation and Processing Experiences

Plastics Waste Processor

Lessons Learned.

1. The more plastic you load per CMU batch, the greater the process rate. The lessplastic you load into the CMU, the firmer (more solid) the disk produced.

2. Before placing waste plastic into the CMU, always spray the ram face, door face andthe inside and top of the chamber with special mold release agent (properly diluted 4:1).This will help keep the completed plastic disk from sticking inside the unit, and helpslubricate the internal sliding parts.

3. Placing excessive food-contaminated waste plastic into the PWP should be minimized.Remove or rinse food from the waste plastic as much as possible. Excessive food wastewill be extruded from under the door onto the top of the CMU and around the ram downonto the lower portions of the CMU and onto the deck. Regardless of where it comesout, large amounts of food placed into the CMU will require excessive time and effortfor equipment clean up after processing.

4. Processing time to produce a plastic disk after starting the PROCESS push-button is40-50 min including a 10-12 minute cooling time. If processing times begin to extendmuch longer than these times, contact maintenance personnel for inspection.

5. Place completed plastic disks into odor barrier bags and store them in the appropriateships’ storage location as soon as possible. Leaving and moving bagged disks around thecompartment will increase the likelihood of tearing the odor barrier bag, contaminatingother disks, thus increasing the potential for odor problems.

6. If an error message is displayed on the message display unit, the operator should makea note of it before securing the unit so that maintenance personnel will know where theproblem can be found. Securing electrical power to the CMU will erase the errormessage from the display.

7. Always retract the CMU ram to the RESET position after ejecting a plastic disk orwhen the unit is not being used. Leaving the ram in the up or eject position for longperiods of time is not recommended, since it is more exposed for damage in that position.

8. PWP equipment needs to be washed down often, inside and out, with detergents anddisinfectants using a warm water hose to eliminate odors and bacteria growth.

What to Process.

The PWP is extremely tolerant to what is placed inside it. It can process the foodand non food-contaminated waste plastic found aboard U.S. Navy ships. Typicalexamples are as follows:


• Lightly Food-Contaminated Plastic - food containers, meat wrappers, milk bladders,bottles, bags, utensils, etc.

• Non-Food Contaminated Plastic - bubble wrap, bags, tape, bottles and containers upto 5 gallon in size, etc.

• Items having plastic components - music tapes, pens, razors, etc.

There are certain items containing plastic that gain little to no benefit in beingprocessed in the PWP. Examples of these items include: foam mattresses, electricalcable, linoleum, shoes and pillows. They should be stored unprocessed.

What NOT to Process.

While the PWP has been designed to be very tolerant, there are several items thatshould not be processed. They include:• Aerosol cans (non-punctured).• Hazardous or flammable materials Pressurized containers.• Butane Lighters

Metal/Glass Shredders

Lessons Learned:1. Use the shredder feed tray to perform a final sort of the in-feed waste.2. Never place waste plastic into the Metal/Glass Shredder.3. Always ensure that a collection bin is placed under the shredder chamber.

What to Shred.

The Metal/Glass Shredder has been designed to shred:• Soda cans.• Food cans.• Empty paint cans.• Glass bottles & jars.

What NOT to Shred.

The following must not be processed in the Metal/Glass Shredder:• All aerosol cans.• All waste plastic including items that are combinations of plastic and metal or glass.• Any loose food.• Any loose paper or cardboard.• Hazardous or flammable materials.

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Pulpers (Large & Small)

Lessons Learned.1. Poor performance caused by large amounts of non-pulped residue found in the tankcan result from:

- Not removing the bulk of plastic tape from cardboard (the tape adheres to thecardboard and develops static charges that hold cardboard away from thecutting mechanism

- Pulping wet strength bags - They either don't process or process very slowly(depending on their design)

- Pulping plastic items and textiles (rags, clothing, etc.)

2. Cutting blades do NOT have to be sharp and therefore are unlikely to be the cause ofpoor performance.

3. The mess crew makes the best equipment operators because they can coordinate theircleanup process with the equipment operation and cleanup. They also tend to be moreconscious of good cleanup practices because they deal with cleanup of food waste in thegalley. Having personnel from other departments assigned as TDY equipment operatorsalso can work out well and it allows these personnel to carry back to their departmentsan appreciation for the impact that source separation has on the equipment operator’sperformance and burden.

4. The most important areas for cleanup are underneath the pulpers and in the top of thefeed chutes.

5. The impeller should only be removed when the impeller is severely bound (bound isdefined as the impeller can't be turned by hand after the slurry chamber has beencleaned). A severe bind (as defined in the technical manual) is one that results in highcurrent readings that are sustained while the pulper is running for 20 minutes with nowaste products in the tank.

6. When ships procure materials in cardboard boxes, they should try to request that non-reinforced paper tape be used rather than fiberglass reinforced or cellophane tape.

7. Do not place any rags, textiles, wood or anything not biodegradable into the pulper.These things will just slow you down. The operator should perform a final sort of allwaste using the pulper feed tray.

8. Operators should watch the ammeter on the electrical control panel to regulate theamount of in-feed and to determine when the unit needs to be shut down for cleaning.

9. Large trash cans (44 gal) should be filled no more than half full to avoid possiblepersonal injury when lifting it into the (large) pulper feed tray.

10. Wet-strength paper bags process fairly slowly in the pulpers. If you have to deal


with wet-strength paper bags, there are basically two alternatives. Either feed them inslowly along with food waste (helps to carry the bag pieces through the pulper), or savethem to process separately. Then when you get to the point where the pulper won’t beneeded for a couple of hours, feed all of the bags in at once, and let the machine run.The bags will be pulped, and much (but not all) of the residue will be discharged.What’s left will have to be manually cleaned out of the machine before resumingprocessing other wastes. The operator will have to make a determination of whichprocedure is best.

11. Plastic residue removed from the pulper can be processed in the PWP.

12. A squeegee with a long handle is useful for pushing heavy food waste through thefeed chute.

13. Experience will show that there are a number of pulpable materials that process moreslowly than others. Materials such as egg shells, meat bones, telephone books, and corn-on-the-cob all take more processing time. However, the rate can be picked up by mixingthese materials with other food waste. This keeps the concentration of “difficult”materials low, and the other food waste helps to “pull” the difficult materials through thesystem much faster.

What to Pulp.• Paper and Cardboard Products - newspaper, computer paper, phone books, napkins,magazines and any other paper products from berthing spaces. IMPORTANT NOTE:The bulk of plastic tape should be removed from paper and cardboard products beforepulping. If you don’t, the plastic will just build up inside the pulper and will reduce thethroughput rate until the pulper has to be shut down and cleaned out to restoreperformance. It may seem like a waste of time to pull the plastic tape off the cardboard,but it’s a classic case of “You can pay me now, or pay me later.” All waste plastic goesinto the PWP.

• Food Waste - Meat poultry, fish and other bones; coffee grounds and filters, fruit andvegetables and nut shells. Note that some bones may find their way into the junk boxinstead of being pulped completely.

• Classified Materials - White bond paper, Xerox paper, manuals, teletypewriter paper(carbon-interleaved), single copy teletype paper (without carbons), type 5081 manilatabulating cards, teletypewriter tape and computer paper. Coordinate any classifieddestruction with Security - you will not want to process other wastes with the classifiedmaterial, since you’ll probably have to prove to Security that there is no leftoverclassified material in the tank after processing is over. The pulper meets therequirements of OPNAVINST 5510.1H – “Department of the Navy Information andPersonnel Security Program Regulation.”

What NOT to Pulp• Metal and glass.• All aerosol cans.

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• All waste plastic including items that are plastic with either metal or glass.• Hazardous or flammable materials authorized under the Shipboard Hazardous

Materials List.• Textiles including rags, wipes, discarded uniforms and shoes.• Non-pulpable classified documents including direct fax master, type M6, carbon

typewriter ribbon, polyethylene plastic film, cotton typewriter ribbon, microfiche,flat sheet film, microfilm, nylon filament paper and aperture cards.

• Steak bones may process too slowly for satisfactory operation.

Lessons Learned Applicable to all Solid Waste Management Equipment

1. Clean each unit of solid waste equipment daily and as required per the MaintenanceRequirements Cards (MRCs) using the hot water hose. Make sure that all electrical tagout procedures are observed during cleaning operations. Not all equipment in the spacewill be watertight, so care must be taken to ensure that those components are not sprayedduring cleaning. Do not use a pressure washer to clean the equipment; the electricalconnectors are not made to handle the extra force and could short out.

2. Keep all electrical control panels tightly closed at all times. Unauthorized opening ofthese units could effect the water tight integrity of the enclosure doors causing severeinjury or death. Only trained electrical maintenance personnel should open and servicethese enclosures.

3. Refer to the technical manual provided with each unit for all troubleshooting, repairand replacement procedures.

4. Perform maintenance procedures using the MRCs provided.

5. If the ship has both a PWP and a pulper, then consider using plastic bags instead ofwet-strength paper bags. Empty plastic bags are easy to process in the PWP. Wet-strength paper bags process slowly in the pulpers. Wet-strength paper bags also costmuch more than their plastic counterparts. There are alternative bags that have beenidentified by the PRIME program as shown below:

Plastic Existing 30 gal 8105-01-183-9768Existing 6 gal 8105-01-184-7159

Wet Strength Paper Existing 30 gal 8105-01-284-2924w/labeling – “Plastics Only” 30 gal 8105-01-437-4921

w/labeling – “Metal & Glass Only” 30 gal 8105-01-437-4924w/biodegradable liner 30 gal 8105-01-437-4925

Existing 7 gal 8105-01-284-2923w/labeling – “Plastics Only” 7 gal 8105-01-437-1600

w/labeling – “Metal & Glass Only” 7 gal 8105-01-437-4923w/biodegradable liner 7 gal 8105-01-437-4926


Manning

Supervision

The success or failure of your solid waste management program will depend on thepresence of adequate supervision and support for the program. Operators left tothemselves are likely to continue processing at whatever rate is necessary to keep upwith the incoming feed streams, and may not consider the need to periodically shut downfor clean-up of the equipment and the space. This can be a particular problem on largerships where the equipment may be operated multiple shifts, and shutting down for clean-up might seem like a wasted effort. Adequate supervision is needed throughout theprogram to ensure that equipment is operated and maintained properly, source separationprocedures are established and enforced, that spaces are properly cleaned andmaintained, that the correct level of spares support is available and that operatingschedules can accommodate the projected waste flows.

Operators

Manpower requirements for operation of the solid waste equipment are to be metby the normal ship’s compliment of Mess Management Specialists (MS), ShipServicemen (SH), Storekeepers (SK), Aviation Storekeepers (AK), or others asappropriate. The installation of this equipment was not accompanied by a change in theShip’s Manning Document, so the operation of the equipment must be accomplishedusing existing ship’s force. On large ships, TDY personnel from other departments toaugment the number of equipment operators has been successful during longdeployment. It is not required that trash disposal and processing spaces be mannedunder any condition of readiness. If the operators are called away to assigned GeneralQuarters stations, deactivate the machines using their respective emergency stop push-buttons, and deactivate supply power. Also, secure all firemain isolation valves classifiedas a “Z” valve during General Quarters.

Enforcement

The need for enforcement covers two overlapping areas. First, shipboard sourceseparation needs to be mandated and maintained throughout the ship. Enforcement mustcome from the “top down” so that everyone onboard is made aware of theirresponsibility to accomplish source separation of their disposed solid waste. Failure tocomply is generally addressed on a case-by-case basis, assuming that it’s not ship-wide.Secondly, there is a need to assure accountability (ownership) for each bag of trashbrought into a processing room. Normally, the bag should be inspected for propersorting by one of the equipment operators before the crew member who brought the bagin is allowed to leave. If you don’t do this, sailors will be dropping off bags of trashwherever and whenever they feel like it. Since some of these bags may not be properlysorted, having the name and work center identification on each bag is necessary. Thiswill keep the operator from having to stop processing in order to perform a sortingoperation that should have been completed at the work center. While long lines of crewmembers are not desirable, the lines are preferable to unattended waste bags piling up ina passageway. Depending on the ship, this type of enforcement can be performed byMasters-At-Arms (MAA) or by the equipment operators. However, if it is left to the

NSWCCD–TR–63—97/25 29

operators, then they must have sufficient authority to impose penalties for non-compliance where needed.

Maintainers

All of the solid waste management equipment is considered hull, machinery andelectrical equipment. Most ships with solid waste equipment have utilized the AuxiliaryDivision of the Engineering Department to maintain their solid waste equipment.


