20X20'_Door_SOW_RFP.pdf

Statement of Work for Bldg. 1293B Vacuum Chamber Electrohydraulic Door Actuation System

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I. Scope:

Bldg.1293B at the NASA Langley Research Center houses a Thermal Vacuum Chamber (TVC) 16 meters in diameter. The chamber is accessed through a 20’ wide by 20’ tall curved opening that includes a sealing door. The door is driven circumferentially by a hydraulic motor on rails around the side of the chamber to open and close. Traverse hydraulic cylinders are used to radially position the door on rails against the chamber opening; wedge blocks and locking clamps actuate to hold and seal the door in place, respectively. The existing hydraulic system and electrical controls are obsolete and no longer provide the precision movements required to execute the door motions in an efficient and reliable manner.

The scope of this task is to procure a new electro-hydraulic control and actuation system using industry-standard hardware, technology, and manufacturing techniques.

The Contractor shall provide all labor, material and equipment to design, procure, manufacture, test, and ship a complete hydraulic and control system to upgrade the TVC’s 20’ x 20’ door operating system. The door’s hydraulic unit shall be replaced with a stand-alone system integrated with an Allen Bradley, or equal, Programmable Logic Controller (PLC) based control system, including a touch screen display Human Machine Interface (HMI) panel. Installation of the hardware at the site will be by others.

The door’s functional sequence shall remain the same, as described below:

1. Peripheral Door Travel Open/Close: The door travels circumferentially around the outside of the chamber on a curved rail at the bottom, while guided by top captive rollers.

The door shall be capable of continuous motion from open to close and reverse;

and manually started and stopped at any location on the rail. (Automatic and Jog modes)

2. Traverse Door In/Out: The door travels radially toward the chamber opening by movement of two door supporting rails and two sections of track at the top rollers using four independent hydraulic cylinders. The new control system shall move the door in and out using closed loop position control with feedback from all four cylinders. The traverse operation shall also allow manual control of any one cylinder. (Automatic and Jog modes) Traverse position control requirements are listed below.

3. Insert/Retract Wedges: Eighteen frame mounted stationary wedges are inserted into door slots to ensure that the door is centered and closed over the chamber opening. Wedge control shall be all wedges Inserted or Retracted as a group.

4. Door Clamps On/Off: The door is sealed against the opening by rotating 56 cam-locked clamps actuated by 8 hydraulic motors. Clamp rotation shall be all clamp motors On or Off as a group.

The existing hardware shall be integrated into the new control system:

8 Limit switches for Door Traverse position (limit switches to be integrated as inputs into the new PLC Control system, reference the electrical control system requirements below)

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8 Rotary Seal Clamps and associated limit switches (limit switches to be integrated as inputs into the new PLC Control system, reference the electrical control system requirements below) 18 Wedge Lock Cylinders and associated limit switches (limit switches to be integrated as inputs into the new PLC Control system, reference the electrical control system requirements below)

II. Control System Requirements:

1. The control system shall be designed and manufactured in accordance with the current NFPA 70, National Electric Code.

2. The control system shall be a Contractor’s standard product and UL listed.

3. All materials and equipment shall be new.

4. The control unit shall be an Allen Bradley, or equal, PLC based control system with

HMI.

5. The input power shall be 120 VAC, 60Hz, derived from the Government-provided

480 vac, 3 phase source.

6. The control system shall be housed in an appropriately sized, NEMA 12 enclosure with a Human Machine Interface (HMI) display panel to be integrated into the enclosure. The appropriately sized enclosure shall be large enough to safely troubleshoot and wire components mounted in the enclosure. All components shall be surface mounted to an internal panel in a manner that allows easy and secure replacement. All mounting hardware shall be included.

7. It is intended that the Control system shall be mounted adjacent to the hydraulic system unit. The Contractor shall supply all interconnection wiring, raceways, terminals, and hardware to configure these components together without additional electrical requirements.

8. The control system shall be designed and rated for continuous duty without overheating when continuously operated in an ambient temperature of no more than 95 degrees F.

9. The control system shall be designed for 25 year operating life at continuous duty.

10. Manufacturer’s Warranty shall be minimum 12 month after delivery.

11. On-site start-up services shall be provided to commission the system.

III. Electrical and Control Design Requirements

1. The hydraulic unit and control system shall be sized to interface to the facility’s available electrical power: 480VAC, 3 phase, 60 Hz, maximum 30-amp service.

2. The control unit shall include a lockable fused disconnect to remove all power from the unit for maintenance.

3. The control system shall utilize and incorporate all of the existing 120 VAC limit switches for each sequence; and permissive interlocks and indicators for the 20x20’ door. An easily accessible, interface terminal block shall be provided to wire the existing field devices.

