Air Compressor Test Bench Specification.docx
DOCX document 58 KB Posted
- Attached to
- RFP:44-25 Air compressor test bench
- Solicitation number
- BD-24-1206-MBTA-MBTA-115528
- Issued by
- Middlesex County, Massachusetts
About this file
This document is a Technical Specification (EE&QA-973) issued by the Massachusetts Bay Transportation Authority (MBTA) for Air Compressor Bench Test Equipment. The MBTA seeks to purchase up to two bench test systems designed to evaluate air compressors after overhaul at their Everett Main Repair Facility, specifically for testing Wabtec and Knorr air compressors used in their subway fleet vehicles. The test equipment must perform comprehensive testing including operating pressures, air outlet temperature, micro-switch functionality, airflow rate, pneumatic functionality, dew point, safety valve performance, and motor electrical measurements. The equipment must automatically generate electronic test reports indicating pass/fail status, with capabilities to export results in multiple formats and provide trend analysis.
The technical specification outlines detailed requirements for the bench test equipment, including safety features, software functionality, physical specifications, and protection mechanisms. The MBTA will require the successful bidder to provide installation, training, documentation, and a 24-month warranty covering all expenses and parts. The bid proposal must include comprehensive details about test parameters, power requirements, software operation, air compressor interface methods, and protective features. The specification indicates that the MBTA will be responsible for preparing the installation area and electrical power needs, while the bidder will be responsible for equipment setup and operational readiness. Technical support and potential post-warranty service contract options are also outlined in the document.
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Text version
MASSACHUSETTS
BAY
TRANSPORTATION
AUTHORITY
TECHNICAL SPECIFICATION
EE&QA-973
Specification for Air Compressor Bench Test Equipment
ISSUED: 3/1/2024
REVISIONS: 1.0
SUBWAY OPERATIONS DIRECTORATE
EQUIPMENT ENGINEERING AND QUALITY ASSURANCE
TABLE OF CONTENTS
SECTION TITLE PAGE
| - | Table of Contents | 2 | |||
| 1.0 | Scope ………………………………………………… | 3 | |||
| 2.0 | General Requirements ……………………………….. | 3 | |||
| 3.0 | Bench Test Equipment Requirements …… …………. | 4 | |||
| 4.0 | Bench Test Equipment Physical Requirements………. | 5 | |||
| 5.0 | Bench Test Equipment Protection Requirements ……. | 6 | |||
| 6.0 | Software ……………….. ……………………………. | 7 | |||
| 7.0 | MBTA Air Compressor Technical Data ……………... | 8 | |||
| 8.0 | Installation and Acceptance Testing …………………. | 11 | |||
| 9.0 | Documentation and Training ………………………… | 11 | |||
| 10.0 | Maintainability and Technical Support ……………… | 12 | |||
| 11.0 | Warranty ……………………………………………. | 12 | |||
| 12.0 | Bid Proposal …………………………………………. | 13 | |||
| 12.0 | Delivery and Payment Schedule …………………….. | 14 | |||
| 13.0 | Approvals ……………………………………………. | 15 |
1.0 SCOPE
The Massachusetts Bay Transportation Authority (MBTA) is in the process of developing plans to purchase up to two Air Compressor Bench Test Equipment.
The Air Compressor Bench Test Equipment is expected to be able to perform testing of the MBTA Fleet of Vehicle’s Air Compressors. This testing is to take place after the Air Compressors have been overhauled at the Everett Main Repair Facility.
Currently the MBTA Fleets consist of Wabtec and Knorr Air Compressors.
2.0 GENERAL REQUIREMENTS
The Bidder is expected to provide an electronics console for all equipment required for testing the Air Compressors, including Test Stands.
The Bidder is expected to provide the Power requirements and the footprint for the installation of the equipment.
The Bidder is expected to perform the installation of their test equipment and test stands.
The Bidder is expected to perform initial testing and training on site at the MBTA’s Everett Main Repair facility (80 Broadway, Everett Ma. 02149)
3.0 BENCH TEST EQUIPMENT REQUIREMENTS
The Bench Test Equipment is expected to perform at a minimum the following tests on the Air Compressors to validate the performance of the air compressor after overhaul:
· Operating pressures
· Air outlet temperature
· Micro-switches functionality
· Airflow rate
· Pneumatic functionality
· Dew Point
· Safety pressure valves
· Air Compressor Motor Currents and Voltages supplied The Bench Test Equipment is expected to record these values and store them electronically and provide a report on the Air Compressor.
The Bench Test Equipment Test Report shall indicate if an air compressor passed or failed and what test failed.
The Bench Test Equipment shall have the capability of exporting the test report in a word or pdf format for storage and the capability of exporting test reports for each air compressor in an excel format for trend analysis.
The Bench Test Equipment shall control the input voltage to the air compressor and have the ability to stop a test on over voltage/current situations.