Crew Training

Training Concepts

The solid waste management equipment developed by the U.S. Navy is notcomplicated to operate and maintain. The baseline training concept developed for theequipment is to “Train the Trainer.” The Navy training plans for the solid wastemanagement equipment12,13 specify computer-based interactive courseware (ICW) as theonly formal training. Each ship receiving solid waste management equipment will haveone or more crew members receive supplemental training by an In Service EngineeringAgent (ISEA) after equipment installation is completed. Detailed training of theequipment operators and maintenance technicians will be accomplished using onboard(computer-based) interactive courseware (ICW) in accordance with the requirements ofOPNAVINST 1540.55 – “Shipboard Training Enhancement Program (STEP).”Experienced operators and senior rates familiar with the equipment will also be availableto provide practical and ‘hands-on’ knowledge to less experienced entry level personnel.There is no school house training planned for the equipment.

Training Course Materials - Interactive Course Ware (ICW)

Training for the solid waste management equipment will be accomplished on boardwith computer based ICW CD-ROMS provided through STEP. There are two CD-ROMs being provided for training. The CD-ROMS will be Windows based products:One CD-ROM for the Plastics Waste Processor (PWP) Compress Melt Unit(CMU) andClosed-Loop Cooling Unit (CLCU) and the Solid Waste Shredder (SWS) and one CD-ROM for the Large and Small Pulpers. Initially the ICW CD-ROMS will be delivered tothe ship at the time of installation Eventually, the ICW for solid waste managementequipment will be provided via the STEP program.

Each ICW contains separate operator and maintenance modules with separatelessons for each. There are pre- and post-tests for each module and lesson. The post-testis used to check a student’s comprehension of the lesson material. The ICW requiresthat the student re-take the subject lesson if a score below 75% is achieved. Theoperator modules describe equipment description and operation. The maintenancemodule includes integrated lessons for operation as well for troubleshooting, adjustmentand repair. Each lesson is 40-50 minutes long and was developed to a level III categoryof functionality in accordance with STEP Program Specifications and MIL-STD-1379D.The following is a summary of the material covered under each module:

Large Pulper or Small Pulper ICW (Module formats are the same)

Operator Training ModulePre-TestHow-to Module (on using the ICW CD-ROM)IntroductionModule 1

Lesson 1 - General InformationLesson 2 - Equipment Description and FunctionalityLesson 3 - Equipment OperationPost Test

NSWCCD–TR–63—97/25 31

Maintainer ModulePre-TestHow-to Module (on using the ICW CD-ROM)Introduction

Module 1Lesson 1 - General InformationLesson 2 - Equipment Description and FunctionalityLesson 3 - Equipment OperationPost Test

Module 2 - Troubleshooting and MaintenanceLesson 1 - TroubleshootingLesson 2 - Maintenance Adjustment and Alignment RepairPost Test

PWP and SWS

Operator ModulePre-TestHow-to Module (on using the ICW CD-ROM)IntroductionModule 1 - Solid Waste Shredder

Lesson 1 - Safety Summary and General DescriptionLesson 2 - Equipment Description and FunctionalityLesson 3 - Operating ProceduresPost Test

Module 2 - CMU, CLCU and Heat SealerLesson 4 - Safety Summary and General DescriptionLesson 5 - Equipment Description and FunctionalityLesson 6 - Operating ProceduresPost Test

Maintenance ModulePre-TestHow-to Module (on using the ICW CD-ROM)IntroductionModule 1 - Solid Waste Shredder (Same as Operators)Module 2 - CMU, CLCU and Heat Sealer (Same as Operators)Module 3 - SWS Troubleshooting and Maintenance Information

Lesson 7 - SWS Troubleshooting GuideLesson 8 - SWS Adjustment, Alignment and Repair Procedures

Module 4 - CMU, CLCU and Heat Sealer Troubleshooting and Maintenance InformationLesson 9 - Troubleshooting GuideLesson 10 - Adjustment, Alignment and Repair ProceduresPost Test


Follow-on training will also be accomplished using the same ICW packages. Inaddition to its effectiveness as a training tool for new operators and maintainers, theICW will serve as a valuable resource for future training refreshment and a prompt forhelping resolve maintenance problems.

Training Hardware (Computer) Requirements

The ICW CD-ROMS are designed to operate on the Naval Education and TrainingPersonnel and Management Support Activity (NETPMSA) supplied computer hardwarescheduled to be in the Learning Resource Center aboard each ship. If a NETPMSAsupplied computer is not installed on your ship, the following computer capabilities arerequired to adequately operate the ICW CD-ROMs:

- 486 (33 MHz) or Faster IBM Type Computer .- VGA Compatible Color Monitor.- 16 Bit SoundBlaster Compatible Sound Card Supporting Stereo Headphones or

Speakers.- 2x or Faster CD-ROM Drive (CD-ROM can be run using ROM Drive or loaded onto

computer hard drive [Approximately 225 MB per CD-ROM]).- 3.5 inch Disk Drive (For scoring individual students on a floppy disk for recordstorage).

Job Qualification Requirements (JQRs)

Sample Job Qualification Requirements for the SWS, CMUs and pulpers areprovided in Appendix B. JQRs were provided by USS GEORGE WASHINGTON andUSS WASP, which were consolidated into the samples provided here. They should betailored as needed to meet the requirements of your ship.

Related Training Materials

Appendix C contains a listing of related training materials and environmentalresources that are readily available to the Fleet.

NSWCCD–TR–63—97/25 33

Logistics and Maintenance Support

Technical Data

Technical Manuals have been developed for the PWP (CMU/CLCU), SWS and theLarge and Small Pulpers. These technical manuals contain information to operate,maintain, troubleshoot and repair each type of equipment. The repair procedures addressorganizational and intermediate levels of maintenance. The PWP and SWS are beingprovided in two different electrical configurations. The electrical enclosures come witheither military type components in one configuration or all commercial type componentsin the other. A single technical manual covers both configurations. Technical manualsfor the pulpers are under final revision. The Technical Manual Identification Numbers(TMIN) currently assigned for the Solid Waste Management Equipment are:

PWP6 - S9593-C4-MMM-010

SWS7 - S9593-C5-MMM-010

Large Pulper8 - S9593-C2-MMM-010

Small Pulper9 - S9593-C3-MMM-010.

An operator’s manual for the heat sealer comes with each unit.

Planned and Scheduled Maintenance

The required preventive maintenance procedures to be performed on a scheduledbasis are provided in Planned Maintenance System (PMS) documentation developed foreach type of solid waste management equipment. Chapter 4 of each technical manualincludes a maintenance index summary for each of the MRCs developed including howfrequently each is to performed. MRCs (at the time this document was written) for eachtype of solid waste management equipment are listed in the Table 6, but check the mostcurrent PMS documentation to make sure there have been no changes:

Table 6. Solid Waste Management Equipment MRCs

Plastics Waste ProcessorMRC Number Description Frequency

76 C3PX N Clean CMU and cooling unit Daily76 C3PY N Clean and inspect sea water strainer Monthly as required76 C3PZ Y Change PLC battery Annually76 C3QA N Remove and clean CMU ram After every 80 cycles

(Plastic Disks)76 C3QB N Inspect CMU and cooling unit After every 350 cycles

(Plastic Disks)76 C3QC N Clean air filter water collection bowl After every 350 cycles

(Plastic Disks)76 C3QD N PWP lay-up procedures As required76 C3QE N PWP start-up procedures As required

Solid Waste Shredder


MRC Number Description Frequency76 C3QL N Clean and inspect SWS Daily76 C3QM N Lubricate shredder chamber bearing Weekly (should be daily)76 C3QN N Clean and inspect SWS Monthly76 C3QP N Inspect speed reducer oil level Quarterly76C3QQ N Clean and lubricate chain coupling Semi-annually76 C3QPZY Change PLC battery Annually

Heat SealerMRC Number Description Frequency

N/A Remove and clean stationary andfloating guide bars

As required

N/A Lubricate carrier chains Every 8 operating hoursN/A Check lubrication of drive gear MonthlyN/A Check and replace motor brushes As required

Large PulperMRC Number Description Frequency

59331 D1R Clean and Inspect Large Pulper Daily59331 D2R Clean and inspect strainer Daily59331M-1R Inspect impeller drive bearing

housing mechanical face sealMonthly

59331 Q-1R Inspect impeller drive belt assembly Quarterly59331 Q-2R Lubricate latch assembly on access

and junkbox doorQuarterly

59331 S-1 Inspect conductivity sensor Semi-annually59331 S-2 Inspect power indicator lights Semi-annually59331 S-3R Inspect proximity switches on access

and junkbox doorSemi-annually

59331 S-4R Inspect impeller drive assembly Semi-annually

Small PulperMRC Number Description Frequency

59332 D1-R Clean and inspect the Small Pulper Daily59332 M1-R Clean and inspect the strainer Monthly59332 M2-R Inspect the mechanical face seal Monthly59332 Q1-R Inspect drive belt Quarterly59332 Q2-R Inspect conductivity switch Quarterly59332 Q3-R Conduct cleaning of Small Pulper Quarterly59332 S1-R Change the PLC battery Semi-annually

Chapter 5 in each technical manual provides information to help maintenancepersonnel troubleshoot the solid waste management equipment. The tables and charts inChapter 5 list symptoms, probable causes, immediate actions and remedies for repair.Chapter 6 in each technical manual describes corrective maintenance instructionsincluding adjustment, alignment and repair procedures.

Spare Parts

NSWCCD–TR–63—97/25 35

Spare parts have been identified for each type of solid waste managementequipment. Approved Allowance Parts Lists (APLs) exist for the PWP and SWS..Separate APLs are provided for the military and all commercial component electricalenclosure configurations. Preliminary APLs exist for the Large and Small Pulpers

For the PWP, APLs have been generated as follows:

CMU 439990247

CMU Rear Electrical Panel (military version) 509991552

CMU Rear Electrical Panel (commercial version) 509991760

CMU drive motor 171370006

CMU limit switches 213190362

CLCU 039990143

CLCU Rear Electrical Enclosure (military version) 509991553

CLCU Rear Electrical Enclosure (commercial version) 509991761

CLCU Centrifugal Pump 018650003

CLCU Pump Motor 179990341

The odor barrier bag National Stock Number (NSN)(8105-392-6510) for plasticdisks is found in the CMU APL. Initial PWP spares can now be ordered using theConsolidated Residual Asset Management System Information (CRAMSI) method (seeAppendix E for points of contact).

The SWS APLs are as follows:

SWS 439990250

SWS Electrical Power Panel 509991550

SWS Speed Reducer 698880367

SWS Limit Switches 21319061

SWS Drive Motor 174081084

SWS spares can be ordered through CRAMSI.

Pulper APLs are as follows:

Small Pulper 439990264.

Small Pulper Electrical Power Enclosure 509991714

Small Pulper Actuator 617770171

Large Pulper 439990265

Large Pulper Electrical Power Enclosure 509991752.

Consumable Items and Special Tools


Allowance Equipment Lists (AELs) have been developed for the solid wastemanagement equipment. The AEL (2-920016532) for the PWP contains the following:

• Heat Sealer - Used to seal close the odor barrier bags.• Gauge Blocks - To check preload settings on compression springs. One unit is required per

space. Four blocks are required per installation.• Eye Bolts - Several different sizes for lifting the CMU and removing the ram.• Four Leg Sling - Used to lift the CMU.• Chain Hoist - Used to pull the ram from the CMU.• Scraping Knives - To assist in removing plastic disk from ram or door face and for cleaning

the inside of the CMU.• Hook Blade Cutters - To assist in removing the plastic disk from the CMU.• Soft Face Hammers - To assist in opening the door when it is stuck in the closed position.

Plastic Spray Bottles - For holding mold release agent (diluted 4:1)• Water Hose with removal Spray Nozzle - For filling the CLCU reservoir and for washing

down the equipment after daily use.

The SWS AEL identifies the collection bin that fits inside the collection chamber.

The Large Pulper AEL identifies the following impeller removing tools:

• 2-3/8” deep socket, (3/4” Drive)• ¾” Drive Breaker Bar• ¾” Drive Ratchet• 3-ft. chain (to secure drive pulley)

General Use Consumable Lists (GUCLs) have been developed for each type ofsolid waste management equipment. The GUCL for the PWP identifies the followingitems:• Mold Release Agent - Liquid agent sprayed on ram, chamber and door surfaces in

contact with waste plastic. Use it to assist in removing the disk from the CMU.• Plastic bags - Used to line the SWS collection bin for collecting and transporting the

shredded plastic to the CMU.• Cleaning agents - Spray on detergents, scouring pads, etc. used to clean the CMU.• Lubricants - Greases, antisieze, thread locking and adhesive compounds.• Electrical - Heat shrink, cable ties and tape.