4. The system inputs and outputs shall be programmed in the control system to provide safety and control features as needed for system operation while

3 | P a g e maintaining system functionality as depicted on LD-655897 - 20Ft. Door Hydraulic System Electrical Schematic.

5. The Contractor shall provide control system instrumentation to provide system information (pump pressure, oil temperature, and reservoir level) for door operation interlocks as well as status and alarm displays.

6. The control system shall monitor the hydraulic filter and alarm on high delta pressure across the filter element.

7. The control system shall incorporate an Emergency Stop circuit with a latching relay that removes power from the hydraulic pump motor and vents system pressure. The circuit shall include two separate, hardwired, panel mounted switches, consisting of one illuminated, hardwired mushroom head, push-pull Emergency Stop switch and one pushbutton panel-mounted E-stop reset switch.

The emergency stop circuit shall also include a PLC output (or relay) to activate the Emergency Stop circuit from software.

8. The control system shall incorporate the new feedback positioning system from the Traverse cylinders. Refer to the Hydraulic and Mechanical Section for details.

9. The HMI screens shall include displays allowing the operator to execute the following motions: Peripheral Door Travel, Traverse Open/Close Door, Insert/Retract Wedges and Door Clamps On/Off.

a. Traverse Door Open/Close operation shall have Automatic and Jog Modes:

i. Automatic - Move all four actuators simultaneously in closed loop, position-controlled operation until the appropriate limit(s) are reached.

ii. Jog - the operator can move each actuator independently between the

Open and Close limits.

10. Door position of each actuator (distance from Closed in inches) and status (Open or Closed) shall be displayed on the PLC HMI.

11. The HMI shall incorporate touch screen sequential operation, instrumentation readouts, system status, alarm/shutdown annunciation and security levels of access control. The HMI layout and sequence of operation shall be developed with collaboration from NASA for displays, sequence, interlocks, alarms, etc.

IV. Electrical Control System Hardware Requirements

1. Digital input/outputs shall be 24 vdc.

2. Analog inputs/outputs shall be either 0-10 vdc, 4-20 ma, TC, RTD, or as approved by the Government.

3. The PLC shall include a minimum of 10% spare I/O of each type used.

4. Power circuits for motors and heaters shall include a 3-pole contactor, thermal overloads, and individual circuit breakers.

5. The Contractor shall provide all field cables required to operate the traverse position control (including connectors) for each traverse cylinder. Cables shall be 100’ in length. Cables shall be used in the factory test of the traverse motion control, and shall be shipped with the control system hardware. Site installation will be by others.

6. The Control System enclosure shall include a combination power and communications port, Graceport External Connector, part number P-P22R2- K3RFO or equal.

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V. Electrical Control System Quality Assurance Requirements

1. A combined, integrated test of the control system and hydraulic unit shall be conducted at the Contractor’s site. Refer to Hydraulic and Mechanical System Quality Assurance Requirements Section.

2. Factory checks shall be Government witnessed. A ten-day advance notification of each test is required.

3. Factory Test Reports (4 copies).

VI. Electrical Control System Hardware Documentation Requirements

1. Component literature and specifications.

2. Design drawings with final factory as-built updates, including electrical schematics, wiring diagrams, mechanical layouts, assembly, and parts lists. Drawings shall be in .pdf format.

3. Ladder logic diagrams.

4. Installation instructions.

5. Certifications of calibrated devices and the frequency of the required calibrations.

6. Operating and Maintenance instructions.

7. Program software.

8. Recommended Spare Parts List, including quantities and pricing.

VII. Hydraulic and Mechanical System Requirements

1. The hydraulic system shall be designed to industrial best practices.

2. Fabrication and manufacturing processes shall be in accordance with component manufacturer’s requirements and specifications.

3. The hydraulic system shall be Contractor’s standard product.

4. All materials and equipment shall be new.

5. The hydraulic system components and function shall be compatible with the

Contractor’s electrical control unit.

6. The hydraulic system shall be housed in a free-standing, appropriately sized, enclosure, but no larger than the existing skid. The Contractor shall minimize the enclosure size to the smallest size necessary for protection and suitable access for maintenance. The enclosure shall include doors/removable panels to access pertinent areas of the unit for inspection and service. Insulation may be used on the interior of the enclosure to dampen the unit noise.

7. An integral drip pan shall be included. The pan shall be capable of covering all the floor area under hydraulic components, including the reservoir. The pan shall be sloped to one end that is accessible and can be drained without pan removal. The sloped area shall incorporate an ‘oil present’ sensor integrated into the PLC as an alarm.

8. All components shall be skid or surface mounted to an internal panel in a manner that allows easy and secure replacement. All mounting hardware shall be included.

