15817-21-001 PWT Plenum Evacuation System (PES) Compressor Antisurge and Performance Controls SOW DRAFT.pdf

15817-21-001

SOW NO. 15817-21-001

15 March 2021

STATEMENT OF WORK FOR PWT

PLENUM EVACUATION SYSTEM (PES)

COMPRESSOR ANTISURGE &

PERFORMANCE CONTROLS

ARNOLD ENGINEERING DEVELOPMENT COMPLEX

ARNOLD AIR FORCE BASE, TN 37389-9998

DISTRIBUTION STATEMENT A

Approved for Public Release

Distribution Unlimited

IRA-5421

DRAFT

DISTRIBUTION STATEMENT A

Approved for Public Release: Distribution Unlimited

IRA-5421 Table of Contents-1

Table of Contents

1. SCOPE

1.1 Scope of Work

1.2 Existing Operational Conditions

1.3 Site Visit

2. APPLICABLE DOCUMENTS

2.1 Government Documents

2.2 Non-Government Documents

3. REQUIREMENTS

3.1 General

3.2 System Interfaces

3.3 Performance Characteristics

3.4 Physical Characteristics

3.5 Design and Installation

3.6 System Integration

3.7 System Security Requirements

3.8 Submittals

3.9 Verification

3.10 Warranty

Appendix A – 16T Environment Controls

Approved for Public Release: Distribution Unlimited

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1 SCOPE

1.1 Scope of Work: The Contractor shall design and supply all hardware and software for a replacement compressor antisurge and performance control system. The system shall control 12 axial flow compressors which comprise the Arnold Engineering Development Center (AEDC) Propulsion Wind Tunnel (PWT) Plenum Evacuation System (PES). The Contractor shall supply new controllers for each of the compressors to perform performance control and compressor antisurge protection. The compressor antisurge and performance control system shall interface with existing process control instrumentation, existing control valves, and with an existing GE Rx3i PES Supervisory Controller. The Government/AEDC personnel will install the hardware. The Contractor shall commission and checkout the control system at Arnold Air Force Base, TN.

1.2 Existing Operational Conditions: The PES plant compressors consists of twelve (12) axial flow compressors manufactured by Allis Chalmers. The compressors are of two types: 9 stage machines and 7 stage machines.

The 9 stage compressors are rated at 280,000 cfm and the 7 stage compressors are rated at 75,000 cfm. The compressors are capable of being connected in different configurations to support wind tunnel testing and other AEDC test facilities. The 12 machines are configured in two increments. The first increment consists of compressor units A, B and C.

The second increment consists of units D, E and F. Units A, B, D, and E each consist of two compressors operating in parallel, driven by a single synchronous motor. The motors cannot be operated at sub-synchronous speeds. Each of the compressor "double units" share a single bypass valve, have common inlet and discharge valves, and share a discharge air cooler. Units C and F each consist of two compressors configured in series, driven by a single synchronous motor. Each compressor has its own discharge air cooler and bypass valve. Each compressor is currently capable of supporting different tunnel applications. All individual compressors have inlet guide vanes (IGV’s) for throughput modulation.

Compressor configurations are established by operating various plant configuration valves. The compressors can be staged to support multiple test requirements simultaneously. Configuration changes can be made dynamically (while compressors are operating). Staging valves are controlled by the existing supervisory controls.

1.3 Site Visit: A visit to AEDC to inspect, discuss, and understand the existing antisurge and performance control system (and any existing deficiencies) and to verify/validate physical requirements prior to bidding on this contract is highly encouraged.

Approved for Public Release: Distribution Unlimited IRA-5421 Page -2

2 APPLICABLE DOCUMENTS

2.1 Government Documents: None.

2.2 Non-Government Documents:

2.2.1 Insitute of Electronical and Electonics Engineers (IEEE):

A. IEEE C63.12-15 Standard Recommended Practice for Electromagnetic Compatiblity Limits and Test Levels.

2.2.2 National Fire Protection Association (NFPA) Standard:

A. NFPA 70-20 National Electrical Code (NEC).

3 REQUIREMENTS

3.1 General: The new PES compressor antisurge and performance control system shall replace the existing obsolete Compressor Controls Corporation Series 3+ controllers. The new system shall have the same functionality as the existing system. The new system shall consist of electronic, microprocessor based, controllers that will optimize control of the PES Plant Compressors.