The GUCL for the SWS identifies the following items:

• Burlap Bags• Burlap Bag Stand

The GUCLs for the Large and Small Pulpers identifies the following items:• Lubricants - Greases, lubricating oils, antisieze, thread locking and adhesive

compounds.• Electrical - Heat shrink, cable ties and tape.

NSWCCD–TR–63—97/25 37

NOTE: It is important that your ship order and stock appropriate quantities ofthe consumable items and special tools identified for the solid waste managementequipment installed aboard your ship. Failure to do so will cause a marked increasein processing, clean up and maintenance times.

Consumable Items Usage Rates

PWP

The high usage rate consumable items for the PWP consist of odor barrier bags,mold release agent and plastic shredder bags. Exact usage rates for each ship class arenot available at this time. Based on usage rates from prototype shipboard installations,conservative, rough order of magnitude estimates for PWP consumable items for severalclasses of ships during a six month deployment are provided in Table 7.

TABLE 7. Estimate of PWP Consumable Items Used in a Six Month Deployment for Several ShipClasses

ShipClass

CrewSize

Estimated No. ofDisks

OBB Rolls* Mold Release* PlasticShredder

Bags*FFG 7 220 400-500 4-5 1-2 **DDG 51 303 600-700 6-7 2-3 18-20LHD 1 3151 10-12,000 100-120 18-23 250-350CVN 68 6286 20-25,000 200-250 35-45 550-725

* OBBs are supplied 100 to a roll; mold release agent is supplied in 1 or 5-gallon containers (to be diluted with water 4:1); plastic shredder bags are supplied 100 to a box. ** FFG class ships do not have plastic shredders.

SWS

The high usage rate consumable item for the Metal/Glass SWS consist of burlapbags. Exact usage rates for each ship class are not available at this time. Based on usagerates from prototype shipboard installations, conservative, rough order of magnitudeestimates for burlap bag consumption for several classes of ships during a six monthdeployment are provided in Table 8.

TABLE 8. Estimate of SWS Consumable Items for a Six Month Deployment for Several Ship Classes

Ship Class Crew Size Metal/Glass Waste* Burlap Bags Needed**


DDG 51 303 29,000 lb. 700-900LHD 1 3151 306,000 7-10,000CVN 68 6286 611,000 15-20,000

* Based on calculations as found in U.S. Navy Shipboard Solid and Plastic Waste Management Program Plan, April, 1993. ** Burlap bag estimates based upon 30-40 lb. of metal and glass per bag.

NSWCCD–TR–63—97/25 39

APPENDIX A

DEVELOPING A SHIP INSTRUCTION FOR SOLID WASTE MANAGEMENT PLAN


Shipboard Solid Waste Management Plan

A shipboard solid waste management strategy is essential to minimize the impact of solid wasteenvironmental laws on ship combat readiness, crew morale and shipboard safety and habitability. Theessential elements described in this sample plan have been developed through experience by ships thathave prototype equipment. The major components are as follows:

• Promulgation of management policy.• Assignment of rules and responsibilities for personnel management.• Maintaining a current knowledge of environmental laws and regulations.• Source Reduction Initiatives• Providing a mechanism for communication and feedback up the chain of command.• Developing and enforcing regulations to maintain quality of life.• Responsibilities for equipment operation and maintenance.

- Waste handling. - Equipment operation. - Equipment maintenance.

Promulgation of Management Policy. Management policy should be formally promulgated by a shipinstruction. Attachment (1) is a sample ship instruction for a Solid Waste Management Plan (SWMP),the bulk of which has been written and developed through the collective efforts of the U.S. Navy shipslisted below. Each ship developed their own plan or instruction by starting with copies of other ships’plans who had prior solid waste equipment operation and management experience.

o USS THEODORE ROOSEVELT (CVN-71)o USS GEORGE WASHINGTON (CVN-73)o USS VANDEGRIFT (FFG-48)o USS WASP (LHD-1)o USS KEARSARGE (LHD-3)o USS CORONADO (AGF-1)o USS STETHEM (DDG-63)

Assignment of Rules and Responsibility for Personnel Management. Section 5 of the sample SolidWaste Management Plan entitled “Action” lists responsibilities throughout the chain of command. Asummary of these responsibilities are as follows:

Commanding Officer: Promulgates the ship instruction.Executive Officer: Ensures that the Solid Waste Management Plan is executed.

Environmental Protection Coordinator/Officer: (A collateral responsibility):Implements the Solid Waste Management Plan.Provides for crew education.Ensures policies are adjusted to meet changes in law or Navy policy.Ensures policies are posted for the crew.

Environmental Protection Technician: (A collateral responsibility)Executes the Coordinator’s plans.Manages the daily activities of the Trash Disposal Room(s).Reports infractions of solid waste policy and regulations.Performs regular inspections of the trash processing space(s).

NSWCCD–TR–63—97/25 41

Supply Officer:Develops and implements policies to minimize at sea generation of solid waste.Ensure that solid waste equipment is utilized.

Department and Division Officers:Ensure their department/division complies with shipboard regulations and environmental laws.

Maintaining Current Knowledge of Environmental Law. The chain of command will be required tomaintain knowledge of current and future environmental regulations governing solid waste discharge andensure that those under their direction comply with the law. Policies, procedures and schedules forequipment use should be posted appropriately throughout the ship, placed in the Plan-of-the-Day (POD),and announced over the ship’s closed circuit television (CCTV) and loud speaker systems to keep allcrew members informed.

Source Reduction Initiatives. A Solid Waste Reduction Guide is under development by the WRAPSProgram Office, NAVICP, Mechanicsburg, PA. Methods for reducing the source upfront will beaddressed, and once available should be included in the ship’s SWMP.

Providing for Communication and Feedback. To ensure that ship policies are effective, comply withthe law, and do not adversely impact ship operations or life, a mechanism for regularly scheduledmeetings is essential. Meetings should be conducted in accordance with Navy established Total QualityLeadership principles. There is an environmental newsletter published and distributed quarterly byNAVSEA 03L1, that will be sent to all ships. This newsletter, “Shipboard Environmental ProtectionNews,” will contain information that is pertinent to the operation and maintenance of the solid wasteequipment, and should be routed to all involved with the equipment.

Developing and Enforcing Regulations to Maintain Quality of Life. To ensure that individual crewmembers share the burden of a clean, environmentally friendly ship, regulations need to be establishedand strictly enforced. The following critical rules have been enacted by ships with environmentalequipment to maintain shipboard habitability.

Departmental responsibility for trash sorting. The cornerstone of effective solid waste management issource separation. Ships with solid waste equipment have simply empowered the trash disposal roompersonnel to turn away trash that isn’t properly sorted and required the trash to be resorted where it isgenerated. Within a few weeks of enforcing this policy, the crew polices one another because no onewants trash being sorted in their living or work space.

Individual accountability for proper waste disposal. If accountability for properly disposing of solidwaste at the trash disposal room is not enforced, bags of trash will be dumped in passageways, weatherdecks, or in other spaces, causing serious habitability and possibly safety problems.

Responsibilities for Equipment Operation and Maintenance

Waste handling. Enclosure (6) of the sample SWMP ship instruction provides sample instructions forsolid waste handling. This plan not only should specify normal operations, but contingencies if solidwaste equipment is not operational. In order to maximize efficiency of manpower and equipmentoperations, waste transport to the trash disposal room should be done in accordance with an operatingschedule. Most operating schedules have consisted of one or more hours following each meal.


Equipment operation. Equipment operation should be handled by food services personnel.Approximately 1/2 of shipboard trash, and almost all food contaminated waste is generated in thegalley/mess deck areas of ships. Therefore, utilizing food service personnel for equipment operation isthe most efficient because they are already engaged in waste disposal and are most likely to keep thetrash disposal room clean. Solid waste equipment is, for most ships located very close to the mess decksto minimize the labor for transport of waste to the trash disposal room. Most of the ships with solidwaste equipment have utilized food services personnel for solid waste equipment operation with greatsuccess.

Equipment maintenance. All of the solid waste equipment is considered HM&E equipment. Thereforemost of the ships with solid waste equipment have utilized the Auxiliary Engineering Department tomaintain the solid waste equipment.

NSWCCD–TR–63—97/25 43

ATTACHMENT 1

Sample Shipboard Solid Waste Management Plan Ship Instruction

[ship name] INST 5090.1[Date]

USS [ship name] ([hull number]) INSTRUCTION 5090.1

Subj: PLASTIC AND SOLID WASTE MANAGEMENT

Ref: (a) OPNAVINST 5090.1B (ENVIRONMENTAL AND NATURAL RESOURCES PROGRAMMANUAL)

Encl: (1) Summary of Navy Pollution Control Discharge Restrictions(2) Naval Message R271245Z MAR 95, entitled “PLASTIC WASTE MANAGEMENT” which describes procedures for using heat sealed odor barrier bags.(3) Sample Plastics Discharge at Sea Report(4) Sample Departmental Environmental Compliance Representative Letter(5) Sample Divisional Environmental Compliance Petty Officer Letter(6) Preparation of Shipboard Trash for Processing(7) At Sea Trash Disposal Room Operating Hours

1. Purpose. To establish policies, procedures and responsibilities for the control of plastic and solidwaste disposal aboard [ship name] and to prevent/reduce its discharge at sea.

2. Background. Legislation has been passed to adopt worldwide standards for the discharge of waste atsea. The Act to Prevent Pollution from Ships (APPS), as amended by the Marine Plastics PollutionResearch and Control Act (U.S. Public Law 100-200) of December 1987 and by the National DefenseAuthorization Act for FY 1994, implements the Annex V requirements of the International MaritimeConvention for the Prevention of Pollution from Ship (MARPOL), by established deadlines. Enclosure(1) summarizes the restrictions on the discharge of solid waste by the U.S. Navy at sea. Annex V ofMARPOL addresses shipboard solid waste discharge at sea and has three major requirements:

a) Distance-from-shore restrictions for solid waste discharge.b) Prohibition of discharging plastics waste into the seas.c) Designation of special sea areas where enhanced efforts are required to minimize pollution

from ships. Special areas that are now in effect are the Baltic Sea, the North Sea and the AntarcticArea. Other special areas that have been designated but are not yet in effect are: The Persian Gulf,Red Sea, Black Sea, Mediterranean Sea, Caribbean Sea and the Gulf of Mexico.

3. Definitions

a. Food Waste - Spoiled or unspoiled food substances, such as fruits, vegetables, dairy products, meatproducts, food scraps, and food particles.


b. Garbage - Any food or operational waste generated during the normal operation of the ship. TheMARPOL term "garbage" therefore encompasses all forms of shipboard solid waste, including plastics,food waste, and dry waste such as paper, cardboard, and wood, which have traditionally been referred toas "trash."

c. Pulped Waste - Pulped or ground waste capable of passing through a screen with openings nogreater that 25 millimeters (0.98 inch). Note: U.S. Navy pulpers are designed with ¼” openings.

d. Plastic Waste - Styrofoam, nylon, vinyl, polypropylene and similar synthetic materials producedby polymerization, all materials that contain plastic (e.g. punctured spray cans which contain plastictubes).

e. Dunnage - Waste materials consisting of wood and wood products, textiles, and rags.

4. Policy

a. All waste plastic shall be separated from other types of waste and placed into "plastic waste only"receptacles for the collection and processing in the Plastic Waste Processor. Plastic waste, whetherprocessed or unprocessed, shall be held onboard for disposal ashore.

b. In the event that the Plastic Waste Processors are inoperative, [ship name] shall retain wasteplastic onboard by utilizing odor barrier bags for storage of waste in accordance with instructionsprovided in enclosure (2).

c. If retention of waste plastic endangers the health or safety of crew members, creates unacceptablenuisance conditions or compromises combat readiness, overboard discharge is authorized beyond 50miles from any shoreline provided it is properly packaged and weighted for negative buoyancy.Discharge of plastic shall be recorded in the ship's deck log. Log entry shall include:

(1) The date, time and location of discharge.

(2) Approximate weight and cubic volume of the discharge.

(3) Nature of the material discharged.

d. Under APPS, the Secretary of Defense is required to report annually in the Federal Register theamount and nature of discharge into special areas in effect in which the discharge did not meet Annex Vlimitation. Accordingly, upon completion of operations in these areas, Navy ships shall report by routinemessage per enclosure (3) the log entry information described in par. 5.c. to OPNAV (N45) and the chainof command regarding all discharges other than food waste into the in-effect special area.

{Note: “food waste” should be changed to “pulped or shredded solid waste” when pulpers andshredders are installed and Navy policy is modified to reflect this}

e. Non-plastic solid waste shall be discharged at sea only where permitted by law as summarized inenclosure (1).