9. The hydraulic system shall be furnished as a single integral unit mounted on a common base frame suitable to fit in the general area of the existing skid shown on

5 | P a g e drawing LD-705095 – Pump Unit Isometric and Valve Cover Details. The hydraulic skid shall incorporate floor-mounting flanges and include a ground lug to connect to the building ground system.

10. The hydraulic system shall be configured with major components mounted near ground level to the greatest extent possible to facilitate access and maintenance.

11. All piping, tubing, gages, and fittings shall be stainless steel.

12. Hoses shall not be used for any part of the system.

13. The hydraulic system shall include a flange-bolted or thread mounted reservoir electric heater with integral, adjustable snap action thermostat. Power to the heater shall be derived from the 480 vac input power and shall be operable in the event that the control system is de-energized. Heater operation shall be monitored by the PLC.

14. The hydraulic reservoir shall include an integral oil level sight glass, top-vent, top-fill opening, drain plug, and spare return connection.

15. The hydraulic unit shall be pressure tested prior to shipment.

16. The hydraulic unit shall be operated and flushed prior to delivery. A certification of flush oil cleanliness shall be included at delivery. The system filter shall be immediately replaced after final flushing.

17. Contractor shall ship the clean factory test hydraulic oil with the new hydraulic unit in a clean container.

18. Contractor shall provide (2) spare hydraulic filters, plus all filters needed to start-up and commission the hydraulic system.

19. Manufacturer’s Warranty shall be minimum 12 months after delivery.

20. On-site start-up services shall be provided to commission the system.

VIII. Hydraulic and Mechanical System Design Requirements

1. The new hydraulic unit shall be designed to be compatible with the existing system’s hydraulic oil type – MIL-H-5606.

2. The new hydraulic unit controls shall be designed to be compatible with the door’s rotary seal clamps and wedge lock cylinders that are being retained.

3. The (4) Door Traverse Open/Close hydraulic cylinders may be replaced with new cylinders equipped with position feedback or new position feedback devices may be added to the existing cylinders. Any and all redesign, rework, mounting brackets, etc. that is required to fit the new cylinders/new feedback devices in the existing space to achieve position feedback from the four traverse locations at each corner of the door shall solely be the responsibility of the Contractor. The new cylinders/new position feedback devices shall fit in the existing space without interfering with the door’s operation. The Contractor shall be responsible for making all field measurements to ensure proper integration into the existing space.

The manufacturer’s data for the existing hydraulic cylinders is listed below:

Sheffer Corp “MH” Series Hydraulic Cylinder, Clevis Mount Style C, 3-1/4” Bore, 33-1/4” Stroke, Std. Rod Size, No Cushions, Operating Pressure: 500 psi. (Reference dwgs. 702380 & 702381)

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4. The new Door Traverse motion shall incorporate position control. The position control loop shall meet the following requirements:

a. Each Traverse cylinder shall have a dedicated control valve.

b. The control valve shall be easily replaced in the event of failure.

c. The control algorithm for the traverse cylinder stroke shall consist of individual cylinder closed loop position control with adjustable and controlled acceleration, deceleration, and stroke velocity.

d. In Automatic mode, the four cylinders shall be commanded simultaneously with one position command. During this motion, the control system shall, independently from the control loop, monitor the four position feedback signals and compare them to a pre-programmed error band motion profile.

If any of the cylinders are out of the position error band of ±0.050” (steady state), the system shall display an alarm, and automatically stop door motion.

e. Automatic operation shall only be initiated from either ‘door full open position’ or ‘door full closed position’.

f. The positioning system shall have an accuracy of ±0.050” and have a resolution of 0.010”.

5. The new hydraulic system shall be designed for continuous duty and an operational life of 25 years.

6. The pump and motor mounting shall be selected to minimize noise and vibration.

7. The new hydraulic system shall be equipped with minimum 40-micron filter.

8. The hydraulic and mechanical system design shall specify every device and component required to make a fully operational system. A Bill of Material shall be included with sub-supplier name and component model number.

a. Component sizing calculations to establish minimum and maximum flow and pressure shall be provided.

b. Piping and fittings shall be welded stainless steel, schedule 40 minimum.

c. Tubing shall be seamless stainless steel with stainless steel fittings.

d. All instruments shall be equipped with isolation valves.

e. Pressure gages shall be equipped with snubbers.

9. The Contractor shall furnish and install device tags for all valves and devices. The Government will provide valve and device numbers after the 30% review.

10. The hydraulic and mechanical system design shall include details of all lines, valves, instrumentation, components and mounting.

11. The new hydraulic piping shall connect to the existing hydraulic pipes as shown on drawing LD-705095 – Pump Unit Isometric and Valve Cover Details.

Interconnection piping shall match the fitting style of the existing lines. The Contractor shall obtain field measurements of the existing lines such that the new connections fit correctly and shall be responsible for all costs associated with the site visit.