3.2 System Interfaces: The Contractor shall verify all interface requirements to ensure that the compressor antisurge and performance control system is a complete, fully integrated and operable part of the PWT facility control system. The compressor antisurge and performance control system shall interface with the PES plant as described below:

3.2.1 Electrical Power Interfaces: The compressor antisurge and performance control system hardware shall be powered by 120 VAC, 60 Hz. Any special connectors and/or cables shall also be provided.

3.2.2 Instrumentation Interfaces: The compressor antisurge and performance control system shall have the following input/output interfaces.

A. Analog Inputs: Minimum of 8 isolated, floating-ground inputs configurable for 4 to 20 mADC. Provide loop power for up to 750 Ohm load impedance. All measurements shall be displayed as engineering units.

B. Analog Outputs: 2 minimum. Ranges shall be Configurable for 4 to 20 mADC (up to 750 Ohm load impedance) or 0 to 10 VDC. All measurements shall be displayed as engineering units.

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C. Discrete Inputs: 4 minimum. On-Off voltage levels with return, each rated at 30 VDC (max.). Energized state: +10 to +30 VDC; de-energized state: 0 to 1 VDC.

D. Discrete Outputs: 4 minimum. Single-pole relays, each rated 1A (minimum) at 28 VDC, selectable as NO or NC.

3.2.3 Communication Interfaces: The compressor antisurge and performance control system shall communicate with the existing GE Rx3i PES Supervisor PLC via Modbus TCP/IP network connections.

3.3 Performance Characteristics: The Contractor shall provide compressor antisurge and performance controllers (one per compressor and two spares) with the following functional, physical, performance, and operating characteristics. Provide all equipment with ratings compatible with the performance requirements of this specification.

3.3.1 Control Functions:

A. Performance Control: The control system shall control compressor inlet guide vanes and compressor bypass valves to meet process requirements while reducing excess energy costs. There are three

(3) process control strategies to be optimized:

1. Plant bypass valve position control: Excess compressor plant capacity is recycled using plant bypass valves (Reference Figure 1). The control system shall modulate compressor inlet guide vanes and control compressor bypass valves for multiple compressors in order to maintain plant bypass valve position at some nominal position (e.g. 50%) to enhance mach controllability with minimal recycling at the PES. Plant bypass valves are controlled with an existing AEDC Controller.

2. Humidity Control: Wind tunnel humidity is controlled by exchanging moist air with dry air pulled through a dessicant drier. Humidity control shall be accomplished by modulating external valves (Reference Figure 1) under control of an existing AEDC Controller. The compressor antisurge and performance control system will optimally modulate compressor inlet guide vanes and control compressor bypass valves for multiple compressors to maintain the wind tunnel humidity setpoint.

3. Suction Header Pressure Control: Suction header pressure is controlled by modulating external valves under control of an existing AEDC Controller. The compressor antisurge and performance control system will optimally modulate compressor inlet guide vanes and control compressor bypass

IRA-5421 Page -4 valves for multiple compressors to maintain the wind tunnel suction header setpoint.

B. Antisurge Control: Compressor surge shall be prevented by quickly opening compressor bypass valves in the event that eminent surge conditions are detected. The control system shall modulate individual compressor bypass valves to maintain an adequate margin of safety between compressor operating point and compressor surge limits.

3.3.2 Controller Characteristics:

A. Controller Type: All controllers shall be digital, microprocessor-based. Controllers shall be optimized for axial flow compressor control applications.

B. Control Output Characteristics: Controllers shall be capable of transforming their output signals to compensate for non-linear final control element characteristics.

C. Control Output Diagnostics: Controllers shall be capable of measuring their own analog output signals and signaling a fault condition when the actual signal differs from its intended value by more than ±0.5 percent.

D. Fault Relay: The controller shall provide a “watch dog” fault relay output (dry contact type) to the Government’s RX3i based control system when the controller fails.