NSWCCD–TR–63—97/25 45

f. Recyclable materials will be collected and recycled when practical without negatively impactingshipboard habitability and readiness. No materials containing food residues will be retained on boardlonger than necessary to process or properly dispose.

g. Hazardous and potentially infectious medical waste materials will be handled separately from therest of the waste stream in accordance with applicable laws, regulations, and instructions.

h. If the solid waste equipment becomes non-operational because of a failure, it should be reportedvia CASREP. Equipment should be designated “mission critical” since it enables unrestricted Navaloperations worldwide.

5. Action

a. The Commanding Officer shall:

(1) Designate in writing an Environmental Protection Coordinator to serve as the focal point for allwaste disposal issues aboard [ship name].

(2) Ensure command support throughout the chain of command for the shipboard Plastic and SolidWaste Management Program.

(3) Approve any plastic or other solid waste discharges not in compliance with current laws.

(4) Notify higher authority in the event of over board discharge of plastic or other solid waste inaccordance with ref (a) Chapter 19.

b. The Executive Officer shall:

(1) Ensure all ship's company and embarked staff personnel adhere to the policies in accordancewith reference (a) and this instruction.

(2) Ensure shipboard environmental protection systems are properly maintained and operated toconform with Navy regulations.

(3) Ensure ship's personnel whose actions could adversely affect the environment are properlytrained, attend appropriate schools, and are fully aware of appropriate documentation.

(4) Receive reports on any conditions or systems/equipment malfunctions or personnel errors thatcould result or have resulted in unlawful emissions or discharge.

(5) Ensure reports of all plastic discharges and, in MARPOL special areas only, non-processedpulpable and shreddable waste are properly entered in the deck log.

(6) Ensure messages required by law and Navy policy regarding solid waste discharges inMARPOL special areas are prepared and released in a timely manner.

(7) Establish an annual command environmental compliance self evaluation process. The AfloatChecklist of reference (a), Appendix K may be used in the performance of this evaluation.


(8) Establish, maintain and enforce solid waste management practices that ensure proper solidwaste segregation at the point of generation.

(9) Ensure all solid waste management equipment spaces are inspected daily.

c. The Environmental Protection Coordinator/Environmental Compliance Officer shall:

(1) Be responsible to the Executive Officer for the implementation and maintenance of theshipboard Plastic and Solid Waste Control Program in accordance with all applicable references.

(2) Report the discharge of plastics at sea in accordance with reference (a) using enclosure (3)format.

(3) Ensure marine plastic and solid waste pollution education is provided to the crew via PODnotes, CCTV, GMT, posted notices, etc.

(4) Report to the Executive Officer infractions of environmental protection regulations, orders, andinstructions.

(5) Maintain a copy of this instruction and other orders, and ensure that the applicable parts areposted where accessible to subordinates.

(6) Conduct bi-monthly meetings with Departmental Environmental Compliance Representatives.Record minutes from each meeting and discuss all action items not completed from prior meetings forreview and further action.

(7) Maintain solid waste management practices that ensure proper solid waste segregation at thepoint of generation. Provide the necessary resources required to accomplish this, including an adequatesupply of properly labeled collection containers.

(8) Maintain an awareness of any changes in regulations governing solid waste discharges andmaintain this document.

d. Environmental Protection/Environmental Technician Shall:

(1) Be responsible to the Environmental Protection/Environmental Officer for the implementationand maintenance of the shipboard Plastic and Solid Waste Control Program in accordance with allapplicable references.

(2) Report the discharge of plastics at sea in accordance with reference (a) using enclosure (3)format.

(3) Ensure marine plastic and solid waste pollution education is provided to the crew via PODnotes, CCTV, GMT, posted notices, etc.

(4) Report to the Environmental Protection/Environmental Officer, infractions of environmentalprotection regulations, orders, and instructions.

NSWCCD–TR–63—97/25 47

(5) Maintain a copy of this instruction and other orders, and ensure that the applicable parts areposted where accessible.

(6) Attend mandatory environmental meetings chaired by the Environmental ProtectionCoordinator.

(7) Ensure compliance with the operating procedures as described herein of the trash disposal andprocessing facilities.

(8) Manage the daily operations of the Trash Disposal Room and provide training on equipmentoperation and maintenance.

(9) Perform regular Trash Disposal Room inspections, ensuring proper maintenance of the spaceand equipment and ensuring that it is kept habitable and free from pests.

(10) Assist the Environmental Protection Coordinator/Environmental Compliance Officer inmaintaining solid waste management practices that ensure proper solid waste segregation at the point ofgeneration. Provide the necessary resources required to accomplish this, including an adequate supply ofproperly labeled collection containers.

e. The Supply Officer shall:

(1) Ensure that plastic wrapping and shipping materials are removed to the maximum extentpossible from supply items prior to receipt onboard. Do not remove plastics if degradation or damage tothe supply item will result.

(2) Ensure that all waste plastic is properly collected and processed in the Plastic Processors andstored in [selected ship location] for shore side disposal/retrograde to logistic support ships. In theevent that the Plastic Processors are inoperative, ensure that all waste plastic generated in food serviceoperations is held onboard in odor barrier bags as described in enclosure (2).

(3) Ensure that installed garbage grinder(s) (disposal) and/or pulper(s) is (are) used for disposal ofall garbage at sea in accordance with enclosure (1). Ensure that the pulper(s) is(are) used for the disposalof all other pulpable waste, including paper and cardboard which is not being collected for recycling, atsea in accordance with enclosure (1). In the event that the pulper and/or garbage grinder are inoperative,ensure that all unprocessed food contaminated waste is stored inside large metal/plastic trash containersand stored on [selected ship location] until equipment operation has been restored.

{For ships with a metal glass/shredder}(4) Ensure that the installed metal/glass shredder is used for the disposal of all non-hazardous

metal and glass waste in burlap bags in accordance with enclosure (1). Ensure that the metal/glassshredder is not used for processing waste plastic. In the event that the metal/glass shredder isinoperative, ensure that metal/glass waste is placed large metal/plastic trash containers and stored on[selected ship location] until equipment operation has been restored.

{For ships without a metal glass/shredder}(4) Ensure that all non-hazardous metal and glass waste is rinsed out, compacted by hand and

placed in large metal/plastic trash containers and stored on [selected ship location] until it can be off-loaded.


(5) Ensure that all non-processed solid waste overboard discharges of non-plastic waste (e.g. metaland glass) are in accordance with reference (a) and enclosure (1).

(6) Ensure that no empty HAZMAT (hazardous materials) containers including all empty aerosolcans and HAZMAT materials are disposed of overboard with non-plastic garbage.

(7) Minimize the number of items available for shipboard use that use aerosol containers.

(8) Support the Environmental Protection Coordinator/Environmental Compliance Officer inprocuring an adequate supply of properly labeled collection containers.

(9) Ensure that all solid waste management equipment operators are properly trained and qualifiedin accordance with the appropriate Job Qualification Requirement(s) (JQR).

(10) Establish daily Trash Disposal Room procedures to include: hours of operation, cleaningschedule, unsorted material rejection policy, etc.

(11) Perform daily health and safety inspections of the equipment operators and the TrashDisposal Room.

f. Chief Engineer shall:

(1) Ensure all solid waste management equipment is properly maintained and kept in workingorder.

(2) Ensure that maintenance personnel are assigned and adequately trained to properly maintainand repair all plastic and solid waste management equipment.

(3) Ensure that up to date training materials including equipment Interactive Courseware andcompatible computer hardware is available to all maintenance personnel and that all maintenancepersonnel have met applicable qualifications.

g. Medical Department Head shall:

(1) Ensure that potentially infectious medical waste shall be segregated from the normal solidwaste stream and processed and stored in accordance with applicable shipboard and Navy regulations.

h. Department Heads shall:

(1) Designate in writing (enclosure (4) and (5)), an E-5 or above as a Departmental EnvironmentalCompliance Representative and/or Divisional Environmental Compliance Representative to activelypromote environmental compliance efforts within the department and [ship name].

(2) When loading stores, ensure removal of excess plastic wrapping and shipping material prior toreceiving onboard. Do not remove plastics if degradation or damage to the material will result.

NSWCCD–TR–63—97/25 49

(3) Ensure that wastes are properly sorted prior to transporting it for solid waste processing atdesignated time(s) and location(s).

(4) Ensure that plastic wastes are properly cleaned, separated, stored and disposed of upon arrivalin port.

(5) Ensure the assignment of personnel as set forth in this instruction.

(6) Ensure that their department has an adequate supply of properly labeled collection containers.

i. {Large ships only} Departmental Environmental Compliance Petty Officer shall:

(1) Actively promote departmental environmental compliance efforts within their department and[ship name].

(2) Ensure compliance with the operating procedures of the trash disposal and processingfacilities.

(3) Provide training on HAZMAT and environmental compliance procedures to departmentalpersonnel, to include the latest information on environmental policy changes and trends that apply to thedepartment and [ship name] as a whole.

(4) Perform regular departmental space inspections, ensuring proper storage of any HAZMAT(one week supply) and appropriate receptacles are provided for segregation of plastics, pulpable waste,metal and glass, and textiles.

(5) Report all intentional and unintentional violations of environmental compliance procedures viathe departmental chain of command.

(6) Act as the departmental point of contact for environmental concerns and perform other tasks asrequired to support the [ship name] Environmental Program. See enclosure (4) for sample of theDepartmental Environmental Compliance Representative letter.

(7) Attend mandatory environmental meetings chaired by the Environmental ProtectionCoordinator.

(8) Ensure that their department has an adequate supply of properly labeled collection containers.

j. Division Officer shall:

(1) Actively promote divisional environmental compliance efforts within their division.

(2) Ensure compliance with the operating procedures of the Hazardous Material Control andManagement (HMC&M) Program and trash disposal and processing facilities.

(3) Provide training on HAZMAT and environmental compliance procedures to divisionpersonnel, to include the latest information on environmental policy changes and trends that apply to thedivision.


(4) Perform regular divisional space inspections, ensuring proper storage of any HAZMAT (oneweek supply) and appropriate receptacles are provided for segregation of plastics, pulpable waste, metaland glass, and textiles.

(5) Report all intentional and unintentional violations of environmental compliance procedures viathe chain of command.

(6) Act as the divisional point of contact for environmental concerns and perform other tasks asrequired to support the [ship name] Environmental Program.

k. Officer of the Deck (OOD) (underway) shall ensure Deck Log entries are properly maintainedidentifying date, time, location of any unprocessed solid or plastics waste discharge, approximate weightand cubic volume of the discharge, amount and nature of the material discharged. The OOD shall also beresponsible for permitting pulper and MGS operation when appropriate. Pulpers may be operated whengreater than 3NM from any shoreline, and shredded metal/glass can be discharged when greater than12NM from any shoreline.

6. Procedures.

a. Shipboard Waste Handling and Storage. Limitations on discharge of waste from ships aresummarized in enclosure (1) and must be observed per reference (a).

(1) Collection and Separation Procedures for collecting and separating disposable wastegenerated aboard ship will be based on what can and cannot be discharged overboard in an authorizeddumping area. Enclosure (6) provides guidelines for trash collection and handling shall be strictlyadhered to by all crew members. To avoid the need for sorting after collection, separate wastereceptacles will be provided as required for:

(a) Plastics, including plastic mixed with non-plastic materials.

(b) Pulpable materials including food waste, cardboard and paper.

(c) Shreddable wastes including non-hazardous metal and glass containers.

(d) Each waste that is recycled.

(e) All non-processed waste.

(f) {Ships with incinerators} Waste that can be incinerated.

(2) Waste Receptacles. Each waste receptacle will be clearly marked by category. Appropriatenumber and types of containers will be determined by location such as mess decks, crew living space,galley, or general work area. Post signs to alert crew members as to what should be placed in thesereceptacles (e.g. METAL/GLASS; PLASTICS; PULPABLE WASTE).

NSWCCD–TR–63—97/25 51

(3) Processing shipboard solid waste that can be disposed of at sea and/or in port are grouped into4 categories: Recyclable, Plastics, Pulpables, Metals/Glass.

(a) Recyclable Material: Recyclable material{Ships with recycling programs should provide procedures here that describe their collection,processing and storage requirements)

(b) Plastics: Plastic waste should be collected in plastic bags (clear bags preferred). Plasticwaste collected in the galley shall be taken to the Trash Disposal Room for processing immediately aftereach meal. All plastic collected in other areas of the ship should be processed during the posted TrashDisposal Room operating hours, enclosure (7). The Environmental Compliance Division personnel willinspect all trash brought to the trash for non-plastics and not accept it if improperly sorted. If the bag isrefused, the person who delivered it is responsible for sorting it in the compartment where it wasgenerated and returning it again for processing. In the event that the Plastic Waste Processors areinoperative, all waste plastic generated in food service operations shall be held onboard in odor barrierbags in [selected ship location] as described in enclosure (2). The following materials shall not beprocessed in the Plastic Waste Processor Compress Melt Unit:

HAZMAT PLASTICS: Any plastic items which are hazardous, or previously contained hazardousmaterials especially those that contain flammable materials (e.g. cigarette lighters).