The Bench Test Equipment shall automatically perform all tests and have an option to perform manual tests The Bench Test Equipment shall prompt the Tester on necessary steps to perform the tests such as the necessary connections to the motor The Bench Test Equipment shall have the ability to select different Fleet Air Compressors and automatically set up the necessary testing parameters The Bench Test Equipment is expected to be able to record the Air Compressor Name Plate as part of the Test Record.
The Bench Test Equipment shall record the values for each test in Air Compressor test sequence.
The Bench Test Equipment Interface Box to the Air Compressor shall clearly define the phases of the input voltage The Bench Test Equipment Bidder shall work with the MBTA in developing the cable interface from their Interface Box to the Air Compressor.
The Bench Test Equipment shall have the ability to monitor air compressor temperature and allow the air compressor to warm up before starting the test sequence.
The Operator’s console for running the test shall be separated from the Air Compressor test area.
The Operator’s console shall have emergency shut offs to stop all testing.
4.0 BENCH TEST EQUIPMENT PHYSICAL REQUIREMENTS
The Operator’s Console and all Electronics shall be encased in a steel or similar material cabinet providing protection to the Operator.
The Air Compressor test area shall be a segregated from the Bench Test Console.
The Bidder shall supply a safety system, such as fencing, to stop unauthorized access to the test area during testing.
The Bidder safety system shall protect the Bench Test Equipment Operator from objects projected during the Air Compressor Unit test.
The safety system shall supply an interlocking door for access to the test area.
The interlocking door which will disable power to the air compressor under test if unauthorized access occurs.
The Bench Test Equipment shall come with an Air Compressor Test Fixture for mounting all MBTA Air Compressors.
The Air Compressor Test Fixture shall support the Air Compressor as to reduce the vibrations to the floor.
The Air Compressor Test Fixture shall be secured to the work floor without the need of extensive modifications to the work floor.
The Air Compressor Test Fixture shall allow for the mounting of external sensors.
The Air Compressor Test Fixture shall include the interface structure for each type of air compressor specified in the Section 7.
5.0 BENCH TEST EQUIPMENT PROTECTION REQUIREMENTS
The Bench Test Equipment requires a main circuit breaker with current protection.
The Air Compressor Motors shall be protected through the Bench Test Equipment (i.e. Inverter) and not through a fuse The Bench Test Equipment shall provide current limitations to protect its internal electronics Warning lights on the Bench Test for when tests are running, bench on with no test running and warning light for Bench Test Equipment errors Emergency shutdown button on the console to immediately power down the Bench Test Equipment Activating the Emergency Shutdown feature should safely stop the Air Compressor if tests are being run.
6.0 SOFTWARE
The Bench Test Equipment Software shall be controlled through a keyboard, mouse, touch screen or external pushbuttons A keyboard shall be provided to enter Air Compressor information from the name plate.
The language of the software shall be in English.
The software shall store all test results in word format or pdf and also in excel format The software shall allow for the printing of test reports The software shall allow for the exporting of test reports.
The test software shall have two modes of test, automatic and manual The software shall prompt the Operator when Operator action is required during testing.
The System shall have different permission levels, Operator and Engineer, allowing the engineer to modify test pass fail levels.
The System shall provide a method for the MBTA to upload software updates and recover from system crashes.
If remote access is available, the Bidder shall work with the MBTA Information Technology Department in identifying access needs.
7.0 MBTA AIR COMPRESSOR TECHNICAL DATA
7.1 Blue Line #5 Car Wabtec D-4-AS Air Compressor
| Characteristic |
| Specification |
air compressor data
| Motor Operating Voltage |
| 230 VAC 3-Phase |
| Current Consumption |
| 40A Max. |
| Number of Revolutions |
| 1750 RPM |
| Control/Heater Circuit Voltage Range |
| 37.5 VDC nominal (24 – 44 VDC) |
| Power Consumption of Low Voltage Control |
| < 570 Watts |
| Air Supply Capacity |
| 24.5 SCFM at 150 PSIG |
| Max. Operating Pressure |
| 150 PSIG |
| Spring Setting |
| 95 PSIG |
| Nominal weight (without oil in crankcase) |
| 800 LBS |
E-1A Twin Tower Air Dryer with Panel
| Maximum Input Pressure |
| 160 PSIG |
| Operating Temperature: |
| -40 F to 140 F |
| Input Voltage |
| 37.5 VDC |
7.2 Orange Line #14 and Red Line #4 Wabtec D-4-AS Air Compressor
| Characteristic |
| Specification |
air compressor data
| Motor Characteristics |
| 230 VAC, 3-Phase, 60 HZ, Class F Insulation |
| Motor Speed |
| 1725 RPM MIN. |
| Service Factor |
| 1.15 |
| Rated Power |
| 15 HP (11.2 KW) |