E. Controller Parameters: The surge controllers shall be capable of switching tuning parameter and key surge control line setting changes from the Government’s RX3i PLC based control system as required for unique test requirements. These settings should be changeable while the system in operation and on line. The Government’s Supervisory RX3i PLC shall have read access to controller data such as flow, pressures, and temperatures, surge control margin in the surge controllers and shall be allowed to send commands to the surge controllers via the Modbus TCP/IP communication network

F. Program Execution Speed: The compressor control application is a high speed application. The control system shall read all inputs every 5 milliseconds (minimum) and update all output signals every 40 milliseconds (maximum).

3.3.3 Controllers: Controllers shall modulate compressor inlet guide vanes (IGV's) and compressor bypass valves for the purpose of minimizing

IRA-5421 Page -5 overall PES energy consumption. Under no circumstances should the control system compromise compressor antisurge protection. The compressor antisurge and performance control system shall meet the following control requirements:

A. Performance Control:

1. Inlet Guide Vane Control: Control shall be provided to regulate the throughput of each compressor by manipulating the compressor’s IGV’s (15 degrees to +15 degrees of rotation).

The vendor shall establish a control strategy to limit the position of compressor IGV’s to avoid negative stall conditions.

2. Compressor Bypass Valve Recycling: The Contractor shall establish a control strategy to prevent unnecessary recycling of compressor bypass valves.

3. Compressor Motor Power Limitation: The Contractor shall establish a control strategy to limit the compressor’s motor power consumption.

4. Feed Forward Capability: All control system distributed controllers performing a control function shall exchange process control data. Controllers shall have the capability to implement a feed forward control response to increase the precision of control by reducing adverse loop interactions.

5. Fail Safe Strategy: In the event that a distributed controller fails to receive process control data from other distributed controllers performing a control function, it shall revert to a “failsafe” control mode using its own input signals. It shall implement a fallback control strategy that is fully configurable by the user.

6. Mode Switching: The controller shall provide a bumpless transfer between automatic and manual operation and between remote and local control of set point.

7. Compressor Start and Shutdown: The compressor antisurge and performance control system shall receive inputs from the existing PES Supervisory controller to make the correct responses (position IGV’s and compressor bypass valves) for compressor start-up and shutdown.

8. Pressure Override Control: For suction pressure control, the control system shall include a pressure override control (POC) response that opens the compressor bypass valves during a fast pressure change in the main control variable (pressure drop). During this response, the controller output shall override the load sharing control response and permit the compressor bypass valve to restore suction pressure quickly..

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9. Loop Decoupling: Minimize adverse interactions between the control functions to maximize process stability through real time control loop decoupling techniques.

B. Anti-Surge

1. The control system shall manipulate the compressor bypass control valve in order to maintain an adequate but not excessive margin of safety between its compressor section's operating point and surge limit, as described below.

2. The control system shall calculate compressor operating point deviations in a manner that is invariant to changes in compressor inlet conditions, including but not limited to changes in inlet pressure and inlet temperature. Since compressors can be staged in series, inlet pressure and temperature invariance is crucial. For the compressor double units (units A, B, D, and E) due to plant piping geometry, it is not feasible to obtain accurate compressor air flow measurements. This will preclude the use of flow in the anti-surge control algorithm. For the single compressor units (units C and F) marginal flow measurements are obtainable.

3. Controller Response: The control system anti-surge algorithm shall employ an adaptive open-loop response that quickly increases the recycle flow rate in the event of large and/or fast process disturbances. To minimize the possibility of process upsets, this response shall take the form of variable-sized step changes in the controller output that repeat at regular, user-defined intervals so long as the margin-of-safety between the compressor operating point and surge limit is less than the set point for this response. The magnitude of each step change shall be a function of the rate at which the operating point of the compressor is moving toward the surge limit. After the potential for surge has been forestalled, the open-loop response shall decay at a user-selectable rate until the level required by the control function is restored. The set point for this open-loop response shall be a user-configurable function of volumetric flow (function may be derived), thus compensating for changes in compressor rotational speed or guide vane geometry, and shall be increased each time a surge cycle is detected.

4. Surge Detection: The antisurge control algorithm shall incorporate a surge detector and surge cycle counter. Surge detection shall be based on comparing the rate of change of the flow and/or discharge pressure to user-configurable limits.

Provisions shall also be made for recording and displaying the maximum observed rate-of-change for each of those variables as an aid to basing these thresholds on the results

IRA-5421 Page -7 of a surge test on the given machine. Provision shall also be made for resetting the surge counter.