{ARS-50 AND FFG-7 CLASS ONLY} NON-PROCESSABLE PLASTICS: Plastics that cannot beplaced into CMU should not be collected but held on station or in a designated location for shore sidedisposal (e.g. 5 gallon jugs).

(c) Food Waste and Pulpables: Pulpables will be processed inside the trash room by theequipment operator with the approval of the OOD, and during the posted Trash Disposal Room operatinghours, enclosure (7). All wet garbage will either be processed in garbage grinders or collected inplastic/metal containers by mess personnel in the scullery. Pulpable waste containers, cardboard andpaper waste generated in the kitchen, scullery and mess decks shall be transported to the Trash DisposalRoom for processing immediately after each meal. Ship's crew members will, during announced hoursonly, bring trash to the Trash Disposal Room for processing. The Environmental Compliance Divisionpersonnel will inspect all trash brought to the trash for non-pulpables and not accept it if improperlysorted. If the bag is refused, the person who delivered it is responsible for sorting it in the compartmentwhere it was generated and returning it again for processing. In the event that the pulper and/or garbagegrinder are inoperative, they shall ensure that all unprocessed food contaminated waste shall be storedinside large metal/plastic trash containers and stored on [selected ship location] until equipmentoperation has been restored. Non-food contaminated waste shall be held on station if the pulper is notoperational.

{Following Par (d) Does not apply to FFG-7, MHC-51, or MCM-1 CLASS}(d) Metal/Glass Containers: Shreddables will be processed inside the Trash Disposal Room

by the equipment operator with the approval of the OOD, and during the posted Trash Disposal Roomoperating hours, enclosure (7). All shreddables that contain wet garbage shall be first rinsed out and thenplaced in bags or plastic/metal containers for transport to the Trash Disposal Room. Mess personnelshall transport shreddable waste containers, cardboard and paper waste generated in the kitchen, sculleryand mess decks to the Trash Disposal Room for processing immediately after each meal. Ship crewmembers will, during announced hours only, bring trash to the Trash Disposal Room for processing.


The Environmental Compliance Division personnel will inspect all trash brought to the Trash DisposalRoom for processing. The Trash Disposal Room operator shall inspect the bag for non-plastics and notaccept it if not properly sorted. If the bag is refused, the work center which delivered it is responsible forsorting it where it was generated and returning it again for processing. In the event that the metal/glassshredder is inoperative, rinse out non-hazardous metal containers and utilize ship can openers to open thetop and bottom. Crush the cans and place them and non-hazardous glass waste inside large metal/plastictrash containers and store on [selected ship location] until equipment operation has been restored, ordischarge overboard where permitted.

{Par (d) for FFG-7, MHC-51, and MCM-1 CLASS only}(d) Metal/Glass Containers: Metal/glass shredders are not planned to be installed on these

ship classes. Rinse out metal containers and utilize ship can openers to open the top and bottom. Crushthe cans and place them along with non-hazardous glass waste inside large metal/plastic trash containersand store on [selected ship location] or discharge where permitted.

(e) Textiles: Textiles cannot and will not be processed but shall be retained on station or in adesignated storage area.

(f) HAZMAT : HAZMAT materials will be collected and processed in accordance with[applicable ship hazmat instruction title/number]. Any question concerning HAZMAT call [Hazmatphone number]

(4) Shipboard Waste Storage

(a) Food and food contaminated waste that cannot be discharged at sea in authorized disposalareas will be retained onboard unless retention causes a health hazard. Food wastes and associatedgarbage which must be disposed of ashore may contain pests or disease organisms. Therefore, segregatethese wastes from all other categories, place in sealed container, and clearly mark as "FOOD WASTE".Areas used for storage of food wastes will be routinely disinfected using both preventative and remedialpest control methods.

(b) Plastic wastes collected from living and working areas will be delivered to the TrashDisposal Room and processed in the Plastic Waste Processor. Disks produced will be sealed in odorbarrier bags and placed in designated storage areas. In the event that the Plastics Waste Processor isinoperative, the food contaminated plastics waste will be segregated from non-food contaminatedplastics waste and sealed in odor barrier bags in accordance with enclosure (2).

(5) Disposal of Shipboard Waste at Sea

(a) Operation of pulpers and overboard disposal of shredded metal/glass waste or other legallydisposable waste should not commence unless authorized by the OOD and in accordance with thelimitations identified in enclosure (1).

(b) At the conclusion of each underway period notify OPNAV (N45) by routine message(enclosure (3)), info chain of command, when policy cannot be followed. Negative reports are notrequired.

NSWCCD–TR–63—97/25 53

(6) Disposal of Shipboard Waste In port: Prior to returning to port a LOGREQ should be sentout requiring trash to be off-loaded upon arrival to port/homeport. LOGREQ should include:

(a) How many cu-ft of trash will be off-loaded.(b) Type of material i.e. plastic, cardboard, garbage, etc.(c) How many plastics waste disks will be off-loaded.

Trash removal is a ship wide responsibility. Duty section personnel will be utilized to movetrash off the ship. The CDO/ACDO should supervise the removal of all trash from the ship.

[Ship Captain’s Name]


Enclosure (1)

SUMMARY OF NAVY POLUTION CONTROL DISCHARGE RESTRICTIONS

NOTE: The National Defense Authorization Act for Fiscal Year 1997, Section 324, allows theU.S. Navy to discharge solid wastes as indicated below, however OPNAVINST 5090.1B has notyet been revised to incorporate these changes.

Plastics. Once equipped with an operable Plastics Waste Processor, surface ships are prohibited fromdischarging plastics into the sea. Until 31 December 1998, Ships without PWPs installed shall follow the3/20 Rule for plastic waste management (Retain last 3 days of food-contaminated and last 20 days ofnon-food-contaminated plastic waste). Once PWPs are installed, and for all U.S. Navy ships after 31December 1998, discharge of plastic waste is prohibited. Exceptions to these retention requirements areallowed only when necessary for the purpose of securing the safety of the ship or the health of ship’sforce.

Pulped Trash & Food Waste. Can be discharged beyond 3 nautical miles from any shoreline.

Metal and Glass. Shreddable metal and glass can be shredded and discharged once the ship is beyond12 nautical miles from any shoreline.

NSWCCD–TR–63—97/25 55

Enclosure (2)

UUUUUUUUUUUUUUUUUUUUUUUUUUUUUUUUUUUUUUUUU U N C L A S S I F I E D UUUUUUUUUUUUUUUUUUUUUUUUUUUUUUUUUUUUUUUUUU

NARRATIVE MESSAGE ADMINISTRATIVE MESSAGE

ROUTINE

R271245Z MAR 95ZYB

FM NAVSURFWARCEN SHIPSYSENGSTA PHILADELPHIA PA//631//

TO COMNAVAIRLANT NORFOLK VA//N43./N43l/N434//COMNAVAIRPAC SAN DIEGO CA//N45Al/N43/N4345//COMNAVSURFLANT NORFOLK VA//N455/N43//COMNAVSURF PAC SAN DIEGO CA//N01/N41/N43/N46//COMSUBLANT NORFOLK VA//N43/403/402/451/40Bl//COMSUBPAC PEARL HARBOR HI//N4/43/402/403/45A2/402S//

INFO CNO WASHINGTON DC//N45//COMNAVSEASYCOM WASHINGTON DC//00T/03R/03V/91/92//CINCLANTFLT NORFOLK VA//N4211/N43/N434/N412/N44//CINCPACFLT PEARL HARBOR HI//N46/N465/N466//NAVSURFWARCEN CARDEROCKDIV BETHESDA MD//00//NAVSURFWARCEN DET ANNAPOLIS MD//63/634/1127//FTSCLANT NORFOLK VA//4330//FTSCPAC SAN DIEGO CA//303//

BTUNCLAS //N09593//

MSGID/GENADMIN/NSWCCD-SSES 631//

SUBJ/PLASTICS WASTE MANAGEMENT//POC/A. BUDZICHOWSKI/CIV/631/-/TEL:DSN 443-1080/TEL:215-897-1080//

RMKS/1. SUMMARY: THIS MSG PROVIDES AN INTERIM SOLUTION FOR LONG TERMSTORAGE OF FOOD CONTAMINATED PLASTICS WASTE ON BOARD SHIP UNTIL PLASTICSPROCESSORS ARE INSTALLED. END OF SUMMARY.

2. NAVY SHIPS WHILE UNDERWAY ARE CURRENTLY REQUIRED TO RETAIN THEIR NON-FOOD CONTAMINATED PLASTICS FOR AT LEAST THE LAST 2O DAYS BEFORE RETURNINGTO PORT. FOOD CONTAMINATED PLASTICS MUST BE RETAINED FOR AT LEAST THELAST 3 DAYS BEFORE RETURNING TO PORT. PLASTICS WASTE DISCHARGE IS TOTALLYPROHIBITED AFTER 31 DECEMBER 1998. SHIPS REQUIRING PLASTICS PROCESSORS WILLHAVE THEM INSTALLED BY THIS DATE.


3. DUE TO HEIGHTENED SENSITIYITY TOWARDS ENVIRONMENTAL ISSUES, MANYSHIPS ARE ATTEMPTING TO TOTALLY AVOID DISPOSAL OF PLASTICS AT SEA RESULTINGIN ODOR AND SANITATION PROBLEMS ABOARD SHIP. THE INTERIM SOLUTIONDEVELOPED BY NSWCCD ANNAPOLIS DET IS TO HEAT SEAL PLASTICS INTO ODORBARRIER BAGS (OBB). BY USING ODOR BARRIER BAGS, ODOR AND SANITATIONPROBLEMS ARE ELIMINATED AND SHIPS CAN VOLUNTARILY EXCEED THE 20/3 DAYRETENTION REQUIREMENTS.

4. NUMEROUS HEAT SEALERS WERE EVALUATED. THE HEAT SEALER SELECTEDAS BEST FITTING THE NAVYS REQUIREMENTS WAS A PORTABLE MOTORIZEDUNIT MANUFACTURED BY DOBOY, INC. (MODEL HS-B) NSN: 3540-00-819-8837.

5. TWO PROCEDURES FOR SEALING OBBS WERE DEVELOPED AND EVALUATEDABOARD SHIP: A VACUUM HEAT SEALING PROCEDURE (ANY COMMERCIALLYAVAILABLE WET-DRY SHOP VAC CAN BE USED AS THE VACUUM SOURCE) AND ANON-VACUUM HEAT SEALING PROCEDURE. THE VACUUM PROCEDURE TAKES ALITTLE LONGER BUT HAS THE ADVANTAGE OF REDUCING THE PLASTICSSTORAGE VOLUME BY 45 PERCENT.

6. VACUUM HEAT SEALING PROCEDURE.

A. MAKE SURE HEAT SEALER ROLLER SPACINGS HAVE REEN SET CORRECTLYFOR THE ODOR BARRIER BAG THICKNESS AND THE HEAT SEALER MOUNTINGCLAMP HAS BEEN INSTALLED OPPOSITE THE TEMPERATURE GAUGE PRIOR TOUSING THE HEAT SEALER.

B. PLUG IN THE HEAT SEALER AND SET THE THERMOSTAT KNOB AT 2.5.

C. DEPRESS THE ROCKER SWITCH TO THE PREHEAT SETTING. THE REDINDICATOR LIGHT WILL COME ON AND STAY ON UNTIL A TEMPERATURE OF 110-140 DEGREES C HAS BEEN REACHED (IF THE TEMPERATURE EXCEEDS 150DEGREES C, ADJUST THE KNOB SLIGHTLY LOWER AND WAIT UNTIL THECORRECT TEMPERATURE IS ATTAINED).

D. WHEN THE RED INDICATOR LIGHT GOES OUT, THE HEAT SEALER IS READYFOR USE.

E. SLOWLY TEAR OFF AN ODOR BARRIER BAG FROM THE ROLL, BEING CAREFULTO TEAR ONLY ALONG THE PERFORATIONS.

F. FILL THE ODOR BARRIER BAG BY FIRST UNTYING OR TEARING OPEN THEPOLYETHYLENE TRASH BAGS FILLED WITH PLASTIC WASTE THAT HAVE BEENBROUGHT TO THE STAGING AREA. UNTYING THESE BAGS WILL ELIMINATEENTRAPPED AIR. PLACE AS MANY BAGS AS NECESSARY TO FILL THE ODORBARRIER BAG, ALLOWING ENOUGH ROOM AT THE TOP FOR HEAT SEALING THEOPEN END. DO NOT JAM WASTE INTO THE ODOR BARRIER BAG SINCE EXCESSIVEFORCE ON HARD PLASTIC WASTE CAN RESULT IN PUNCTURING THE BAG.