12. The hydraulic and mechanical system design of the supply lines shall ensure there is sufficient pressure and flow to allow proper operation of the rotary hydraulic motor, Rotary Seal Clamps, Wedge Lock Cylinders, and Traverse Cylinders. The A/B port line connections shall incorporate Stauff or equal pressure/sample test points within the new enclosure. A pressure gauge kit, Stauff #SMB or equal shall be supplied with the hydraulic system.

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13. For welded pipe, the following NDE requirements shall apply:

a. 100% visual inspection and 100% radiographic inspection of welds.

b. “Tie-in” welds shall additionally receive root pass MT or PT and final weld surface MT or PT.

14. For threaded pipe and tube joints, 100% visual inspection is required.

15. All NDE, other than visual inspections, shall be performed by inspectors certified to the American Society for Nondestructive Testing (ASNT) Level II or Level III requirements.

IX. Hydraulic and Mechanical System Quality Assurance Requirements

1. The completed hydraulic system shall be tested by the manufacturer at a hydrostatic pressure not less than 1.5 x design pressure. The test plan shall be submitted 20 days prior to the test and shall be approved by the Government.

2. The hydraulic system shall be factory flushed prior to shipment.

3. A combined, integrated test of the control system and hydraulic unit shall be conducted at the Contractor’s site. The test shall be conducted after Government approval of the pressure test and flushing of the hydraulic system. The Contractor shall provide new oil for the integrated test, mock up circuits for the door wedges, clamp rotatory motors, peripheral door drive hydraulic motor, and the traverse operation demonstrating position control. The system shall not be shipped until the Government approves the test results.

4. Factory checks shall be Government witnessed. A ten-day advance notification of each test is required.

5. Factory Test Reports (4 copies).

X. Hydraulic and Mechanical System Documentation Requirements

1. Component literature and specifications.

2. Design drawings with as-built updates, Process and Instrumentation Diagram

(P&ID), mechanical layouts, assembly, and parts lists. Drawings shall be in .pdf format. The P&ID drawing shall include the following as a minimum:

a. Each major piece of equipment and component (valves, transmitters, etc.)

b. Valve numbers and fail-safe state (NC=Normally Closed, NO=Normally

Open)

i. The Government will provide the numbers for the valve and devices to be put on the P&ID.

c. Pipe size and pipe size changes, drains, vents, etc.

d. Component sizing calculations to establish minimum and maximum flow and pressure shall be provided.

3. Installation instructions.

4. Certifications of calibrated devices and the frequency of the required calibrations.

5. Operating and Maintenance instructions.

6. Recommended Spare Parts List, including quantities and pricing.

XI. Design Reviews

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1. The Contractor shall host two informal, one-day review meeting(s) at the 30% and 100% design levels at the Contractor’s facility; at a date and time mutually agreeable to all parties. The purpose of these meetings are to review the design and progress of the Contract, to resolve open issues regarding the configuration, interfaces, and performance requirements of the new hydraulic and control system.

a. The 30% review documentation shall include drawings, P&ID, piping isometric drawings, HMI screen layouts, component specifications and description of operation.

b. The 100% review documentation shall include an updated and complete set of drawings, screen layouts, component specifications from the 30% design review meeting. The review shall include a proposed test and checkout plan for the hydraulic and control system to be reviewed by the Government and executed by the Contractor.

c. These meetings may be extended to allow the Government to examine manufacturing areas and quality control activities, or assembly, shop work, and testing associated with this contract.

2. Additional meetings may be scheduled as needed to resolve issues, discuss technical details, or provide additional information to the Contractor.

XII. Government Furnished Drawings and Documentation

LD-655897 – 20Ft. Door – Hydraulic System Electrical Schematic LD-655898 – 20Ft. Door – Electrical Wiring & Interconnection LD-702378 – Dynamics Research Lab – Centrifuge Housing & Vacuum Equipment –

Service Door Bottom Rail Field - Wedges LD-702379 – Dynamics Research Lab – Centrifuge Housing & Vacuum Equipment –

Service Door Bottom Rail Field – Door Cylinders LD-702380 – Dynamics Research Lab – Centrifuge Housing & Vacuum Equipment –

Service Door Bottom Rail Field – Door Cylinder & Wheel Rail LD-702381 – Dynamics Research Lab – Centrifuge Housing & Vacuum Equipment –

Service Door Bottom Rail Field – Drive LD-704824 – Modified System Schematic of Hydraulic Power Unit – Mech. Schematic LD-705093 – Modification of Special Hydraulic Power Unit Located at Bldg. 1293 –

Pump Unit Details LD-705094 – Equipment Arrangement and Routing LD-705095 – Pump Unit Isometric and Valve Cover Details