5. Controller Communications: All control system distributed controllers regulating a compressor train (series or parallel configuration) shall be capable of exchanging process control data in order to implement a feedforward control responses that prevents loop interactions from degrading the quality of surge protection.

6. Surge Control Line: The controller shall utilize a set of points defining a surge control curve that is located on the safe operating side of the surge curve. The control line for compressors in the V-Plant in the low pressure areas is a non-linear function. The ability to represent such a control line is a requirement of the specified controllers. With a surge control curve, differential pressure data, flow data, and inlet temperature, a controller can manipulate the recycle valve to prevent the compressor from crossing the surge curve into the unstable region of surge. The distributed controllers shall maintain operation of the compressors in the safe operating area through control of the individual recycle (bypass) valves.

For the axial stages, the parallel compressors shall be isolated by the existing Government’s RX3i based PLC controlling the discharge valves.

7. Compressor Conditions: The control system shall calculate compressor operating point deviations in a manner that is invariant to changes in compressor inlet conditions, including but not limited to changes in inlet flow, compressor temperatures, compressor polytropic efficiency, and compressor differential pressure.

8. Controller Response: The control system antisurge algorithm shall employ an adaptive open-loop response that quickly increases the recycle flow rate in the event of large and/or fast process disturbances. To minimize the possibility of process upsets, this response shall take the form of variable-sized step changes in the controller output that repeat at regular, user-defined intervals so long as the margin-of-safety between the compressor operating point and surge limit is less than the set point for this response. The magnitude of each step change shall be a function of the rate at which the operating point of the compressor is moving toward the surge limit. After the potential for surge has been forestalled, the open-loop response shall decay at a user-selectable rate until the level required by the control function is restored. The set point for this open-loop response shall be a user-configurable

IRA-5421 Page -8 function of volumetric flow (function may be derived) and shall be increased each time a surge cycle is detected.

9. Surge Detection: The antisurge control algorithm shall incorporate a surge detector and surge cycle counter. Surge detection shall be based on comparing the rate of change of the flow to user-configurable limits. Provisions shall also be made for recording and displaying the maximum observed rate-of-change for each of those variables as an aid to basing these thresholds on the results of a surge test on the given machine. Provision shall also be made for resetting the surge counter via the Ethernet communications network to the Government’s existing RX3i PLC control system.

3.3.4 System Design Life: Provide a compressor antisurge and performance control system with a design life of not less than ten (10) years.

3.3.5 Safety Performance Requirements:

A. Non-volatile memory: Provide for controls to default to a fail-safe de-energized state. Both the system program and the configuration data shall be located in non-volatile Random Access Memory (NVRAM). The configuration shall not be affected in case the power is removed from the controller. The process variables (e.g. analog inputs and outputs) shall be temporarily kept in case of power interruption.

B. Grounding. Provide all equipment in grounded enclosures with no exposed energized parts or terminations. Ground all non-current carrying electrically conductive components and supporting hardware.

3.4 Physical Characteristics: The following physical requirements apply to the Compressor antisurge and performance control system:

3.4.1 Electrical Classification: Ordinary, non-hazardous areas as defined by

NFPA 70.

3.4.2 Space limitation: All new equipment shall be capable of being panel mounted.

3.4.3 Environmental Conditions: Compressor controllers shall be installed by AEDC personnel in outdoor enclosures designed to prevent damage from dirt, grease, oil, dust, or water. Operating and storage conditions are as follows:

A. Operating Temperature: 0 to 50 C.

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B. Storage Temperature: -25 to +85 C.

C. Relative Humidity: 0 to 95% (free from condensation).

3.4.4 Electromagnetic Interface Protection: Suppress electromagnetic interference (EMI) in accordance with IEEE C63.12.

A. Provide electronics that prevent electromagnetic interference from entering the incoming and outgoing power and control lines.

B. Provide electronics that attenuate any radiated electromagnetic interference to levels that will not affect sensitive electronic and communications systems outside of the boundary of the power electronics sets.

C. Controllers shall be protected against radiated electromagnetic interference from any external sources. Provide the Contracting Officer with the design emission figures and / or certifications of previous approval by the Federal Communications Commission (FCC) and any other government agencies.