G. DEPRESS THE ROCKER SWITCH LABELED HEAT-MOTOR ON HEAT SEALER TOACTIVATE DRIVE MOTOR AND CHAINS.

H. PICK UP THE FILLED ODOR BARRIER BAG AND PULL THE OPEN END OF THEBAG TAUT. CAREFULLY PLACE THE LEFT SIDE OF THE BAG INTO THE FEED ENDOF THE HEAT SEALER. GUIDE THE BAG THROUGH UNTIL THE SEAL IS ABOUT 3QTRS OF THE WAY ACROSS. THEN QUICKLY TURN OFF THE HEAT SEALER MOTOR

NSWCCD–TR–63—97/25 57

BY RETURNING THE ROCKER SWITCH TO THE PREHEAT SETTING. THE ODORBARRIER BAG WILL BE HELD IN PLACE BY THE HEAT SEALER ROLLERS.

I. PLACE THE WET-DRY SHOP VACUUM HOSE NOZZLE INSIDE THE ODORBARRIER BAG AND TURN ON THE ELECTRICAL POWER TO THE SHOP VACUUM.MOVE THE HOSE INSIDE THE BAG UNTIL A GOOD VACUUM IS ACHIEVED. THISMAY REQUIRE MANIPULATING THE WASTE PLASTIC INSIDE THE ODOR BARRIERBAG TO PREVENT PLUGGING OF THE VACUUM HOSE NOZZLE. TO ACHIEVE FULLVACUUM, GATHER THE BAG MATERIAL AROUND THE OPEN END OF THE BAGAND SQUEEZE IT AGAINST THE INSERTED HOSE. ALLOW ABOUT 30-60 SECONDSTO COMPLETE THE VACUUM OPERATION.

J. TURN OFF THE SHOP VACUUM AND QUICKLY WITHDRAW THE VACUUM HOSEFROM INSIDE THE ODOR BARRIER BAG. THEN TURN ON THE HEAT SEALER AGAINBY MOVING THE ROCKER SWITCH TO THE HEAT-MOTOR SETTING TO COMPLETETHE HEAT SEAL ACROSS THE BAG. VISUALLY CHECK THE SEAL TO MAKECERTAIN THAT THE SEAL IS A GOOD ONE. A GOOD SEAL WILL NOT SEPARATEWHEN PULLED ON BOTH SIDES. IF IN DOUBT, RESEAL OVER THE INITIAL SEAL.

K. RETURN THE ROCKER SWITCH TO THE PREHEAT SETTING TO MAINTAINSTANDBY MODE OR TURN OFF THE HEAT SEALER BY DEPRESSING THE ROCKERSWITCH TO THE CENTER POSITION.

L. CARRY THE SEALED ODOR BARRIER BAGS CAREFULLY TO THE DESIGNATEDSTORAGE AREA. MAKE SURE THAT THE BAGS ARE NOT SCRAPED AGAINSTABRASIVE OBJECTS IN PASSAGEWAYS DURING TRANSIT OR STACKED UPAGAINST SHARP OBJECTS IN THE STORAGE AREA.

7. NON-VACUUM HEAT SEALING PROCEDURE.

A. MAKE SURE HEAT SEALER ROLLER SPACINGS HAVE BEEN SET CORRECTLYFOR THE ODOR BARRIER BAG THICKNESS AND THE HEAT SEALER MOUNTINGCLAMP HAS BEEN INSTALLED OPPOSITE THE TEMPERATURE GUAGE

PRIOR TO USING THE HEAT SEALER.

B. PLUG IN THE HEAT SEALER AND SET THE THERMOSTAT KNOB AT 2.5.

C. DEPRESS THE ROCKER SWITCH TO THE PREHEAT SETTING. THE RED INDICATORLIGHT WILL COME ON AND STAY ON UNTIL A TEMPERATURE OF 110-140 DEGREES CHAS BEEN REACHED (IF THE TEMPERATURE EXCEEDS 150 DEGREES C, ADJUST THEKNOB SLIGHTLY LOWER AND WAIT UNTIL THE CORRECT TEMPERATURE ISATTAINED).

D. WHEN THE RED INDICATOR LIGHT GOES OUT, THE HEAT SEALER IS READYFOR USE.

E. SLOWLY TEAR OFF AN ODOR BARRIER BAG FROM THE ROLL, BEING CAREFULTO TEAR ONLY ALONG THE PERFORATIONS.

F. FILL THE ODOR BARRIER BAG BY FIRST UNTYING OR TEARING OPEN THEPOLYETHYLENE TRASH BAGS FILLED WITH FOOD-CONTAMINATED PLASTICWASTE THAT HAVE BEEN BROUGHT TO THE STAGING AREA. UNTYING THESEBAGS WILL ELIMINATE ENTRAPPED AIR. PLACE AS MANY BAGS AS NECESSARYTO FILL


THE ODOR BARRIER BAG, ALLOWING ENOUGH ROOM AT THE TOP FOR HEATSEALING THE OPEN END. DO NOT JAM WASTE INTO THE ODOR BARRIER BAGSINCE EXCESSIVE FORCE ON HARD PLASTIC WASTE CAN RESULT IN PUNCTURINGTHE BAG.

G. DEPRESS THE ROCKER SWITCH LABELED HEAT-MOTOR ON THE HEAT SEALERTO ACTIVATE THE DRIVE MOTOR AND CHAINS.

H. PICK UP THE FILLED ODOR BARRIER BAG AND PULL THE OPEN END OF THEBAG TAUT. CAREFULLY PLACE THE LEFT SIDE OF THE BAG INTO THE FEED ENDOF THE HEAT SEALER. GUIDE THE BAG THROUGH UNTIL THE SEAL IS COMPLETEACROSS THE ENTIRE BAG. VISUALLY CHECK THE SEAL TO MAKE CERTAIN THATTHE SEAL IS A GOOD ONE. A GOOD SEAL WILL NOT SEPARATE WHEN PULLED ONBOTH SIDES. IF IN DOUBT, RESEAL OVER THE INITIAL SEAL.

I. RETURN THE ROCKER SWITCH TO THE PREHEAT SETTING TO MAINTAINSTANDBY MODE OR TURN OFF THE HEAT SEALER BY DEPRESSING THE ROCKERSWITCH TO THE CENTER POSITION.

J. CAREFULLY CARRY THE SEALED BAGS TO THE DESIGNATED STORAGE AREA.MAKE SURE THAT THE BAGS ARE NOT SCRAPED AGAINST ABRASIVE OBJECTS INPASSAGEWAYS DURING TRANSIT OR STACKED UP AGAINST SHARP OBJECTS INTHE STORAGE AREA.

8. THERE ARE TWO SIZES OF OBBS AVAILABLE (SMALLER SHIPS WITH CREWSIZES LESS THAN 100 MAY PREFER THE SMALLER BAG):

36- X 50-INCH ODOR BARRIER BAG, NSN: 8105-01-392-6515

24- X 27-INCH ODOR BARRIER BAG, NSN: 8105-01-392-6510.

9. NSWCCD-SSES WILL INCORPORATE THIS INFORMATION INTO REVISION OFNSTM CHAPTER 593 CURRENTLY UNDER DEVELOPMENT.//

BT/16912/ /086 1 MBA 0004 086/17:49Z 271245Z MAR 95

CSN:271245 086/17:50Z NAVSURFWARCEN SHIPSYSENGSTA PHILADELPHIA PA

UUUUUUUUUUUUUUUUUUUUUUUUUUUUUUUUUUUUUUUUU

U U N C L A S S I F I E D U

UUUUUUUUUUUUUUUUUUUUUUUUUUUUUUUUUUUUUUUUU

NSWCCD–TR–63—97/25 59

Enclosure (3)

[ship name]INST 5090.1

SAMPLE PLASTIC DISCHARGE AT SEA REPORT

UNCLASSIFIED

ADMIN DTG 999999Z FEB 99

FROM [ship name]

TO CNO WASHINGTON DC//N45//

INFO [Ship’s chain of command]

UNCLAS //N05090//

MSGID/GENADMIN/[ship name] //

SUBJ/PLASTIC DISCHARGE AT SEA//

REF/A/DOC/OPNAVINST/5090.1//

RMKS/1. IAW REF A, THE FOL REPORT SUBMITTED.

A. DATE U/W: [day]dd [Month]MMM [year]YY

B. DATE STARTED PLASTICS DISCHARGE AT SEA: [day]dd [Month]MMM[year]YY

C. NUMBER OR PERSONNEL ONBOARD: [number]

D. REASON DISCHARGE REQUIRED: MAX STORAGE CAPACITY FORPLASTIC WASTE REACHED THE [number] DAY AT SEA. ONLY DISCHARGEDPLASTICS GENERATED LAST [number] DAYS.

E. DATE ENTERED PORT:[day]dd [Month]MMM [year]YY//

BT

UNCLASSIFIED


Enclosure (4)

[ship name]INST 5090.1

From: Department Head

To: Designated Individual, USN, SSN

Subj: DESIGNATION AS DEPARTMENTAL ENVIRONMENTALCOMPLIANCE REPRESENTATIVE

Ref: (a) OPNAVINST 5100.19C

(b) [ship name] INST [number]

(c) OPNAVINST 5090.1B

(d) HMUG (OPNAV [number)

(e) SHML

1. You are hereby appointed as the Departmental Environmental ComplianceRepresentative.

2. Your responsibilities shall include, but are not limited to the following duties:

a. Become familiar with references (a) through (e).

b. Actively promote environmental compliance efforts within the departmentand [ship name].

c. Establish specific departmental responsibilities and eliminate the improperdischarge of HAZMAT, plastics, and other unauthorized products into the sea.

d. Ensure compliance with the operating procedures of the ConsolidatedHazardous Materials Reutilization Inventory Management Program (CHRIMP) facility,hazardous waste collection, solid waste pulper and plastics melt unit facilities.

e. Provide training on HAZMAT and environmental compliance procedures todepartmental personnel, to include the latest information on environmental policychanges and trends that apply to the department and [Ship Name] as a whole.

NSWCCD–TR–63—97/25 61

f. Perform regular departmental space inspections, ensuring proper storage ofany HAZMAT (one day supply) and appropriate receptacles for segregation of plastics,unpulped trash, soda cans, and aerosol containers.

g. Report all intentional and unintentional violations of environmentalcompliance procedures to the Environmental Compliance Officer via the departmentalchain of command.

h. Be the departmental point of contact for environmental concerns. Performother tasks as required to support the [ship name] Environmental Compliance Program.

Department Head


Enclosure (5)

ship name ]INST 5090.1

{Date}

MEMORANDUM

From: Department

To:

Subj:ASSIGNMENT/BILLET DESCRIPTION AS THE DIVENVIRONMENTAL CONTROL PETTY OFFICER

Ref: (a) OPNAVINST 5200.19B

(b) [ship name] [NUMBER]

(c) OPNAVINST 5090.1B

(d) HMUG OPNAVINST P-45-110-91

(e) SHML

1. You are hereby assigned the duties and responsibilities as DivisionEnvironmental Control Petty Officer and to become thoroughly familiar with references(a) through (e).

2. Your responsibilities shall include, but are not limited to the following:

a. Actively promote environmental control efforts within your division,department and [ship name].

b. Help establish specific division responsibilities and make every effort toeliminate the improper discharge of hazardous materials, plastics and other forbiddenproducts into the sea.

c. Become familiar with the operating procedures of the Consolidated HazardousMaterials Reutilization Inventory Management Program (CHRIMP) facility, hazardouswaste collection site, and Solid Waste Management facilities.

d. Provide training on HAZMAT and environmental compliance procedures todivision work center personnel, to include the latest information on environmental policychanges and trends that apply to your division and [ship name] as a whole.

e. Perform regular divisional space inspections, ensuring proper storage ofHAZMAT (one day supply) and appropriate receptacles for segregation of plastics, trash,soda cans and aerosol containers.

NSWCCD–TR–63—97/25 63

f. Report all (intentional/unintentional) violations of environmental controlprocedures to the Environmental Control Officer via Divisional and Departmental chainof command.

g. Become the divisional point of contact for environmental concerns. Performother tasks as required to support the [ship name] Environmental Control Program.

Div. Officer / Date Department Head / Date

*******************************************************************

FIRST ENDORSEMENT

From:

To: Department Head

1. I have read and fully understand the provisions of references (a) through (e) andaccept the duties and responsibilities of the Division Environmental Control ProgramPetty Officer.