| Full Load Running Current |
| 36.3 AMPS RMS |
| Locked Rotor Current |
| 224 AMP RMS |
| Input Voltage Power |
| 230 +/- 15 % VAC, 3 - PHASE |
| Frequency |
| 60 HZ +/- 5 HZ |
| Input Voltage (Control) |
| 37 VDC Nominal (24 – 44 VDC Range) |
| Input Voltage (Heaters) |
| 115 VAC, 60 HZ |
| Control Pressure Switch Settings |
| Cut-In: 128 – 133 PSIG |
Cut-Out: 148 – 153 PSAG
| High Voltage Power Consumption |
| 230 VAC/ 60 HZ = 9.45 KW |
| Low Voltage Power Consumption |
| Controls (24 – 44 VDC) = 33 Watts |
Dryer Heater (115 VAC) = 75 Watts Nominal Drain Valve Heater (115 VAC) = 75 Watts Nominal
| Air Delivery (After Dryer) |
| 24.0 SCFM @ 145 PSIG |
| Sound Level |
| 72 dBA Max @ 15 FT |
| Over Pressure Protection |
| 70 PSIG Safety Valve |
165 PSIG Safety Valve 220 PSIG Safety Valve
| Nominal Weight (with Oil) |
| 741 LBS |
7.2
7.3 Green Line Type 9 and Type 10 Knorr V10-TAir Compressor
| Characteristic |
| Specification |
Mechanical motor data
| Model No. |
| V10-T |
| Rotation Speed |
| 1695 rpm +/-10% |
| Working Pressure |
| 145 psi (10 bar) |
| Shaft Power |
| 0.97 kW +/- 7% |
| Operating Temperature Range |
| -40 F to 122 F (-40 C to 50 C) |
| Motor Type |
| KB/31A-80B |
| Nominal Voltage |
| 230 VAC, 60 HZ |
| Operating Current |
| 3.6 A +20% / -10% |
| Power Factor |
| 0.76 |
| Apparent Power |
| 1.43 kVA +20% / -10% |
| Starting Current at 20 C |
| 18 A +20% |
| Rush Current (10 C Peak) |
| 33.1 A +20% |
| Cooling Air Flow Rate |
| 0.16 m^3/s |
| Duty Cycle |
| S3 (60%) |
| Allowed Starts |
| 30 per hour |
| Operating Weight |
| 77.16 LB (35 KG) |
8.0 INSTALLATION AND ACCEPTANCE TESTING
The Bidder shall supply to the MBTA all the necessary information for the Bench Test Equipment installation.
The Bidder shall supply to the MBTA the electrical power requirements for the Bench Test Equipment The Bidder shall supply to the MBTA all electrical connection requirements to for the Bench Test Equipment The Bidder shall supply to the MBTA all the electrical connections for the interface for the different MBTA Air Compressors to the Bench Test Equipment The above information shall be supplied to the MBTA at least 3 months prior to the installation of the Bench Test Equipment The MBTA will be responsible for preparing the area and electrical power needs. As specified by the Bidder, prior to the installation of the Bench Test Equipment.
The Bidder will be responsible for setting up the Bench Test Equipment and preparing it for operation.
Acceptance testing of the Bench Test Equipment shall be completed upon the successful testing of each Air Compressor type specified in Section 7.
9.0 DOCUMENTATION AND TRAINING
The Bidder shall supply to the MBTA a set of manuals for operating the Bench Test Equipment The Bidder shall provide documentation for maintaining and repairing the Bench Test Equipment including the calibration schedule for keeping the Bench Test Equipment in proper working order.
The Bidder shall provide training to the Staff on the operation of the Bench Test Equipment.
The Bidder shall provide training to the MBTA Staff on maintaining and keeping the Bench Test Equipment in proper working order.
10.0 MAINTAINABILITY AND TECHNICAL SUPPORT
The Bidder shall provide to the MBTA a list of recommended spare parts and pricing to keep the Bench Test Equipment operational.
The Bidder shall supply provide to the MBTA documentation and instructions on making basic repairs to the Bench Test Equipment The Bidder shall provide Technical Support for the Bench Test Equipment for making repairs to the equipment once the warranty period has expired.
The Bidder shall maintain the software and provide to the MBTA software updates, excluding changes requested by the MBTA.
11.0 WARRANTY
The Bidder shall supply a 24 Month warranty from the installation of the Bench Test Equipment
The Warranty shall include all expenses, labor and spare parts to make the make repairs to the equipment
The Bidder shall supply to the MBTA a proposal for a Technical Support Contract, at the MBTAs option, upon the expiration of the Warranty period.
12.0 BID PROPOSAL
The Bidder shall submit a detailed proposal on their test equipment
The Bidder shall include the tests defined in section 3.0 and additional tests the Bidder can conduct
The bid proposal shall include information on the test parameters that are recorded and how they are saved and exported.
The bid proposal shall include power requirements and the foot print size of the Bench Test Equipment
The bid proposal shall include details on the operating software and how the Operator interacts with the software.
The bid proposal shall include details on how the interface to the Air Compressors is made
The bid proposal shall include details on how the Bench Test Equipment will protect the Air Compressor from damage from over currents
The bid proposal shall include a list of the documentation the Bidder will supply
The bid proposal shall include a list of recommend spare parts and pricing at the time of the proposal
The bid proposal shall include details of the Bidder’s proposed Warranty image1.png image2.png
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