D. Controllers shall not produce Radio Frequency Interference (RFI) or EMI that is :

1. Audibly detectable over the existing PWT intercom or paging system.

2. That causes movement, improper operation, or false readings in any PWT plant control or any PWT plant controller instrumentation circuit.

3.5 Design and Installation:

3.5.1 The Contractor shall provide all engineering and design personnel, equipment, and materials for manufacturing the compressor antisurge and performance control system.

3.5.2 The Government/AEDC personnel will install the hardware for the system.

3.5.3 The Contractor shall perform integration activities to design the interfaces between the compressor antisurge and performance control system and existing PES plant equipment in a safe, efficient, and timely manner.

Government/AEDC personnel will provide equipment to install and check-out the new control system. The Contractor shall provide factory representatives on-site for the checkout phases of each controller.

3.5.4 Design Criteria and Methods: The following criteria identify required design work, but not necessarily all design work required for a completely operational system.

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A. Site Visits and Field Verification: The Contractor shall make sufficient site visits, discussions with Government/AEDC personnel, and contacts with manufacturers of existing equipment at PWT PES, to gather all information required to manufacture a PWT Compressor antisurge and performance control system that will interface with existing PWT PES equipment and systems.

1. Because of Government mission requirements, the

Government may limit the times during which the Contractor can visit the site.

2. The Government/AEDC personnel will provide existing documentation including drawings, design calculations, and any other relevant information to the Contractor upon request to assist in the design phase. These documents shall be for information only. The Contractor shall verify in the field all information critical to the design and installation of the PWT PES compressor antisurge and performance control system.

3. All documents provided will be subject to normal AEDC security reviews prior to release to the Contractor. Security processing may require up to fourteen (14) days.

4. All Contractor personnel working at AEDC shall be U.S.

citizens. The Contractor shall notify the AEDC/PZ Contracting Officer and the AEDC AF Project Manager fourteen (14) calendar days prior to visiting the site to allow time for processing of site passes for U.S. Citizens.

B. Manufactured Components and Materials: Incorporate commercially available components and materials. Handle, store, apply, install, service, and use manufactured items and materials incorporated into the compressor control system in accordance with the original equipment manufacturer's (OEM) instructions and recommendations. Provide only new materials and new equipment. Used, salvaged, rebuilt, or remanufactured products and materials are not acceptable, except for the Government-owned interfaces and equipment designated in this statement of work as available for use by the Contractor.

C. Engineering Studies and Calculations: Engineering data required under this section includes all calculations, computations, computer printouts, graphs, presentations, and details of design analysis. This shall be tabulated, organized, and bound in such a manner that all pertinent information is easily and readily identified and shall be provided to the Government/AEDC personnel.

3.5.5 Identification and Markings: Provide nameplates for all equipment.

Permanently affix nameplates to each major component. Firmly attach nameplates to the equipment with nonferrous rivets or similar connections

IRA-5421 Page -11 to prevent loss or removal. Engrave or emboss all information. Include the following information on each nameplate:

A. Manufacturer's name.

B. Model or style number.

C. Serial number.

D. Date of manufacture.

3.6 System Integration: The Contractor shall be responsible for the integration of all major components of the Compressor antisurge and performance control system. All new or renovated equipment shall conform to the requirements stated below. These requirements do not apply to existing Government-provided equipment deemed satisfactory by the Contractor for use in the system. Maintain all existing electrical and mechanical interfaces to Government-provided equipment and components.

3.6.1 Design Development: Contractor shall provide the following engineering services in order to define the compressor antisurge and performance control system control scheme:

A. Instrumentation Requirements: Contractor shall recommend the location and special requirements of compressor control instrumentation and control elements (field transmitters and valve positioners) to ensure compatibility with the compressor control system. The Government/AEDC personnel will be responsible for procuring any of these recommended instruments.

B. System Design Documentation: Contractor shall provide an engineering manual to document the design requirements and specifications that include:

1. Piping and instrumentation diagrams.

2. Schematics and assembly diagrams for each controller.

3. A process control flow diagram and description of the control scheme including an explanation of the underlying theory.