Signature/Date


Enclosure (6)

PREPARATION OF SHIPBOARD TRASH FOR PROCESSING

1. Environmental protection and trash management is an ALL HANDSEVOLUTION . Everyone is responsible for ensuring trash is properly separated, cleaned,and turned in. These guidelines explain how trash should be sorted, segregated and packedprior to transporting to the Trash Disposal Room [compartment number] for processing.Each berthing and work space MUST segregate refuse into separate containers; Papertrash, Plastics, Glass and Metals. ALL BAGS WILL BE INSPECTED AND REFUSEDIF NOT PROPERLY SEGREGATED . NO ONE SHOULD ABANDON TRASHANYWHERE ON THE SHIP .

2. Plastics.

a. Dry and food-contaminated plastics and items containing plastics are to becollected in containers located in all shipboard compartments which have been clearlymarked “PLASTIC WASTE ONLY.” Personnel responsible for cleaning thecompartment shall ensure that the waste is properly sorted and then take the waste inplastic bags to the Trash Disposal Room at posted times only where the plastics areprocessed in the plastic processor , compressed and melted into solid disks, and sealed intoodor barrier bags, as required, and stored for shore disposal.

b. Waste That Cannot be Processed in the CMUs:

(1) Any loose paper and cardboard products.

(2) Food waste.

(3) Textiles including rags, Kim Wipes, discarded uniforms and leathershoes/boots.

(4) Metal including staples, paper clips, soda and food cans, flatware, servingspoons, hardware such as nuts and bolt, aluminum foil.

(5) Glass including bottles, jars, drinking glasses, and plates.

(6) HAZMAT (hazardous materials) items including aerosol cans and butanelighters (see NOTE below).

NSWCCD–TR–63—97/25 65

3. Pulpable Materials.

a. Pulpable materials, including paper, cardboard, and waste food material are tobe collected in containers located in all shipboard compartments which have been clearlymarked “PULPABLES ONLY.” Personnel responsible for cleaning the compartment shallensure that the waste is properly sorted and then take it at posted times only to the TrashDisposal Room, [room number]. The Pulper then is used to process the material into aslurry which is discharged overboard. The pulper functions in a similar manner to ahousehold garbage disposal, that is pulpable waste is mixed with sea water, pulped into aslurry by a cutting mechanism, and discharged overboard. The operator should note thatthe pulper is generally more efficient when processing a mixture of various waste types.For example, try to mix paper with food waste, rather than processing only paper, followedby only food waste. Mixing the waste usually lets it flow through faster, since one type ofwaste tends to “pull” another through the machine. This is particularly true whenprocessing large amounts of cardboard.

b. Cardboard boxes. To dispose of cardboard boxes properly, all plastic/plasticreinforced tape and labels must be removed from all boxes. Failure to remove plastic tapeand plastic labels significantly degrades equipment performance, and requires morefrequent cleaning. Each individual box must be broken down flat, and turned into theTrash Disposal Room only at posted times. {Small Pulper only} Cardboard should be cutinto approximately 8 in. x 12 in. pieces.

c. Waste That Cannot be Processed in the Pulper:

(1) Plastics including bottles, plastic containers for food and laundry products,storage bags, Saran Wrap, Band-Aids, coffee cream bags, cereal box plasticliners.

(2) Textiles including rags, discarded uniforms and leather shoes/boots.

(3) Metal including staples, paper clips, soda and food cans, flatware, servingspoons, hardware such as nuts and bolt, aluminum foil.

(4) Glass including bottles, jars, drinking glasses, and plates.

(5) HAZMAT items including aerosol cans and butane lighters (see NOTEbelow).

NOTE: The HAZMAT division handles all HAZMAT containers while at seaincluding personal HAZMAT containers.


4. Shreddable Materials.

a. Shreddable materials, including metal and glass containers, are to be collectedin containers located in all shipboard compartments which have been clearly marked“SHREDDABLE WASTE ONLY.” Personnel responsible for cleaning the compartmentshall ensure that the waste is properly sorted and then taken at posted times only to theTrash Disposal Room, [room number]. The Shredder then is used to process the materialinto burlap bags which are discharged overboard when authorized by the OOD at sea.

b. Waste That Cannot be Processed in the Shredder:

(1) Textiles including rags, Kim Wipes, discarded uniforms and leathershoes/boots.

(2) Heavy industrial waste

(3) HAZMAT items including aerosol cans and butane lighters (see NOTEbelow).

5. Non-Processed Materials. Non-processable materials, including textiles, wood,and heavy industrial waste shall be collected in containers located in shipboardcompartments which have been clearly marked “UNPROCESSABLE WASTEONLY” and held on station until the waste can be disposed of in port or retrograded to alogistic support ship.

6. Recyclable Material: Recyclable material.

{Ships with recycling programs should provide procedures here that describetheir preparation requirements).

NSWCCD–TR–63—97/25 67

Enclosure (7)

COMBINED SOLID WASTE MANAGEMENT EQUIPMENT OPERATINGSCHEDULE

1. In support of [Ship Name] environmental efforts, the following combinedpulper schedule is provided. Departments will be held responsible for proper trashsegregation. CLASSIFIED MATERIAL WILL ONLY BE PROCESSED AFTEREACH BAG HAS BEEN PROPERLY OPENED AND INSPECTED FOR NON-PULPABLE ITEMS . Any questions may be directed to :

[Personnel names]

2. Hours of Operation:

0700-2000 - Plastic Waste

0700 -1300 - Metal/Glass

0700 - 2000 - Pulpables

2000 - 2200 - Secured For Cleaning

3. No trash will be dumped overboard without permission from the Officer of theDeck/Commanding Officer.


APPENDIX B

JOB QUALIFICATION REQUIREMENTS (JQR) SAMPLES

NSWCCD–TR–63—97/25 69

COMPRESS MELT UNIT OPERATORJOB QUALIFICATION REQUIREMENT

NAME: RATE: SSN:

Job Qualification Certified for Use in Supply Department

Submitted By: Approved By: Training Coordinator Officer/Date

This page is to be used as a record of satisfactory completion of designated sections of the Job Qualification

Requirement (JQR). Only specified supervisors may signify completion of applicable sections either by written ororal examination, or by observation of performance. The checkout examination need not cover every item;however, a sufficient number shall be covered to demonstrate the trainee’s knowledge.

This qualification section is to be maintained by the trainee and updated to ensure awareness of remaining tasks.

QUALIFICATION RECORD

Trainee has been indoctrinated in this PQR Watch Station and given a target completion date of_______________ which is reflected on the Trainee’s Professional Growth Sheet.

SIGNATURE: Training and Qualification Coordinator/Date

SIGNATURE: Trainee/Date

Trainee has completed all requirements for this watch station. Recommend designation as a COMPRESS MELTUNIT OPERATOR onboard USS ___________________ .

RECOMMENDED DATE (Supervisor)

RECOMMENDED DATE (Officer)

QUALIFIED DATE (Officer)

SERVREC ENTRY DATE (Personnel Officer)


WATCH STATION - COMPRESS MELT UNIT OPERATOR

Estimated completion time: 2 weeks

Total points this watch station: 300 Points

PREREQUISITES

Before starting your assigned tasks, complete the following:

Watch Stations

BASIC DEPARTMENT QUALIFICATION (JQR)

Completed: (Qualifier/Date)

GENERAL DAMAGE CONTROL (301-306)


FOR OPTIMUM TRAINING EFFECTIVENESS, THE FOLLOWING PQR ITEMS SHOULD BECOMPLETED PRIOR TO STARTING YOUR ASSIGNED TASKS BUT MUST BE COMPLETED PRIORTO FINAL WATCH STATION QUALIFICAITON.

Fundamentals From This PQR:

Hearing Conservation Program

Completed 10 pts of Watch Station(Qualifier/Date)

Heat Stress Program


Basic First Aid Indoctrination


NSWCCD–TR–63—97/25 71

Sight Conservation Program


Personal Protective Equipment


Personal Qualification Standard Indoctrination

Completed 50 pts of Watch Station(Training/Date)

Training Program Overview / ETPO Entry

Completed 10 pts of Watch Station(Training/Date)

Tag Out Program


Waste Disposal Procedures and the Importance of Sanitation


NSTM Chapter 593, Section 2


OPNAVINST 5090.1B, Chapter 19


Tools and Tool Control Program



Systems From This PQR:

Compress Melt Unit Overview (Reference: Plastics Processor Technical Manual, S9593-C4-MMM-010/5F565)

Discuss or answer the following as appropriate:1. What is the function of this equipment?2. When can this equipment be used?3. How many major components comprise the plastics processor?4. Identify all the major components.5. Describe the operation of this equipment.6. How many modes of operation are there?7. What are the normal operating temperatures?8. What happens if the normal operating temperatures are exceeded?9. How long does the process typically take?10. Can this equipment be jammed? If so, how would such a condition be remedied?


Ventilation


TASKS

For the tasks below:

A. What are the steps to this procedure?B. What are the reasons for each step?C. What control/coordination is required?D. What means of communication are used?E. What safety precautions must be observed?F. What parameters/operating limits must be monitored?G. Observe/Perform this task in accordance with the

applicable NSTM and/or certified operating procedure.

A B C D E F GGENERAL TASKS:

Compress Melt Unit Safety Devices (Safety Cover, Side Panels, Limit Switches, X X X X X X XAir Flow Switch, Personal Protective Equipment, Fire Fighting Equipment)

2 pts of Watch Station(Signature) Date

Location and Operation of the Compress Melt Unit Power Supplies X X X X X X X


NSWCCD–TR–63—97/25 73

A B C D E F G

Understanding the Indicator Lights and the Message Display Unit Messages X X X X X X X


Following the Equipment Operating Placard X X X X X X X


Unit Startup (Power, Cooling Water, LP Air, Ventilation, System Warm-up) X X X X X X X


Resetting the Compress Melt Unit X X X X X X X


Chamber Preparation X X X X X X X


Plastics Inspection and Loading X X X X X X X


Closing the Door and Safety Cover X X X X X X X


Operating the Push Button Station X X X X X X X


Ejecting the Disk X X X X X X X


Emergency Stop Procedures X X X X X X X



A B C D E F G

Failure Reporting Procedures X X X X X X X


Unit Cleaning Procedures and PMS X X X X X X X


Operating the Heat Sealer and Disk Stowage Procedures X X X X X X X


WATCHES

Stand the following watches under qualified supervision:

Qualifier Date/Time

Qualifier Date/Time

Qualifiers may sign off one line only after completion of one full Under Instruction Watch.

COMPUTER BASED INTERACTIVE COURSEWARE OPERATOR EXAMINATION

Completion of a computer examination is to be arranged through the Training Division prior to routing thisqualification. Upon successful completion, the computer examination shall be attached to this JQR and an OralExamination shall be scheduled with the certifying officer.

EXAMINATION GRADE EXAMINATION PROCTOR DATE

ORAL EXAMINATION

Successfully completed an Oral Examination Board and is qualified to stand this Watch Station:

(Certifying Officer/Date)

NSWCCD–TR–63—97/25 75

SHREDDER UNIT OPERATORJOB QUALIFICATION REQUIREMENT

NAME: RATE: SSN:



This page is to be used as a record of satisfactory completion of designated sections of the Job Qualification

Requirement (JQR). Only specified supervisors may signify completion of applicable sections either by written ororal examination, or by observation of performance. The examination of checkout need not cover every item;however, a sufficient number shall be covered to demonstrate the trainee’s knowledge.






Trainee has completed all requirements for this Watch Station. Recommend designation as a SHREDDER UNITOPERATOR onboard USS ____________________________________.






WATCH STATION - SHREDDER UNIT OPERATOR

Estimated completion time: 2 weeks

Total points this Watch Station: 300 Points

PREREQUISITES


Watch Stations



GENERAL DAMAGE CONTROL


FOR OPTIMUM TRAINING EFFECTIVENESS, THE FOLLOWING PQR ITEMS SHOULD BECOMPLETED PRIOR TO STARTING YOUR ASSIGNED TASKS BUT MUST BE COMPLETED PRIORTO FINAL WATCH STATION QUALIFICATION.

Fundamentals From This PQS:



Heat Stress Program






NSWCCD–TR–63—97/25 77







Tag Out Program








Tools and Tool Control Program




Shredder Unit Overview (Reference: Solid Waste Shredder Technical Manual, S9593-C5-MMM-010/5F565)

Discuss or answer the following as appropriate:

1. What is the function of this equipment?2. When can this equipment be used?3. Identify all major components of the shredder.4. What is the difference between a Plastics Shredder and a Metal/Glass Shredder and why does the Navy

require a separate shredder for each waste stream?5. Describe the operation of the equipment.6. How many modes of operation are there?7. How long does the process take?8. Can the shredder be jammed? If so, what should be done to remedy it?9. What is the proper condition of the cutting blades and how is that determined? When should they be

replaced?