Description should include the calculations behind the suitability of the recycle valve and flow measurement, as well as how the surge control line setting are derived based upon the compressor curves, recycle valves, flow measurements, and system transmitters.

4. Detailed installation instructions.

5. Operating procedures for the compressor control system.

6. Field maintenance and trouble-shooting procedures.

7. Instruction manuals for all control system components.

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3.6.2 Electrical Connections: Provide for electrical terminal connections as follows.

A. Provide copper connectors for external wiring connections.

B. Wire connections shall be screw-held or clamped type. Soldered-type transition joints are not acceptable.

3.6.3 Software: Provide the following:

A. Windows 7 and Windows 10 compatible configuration management software tool (and any necessary connection hardware and/or adapters) to allow the Government/AEDC personnel to upload and download the configuration settings of each controller and organize this for each controller. Software tool shall also provide the Government/AEDC personnel the ability to upload and download firmware on controllers.

B. Executable firmware and configuration data files for all controllers.

3.7 System Security Requirements:

3.7.1 Supplied systerms/hardware shall not contain any wireless communication components.

3.7.2 Contractor personnel shall not be permitted to interface with or operate Government owned computer equipment/networks or internet services.

3.7.3 The use of USB removable flash memory is not allowed under Air Force Security Policy. Configuration and operation of supplied hardware and/or software shall preclude the use of USB removable flash memory.

3.7.4 All Contractor personnel working at AEDC shall be U.S. citizens.

Contractor personnel shall also pass a security background check for base entry.

3.8 Submittals:

3.8.1 The Contractor shall provide submittals as described below. A summary table of required submittals is listed at the end of this section.

A. The Contractor shall develop a schedule (timeline) for the project indicating all project milestones and the delivery dates

B. Provide four (4) printed and bound copies of Engineering Manuals as specified in section 3.6.1 and 3.5.4 C that includes a description system operation applicable to PES, engineering studies and

IRA-5421 Page -13 calculations, design data, I/O lists, controller installation, setup, and maintenance manuals and any other documentation necessary for all elements of the Compressor Antisurge and Performance Control System. Provide one copy in an electronic format.

C. Provide four (4) printed and bound copies, 11” x 17”, of the drawings required for installation and maintenance of all items furnished under this contract.

D. Provide four (4) copies of a list of spare parts required to maintain all items furnished under this contract. Provide one copy in an electronic format. Provide the spare parts listed in the quantity recommended in that listing quantity to ensure reliability during the start-up and first year’s operation of the Compressor Control System. Provide a minimum of two (2) spare controllers.

E. After completion of installation, provide a detailed Field Service Report in electronic format that includes results of valve and compressor performances as well as observations made during startup. Summarys and Recommendations should also be noted.

F. Provide AutoCAD 2020™ compatible electronic drawing files, in a “.dwg” format, of any and all of the drawings required for maintenance of all items furnished under this contract.

G. Provide as-built revisions (4 printed copies and electronic) of any the above items that are modified between initial submittal and completion of installation. Final payment to be contingent upon receipt of printed and electronic as-built revisions.Electronic files shall be provided on DVDs and not USB media.

H. Electronic files shall be provided on DVDs and not USB media.

3.8.2 Submittal Table:

No. Section Reference Submittal Description Due

1 3.3 Controllers Within 16 weeks after contract award

2 3.6.3 A Configuration Software Tool Within 16 weeks after contract award

3 3.6.3 B Executable Firmware and Files (Software)

Within 16 weeks after contract award

4 3.8.1. A Contractor Schedule Within 4 weeks after contract award

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Table I. Required Submittal List

3.9 Verification:

3.9.1 General Verification Requirements:

A. Verification Personnel: The Contractor shall provide personnel experienced in compressor control system equipment checkout and startup for on-site verification and setup/optimization of surge control lines. Provide personnel trained on the specific type of equipment used on this procurement. Provide personnel familiar with the specific requirements and performance criteria for this equipment. Personnel shall be proficient in on-line surge testing of individual machines to verify exact location of the surge limit line.

Provide a commissioning engineer to oversee and coordinate on-site verification activities. The commissioning engineer shall be present for all on-site verification.

B. Verification Equipment: The Contractor shall calibrate and maintain equipment used for verification in accordance with the Contractor’s quality assurance program. Data recorded on equipment with an untraceable or expired calibration is not acceptable.

C. System Measurements: The Contractor shall perform and record system measurements on the completely installed Compressor Control System to verify the specified system The Government will provide dedicated air-on-time to support testing of the Compressor Antisurge and Performance Control System under load conditions.

5 3.8.1. B Engineering Manuals Within 16 weeks after contract award

6 3.8.1. C Printed Drawings Within 16 weeks after contract award

7 3.8.1. D Spare Parts List Within 16 weeks after contract award

8 3.8.1. E Field Service Report 30 days after system commissioning

9 3.8.1. G As-Built Electronic Drawing files (DVDs) 30 days after system commissioning

10 3.9.2 Verification Plan Within 16 weeks after contract award

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D. Inspection of the Compressor Control System: The wiring of the controller and the inter-controller wiring (including power, ground, shields, isolation) shall be checked. The controllers shall be powered up and their proper installation shall be evaluated.

Controller calibration shall be checked along with verification of Contractor-determined parameters and a test of the required algorithm operation.

3.9.2 Verification Plan: Provide a hardcopy and electronic Verification Plan, to verify performance requirements. Structure the plan to progressively reduce risk and minimize PES’s unavailability for AEDC’s mission. In addition to the Contractors procedure for on-line surge limit testing, include the following in the plan:

A. Prior to initial operation of the Compressor Control System, perform on-site subsystem verifications of the Control System components and subsystems to support the requirements

B. Perform subsystem verifications in accordance with the applicable industrial standards and codes, the Contractor's or manufacturers standard practices, and the Contractor's quality assurance plan.

C. Perform a pre-start checkout of PES Compressors including the following steps:

1. Support AEDC personnel in verification of all instrumentation and controls interfaces.

2. Make modifications as required.

3. Document all modifications.

4. Provide a copy of the modifications documentation to AEDC personnel.

D. Perform a mechanical run that:

1. Verifies proper operation of system components.

2. Identifies and eliminates systems anomalies.

3. Provides for revision of the compressor control tuning parameters as required.

4. Surge tests the compressors to determine location of surge limit line, if desired by Government.

3.9.3 Site Acceptance Testing: Perform, in accordance with the Verification Plan, a functional and operational verification of the final installation. It is anticipated that multiple on-site visits may be required to avoid a single, long shutdown of the PES Facility.

A. Contractor shall provide an experienced engineer to provide the following on site services for testing and acceptance:

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1. System Inspection: This will be completed on the compressor, the piping, the primary control elements, the check valves and the instrumentation. The primary control elements shall be calibrated and checked for accuracy, repeatability and speed of response. Transmitters and transducers will be calibrated.

2. Compressor Start-Up: Prior to testing and tuning, Contractor's technician or engineer shall monitor the input and output signals of the controllers to check for validity while the compressors are started up and operated by the Owner.

3. Surge Testing and Tuning: The antisurge controllers and the performance controllers shall be tuned by Contractor to establish all control objectives. The Contractor engineer shall be experienced and capable of performing surge testing if desired by the Owner. The Contractor will be financially responsible for damage to Government’s equipment due to Contractor negligence or failure to protect Government’s compressors from surge during startup.

4. Final Testing: Contractor shall observe the operation of each compressor for possible problems. A Government approved simulation of upsets within the system will be conducted by Contractor as well as a performance test.

B. The Government will accept the system and installation upon inspection and demonstration of successful testing and operation.

The Contractor’s written test plan will be used for both the Contractor and the Government/AEDC personnel to sign/acknowledge that each step of the test plan for each compressor has been successfully performed.

3.10 Warranty: The Contractor shall guarantee system installations to be free of defects in materials and workmanship for a period of 1 year from the date of system commissioning of each controller. Defective materials or equipment will, at Contractor's option, be repaired or replaced at no cost to the Government during this warranty period. This coverage will include the on-site repair, replacement, or checkout of any system components provided under this contract. Provide trained and skilled personnel to provide service for the Compressor Antisurge and Performance Controls System during the one year warranty period.

IRA-5421 Appendix A -1

APPENDIX A

16T ENVIRONMENT CONTROLS

Figure 1 – 16T Environment Controls

END OF SOW