Ventilation


TASKS

For the tasks below:

A. What are the steps to this procedure?B. What are the reasons for each step?C. What control/coordination is required?D. What means of communication are used?E. What safety precautions must be observed?F. What parameters/operating limits must be monitored?G. Observe/Perform this task in accordance with the



Understanding the Shutdown Interlocks and Safety Devices (Air Flow Switch, Limit X X X X X X XSwitches, Blowout Panels, Personal Protective Equipment, Fire Fighting Equipment)


Location and Operation of the Shredder Power Supplies X X X X X X X


NSWCCD–TR–63—97/25 79

A B C D E F G

Understanding the Indicator Lights, Pushbuttons, and Control Knobs XX X X X X X




Unit Startup (Power, Ventilation) X X X X X X X


Inspecting the Waste before Processing X X X X X X X


Operating the Doors and Loading the Shredder Chamber and Hopper X X X X X X X


Operating the Pushbuttons and Control Knobs X X X X X X X


Correcting a Jammed Condition X X X X X X X









A B C D E F G

Disposal of Shredded Waste X X X X X X X


WATCHES


Qualifier Date/Time

Qualifier Date/Time



Completion of a computer examination is to be arranged through the Training Division prior to routing thisqualification. Upon successful completion, the computer examination shall be attached to this JQR and an OralExamination shall be scheduled with the certifying officer.


ORAL EXAMINATION



NSWCCD–TR–63—97/25 81

PULPER UNIT OPERATORJOB QUALIFICATION REQUIREMENT

NAME: RATE: SSN:



This page is to be used as a record of satisfactory completion of designated sections of the Job QualificationRequirement (JQR). Only specified supervisors may signify completion of applicable sections either by written ororal examination, or by observation of performance. The examination of checkout need not cover every item;however, a sufficient number shall be covered to demonstrate the trainee’s knowledge.






Trainee has completed all requirements for this Watch Station. Recommend designation as a LARGE OR SMALLPULPER UNIT OPERATOR onboard USS ______________________________.






WATCH STATION - LARGE OR SMALL PULPER UNIT OPERATOR

Estimated completion time: 2 Weeks

Total points this Watch Station: 300 Points

PREREQUISITES


Watch Stations



GENERAL DAMAGE CONTROL


FOR OPTIMUM TRAINING EFFECTIVENESS, THE FOLLOWING PQR ITEMS SHOULD BECOMPLETED PRIOR TO STARTING YOUR ASSIGNED TASKS BUT MUST BE COMPLETEDPRIOR TO FINAL WATCH STATION QUALIFICATION.

Fundamentals From This PQR:



Heat Stress Program






NSWCCD–TR–63—97/25 83







Tag Out Program








Operational Security Program




Firemain, Salt Water Eductor, and Overboard Discharge Piping Systems


Low Pressure Air System


Pulper Overview (References: Large Pulper Technical Manual, S9593-C2-MMM-010/5F565; Small PulperTechnical Manual, S9593-C3-MMM-010/5F565)

Discuss or answer the following as appropriate:

1. What is the function of this equipment?2. What may be processed in it?3. What is the processing rate?4. When can this equipment be used?5. Identify all major components.6. Describe the operation of this equipment.7. How many modes of operation are there?8. What is the normal operating current?9. What salt water and LP air pressures are required to operate this equipment?10. Can this equipment be jammed? If so, how would such a condition be remedied?11. What is the proper condition of the blades and when should they be replaced?12. How does the waste slurry get out of the system and where does it go?


TASKS

For the tasks below:A. What are the steps to this procedure?B. What are the reasons for each step?C. What control/coordination is required?D. What means of communication are used?E. What safety precautions must be observed?F. What parameters/operating limits must be monitored?G. Observe/Perform this task in accordance with the


NSWCCD–TR–63—97/25 85


Valve Alignment and Operating Pressures (Salt Water, LP Air, Drains) X X X X X X X


Shutdown Interlocks and Safety Devices (Proximity Sensors, Differential Pressure X X X X X X XSwitch, Personal Protective Equipment, Fire Fighting Equipment)


Location and Operation of the Pulper Power Supplies X X X X X X X


Understanding the Indicator Lights and the Message Display Unit Messages X X X X X X X




Pulper and Impeller Inspection X X X X X X X


Unit Startup (Valve Alignment, Power, Timed Start Pushbutton Operation) X X X X X X X


Waste Inspection and Loading X X X X X X X


How to Recognize an Overloaded Pulper and Remedy It (Ammeter, Water Level, X X X X X X XIndicator Lights, Message Display Messages, Alarm)


Unit Shutdown (Timed Stop Pushbutton Operation) X X X X X X X



A B C D E F G







Removal of Junkbox Basket and Disposal of Pulped Waste X X X X X X X


WATCHES


Qualifier Date/Time

Qualifier Date/Time



Completion of a computer examination is to be arranged through the Training Division prior to routing thisqualification. Upon successful completion, the computer examination grade shall be attached to this JQR and anOral Examination shall be scheduled with the certifying officer.


ORAL EXAMINATION



NSWCCD–TR–63—97/25 87

APPENDIX C

TRAINING MATERIALS

&

ENVIRONMENTAL RESOURCES

NSWCCD–TR–63—97/2588

NAVY INSTRUCTIONS

• OPNAVINST 5090.1B Environmental and Natural Resources Program Manual• OPNAVINST 5100.19C Navy Occupational Safety and Health (NAVOSH) Program Manual

for Forces Afloat (NOTAL)• OPNAVINST 5100.23D Navy Occupational Safety and Health (NAVOSH) Program Manual• Navy Ships Technical Manual (NSTM) Chapter 593 Pollution Control• OPNAV U.S. Navy Pollution Discharge Restrictions Wheel• NAVMED PUB P-5010-7 Manual for Naval Preventative Medicine, Sewage Disposal

Ashore and Afloat• OPNAV Publication P-45-113-91 Afloat Medical Waste Management Guide

TRAINING PLANS

• N45-NTSP-X-10-96-01 Environmental and Natural Resources Program Navy TrainingSystems Plan (CNO N45)

• NTP-S-30-9508 Plastic Waste Processor Navy Training Plan (NAVSEA 03L1)• NTP-S-30-9603 Solid Waste Equipment Navy Training Plan (NAVSEA 03L1)

INTERACTIVE COURSEWARE (in CD ROM form)

• Plastics Waste Processor Training• Pulper and Shredder Training

NAVOSH AND HMC&M VIDEOTAPES and PRODUCTION IDENTIFICATION NUMBERS(PIN)

• NAVOSH – It’s Protecting You (Afloat) 804764DN• Hazardous Material Control Afloat 804939DN• Shipboard Respiratory Protection for the User and for the Supervisor 805009DN• Shipboard Electrical Safety 805008DN• Shipboard Hazardous Material User’s Guide 805357DN• Hazardous Material Control Afloat for Users 805544DN• Hazardous Material Control Afloat for Supervisors 805545DN• The Shipboard Hazardous Material Coordinator 805546DN• Hazardous Material Offload 805569DN• Brush Up on Safety: Shipboard Paint Application and Removal 805733DN• Management of Reproductive Hazards in Navy Workplaces 806083.

NSWCCD–TR–63—97/25 89

These videos can be ordered through the Navy’s Media Resource Library by sending the Title &PIN to:

NETPDTC NREMC9770 Decatur Ave., Suite 250Norfolk, VA 23511-3292

Phone: (757) 444-4011/1468 or DSN 564-4011/1468Fax: (757) 444-3711 or DSN 564-3711Internet e-mail: [email protected] or

[email protected]

OTHER

“Shipboard Solid Waste Processing Equipment Basic Ship Installation Integration Package,”Naval Sea Systems Command (NAVSEA 03L-Environmental Engineering & Auxiliary SystemsGroup), Revision E, 30 April 1997, S9593-C6-IIN-010, 0910-LP-012-4560.

The following videos are in production and are soon to be distributed:

• Management of Medical Waste Afloat (NAVOSH)• Oil and Hazardous Substance Spill Prevention and Response – The Key is Preparedness

(NAVOSH)• Plastic Waste Processor Indoctrination Video (NAVSEA 03L1)• ET-35N Oil Content Monitor and 10NP Oil Waste Separator Functional Descriptions and

Operations (NAVSEA 03L1)


APPENDIX D

SAMPLE TRASH DISPOSAL ROOM LOG

NSWCCD–TR–63—97/25 91

NSWCCD–TR–63—97/25 93

APPENDIX E

PROGRAM POINTS OF CONTACT


PROGRAM POINTS OF CONTACT

Program Sponsor: LCDR Steve Markle (SEA 03L1B)

(703) 602-0351 DSN: 332-0351

or

Mr. Joel Krinsky (SEA 03L1)

(703) 602-0547 x250 DSN: 332-0547 x250

Naval Sea Systems Command

2531 Jefferson Davis Highway

Arlington, VA 22242-5160

In-Service Engineering Agent Mr. Tony Budzichowski or Steven Marx

NSWCCD-SESS, Code 631

Philadelphia Naval Business Center

Philadelphia, PA 19112-5083

(215) 897-1080 or (215) 897-7270

Logistics and Spares Mr. Jeff Gibbs (SEA 03L42)

Naval Sea Systems Command

2531 Jefferson Davis Highway

Arlington, VA 22242-5160

(703) 602-9711 ext. 112

DSN: 332-9711

Mr. Rich Laughlan

NAVSEA Staging Facility - Atlantic

116 Lake View Parkway

Suite 150

Suffolk, VA 23435-2696

(757) 686-7940

Mr. Don Ininonencio

NAVSEA Staging Facility - Pacific

5600 Rickenbacker Road

Bell, CA 90201

(213) 268-0163

NSWCCD–TR–63—97/25 95

Abbreviations

AEL Allowance Equipment ListAIT Alteration Installation TeamAPL Allowance Parts ListAPPS Act to Prevent Pollution from ShipsBTU British Thermal Unit (A measure of a quantity of heat)BUMED Bureau of Medicine and SurgeryCCTV Closed circuit televisionCRAMSI Consolidated Residual Asset Management System InformationCHRIMP Consolidated Hazardous Materials Reutilization Inventory Mgmt. ProgramCLCU Closed Loop Cooling UnitCMU Compressed Melt UnitCNO Office of the Chief of Naval OperationsFOT&E Follow-On Test and EvaluationGMT General Military TrainingGUCL General Use Consumable ListHAZMAT Hazardous MaterialsHICS Hazardous Material Inventory Control SystemHS Heat SealerICW Interactive CoursewareISEA In-Service Engineering AgentJQRs Job Qualification RequirementsMAA Master-At-ArmsMARPOL International Maritime Convention for the Prevention of Pollution from ShipsMGS Metal/Glass ShredderMRC Maintenance Requirements CardsOBB Odor Barrier BagOPEVAL Operational EvaluationOPNAVINST Office of the Chief of Naval Operations InstructionNAVICP Naval Inventory Control PointNAVSEA Naval Sea Systems CommandNAVSUP Naval Supply Systems CommandNEHC Naval Environmental Health CenterNETPMSA Naval Education and Training Personnel and Management Support ActivityN/A Not ApplicableNSN National Stock NumberNSWCCD Naval Surface Warfare Center, Carderock DivisionNSWCCD-SSES Naval Surface Warfare Center, Carderock Division, Ship Systems Engineering

StationPLC Programmable Logic ControllerPOD Plan of the DayP2 Pollution Prevention (Afloat)PRIME Plastics Removal in the Marine EnvironmentPS Plastics ShredderPWP Plastics Waste ProcessorSTEP Shipboard Training Enhancement ProgramSWMP Solid Waste Management Plan


Abbreviations (Continued)

SWS Solid Waste ShredderTMIN Technical Manual Identification NumberUNREP Underway ReplenishmentWRAPS Waste Reduction Afloat Protects the Sea

NSWCCD–TR–63—97/25 97

Initial Distribution

External Distribution NSWCCD Distribution

Copies Copies Code Name540 NAVSEA 1 3422 Unclass Lib 5 SEA 03R16 1 602 Morton 5 SEA 91 3 63 Alig 530 SEA 03L 1 6301 Lardis2 CNO 452 (Koss) 1 6301 Caplan2 DTIC 10 631 Reudiger

5 63S File5 634 McGraw5 634 Kelly5 634 Alexander5 634 Upton1 634 Olson1 634 Walters

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