Attachment 2 SOW Wind Tunnel and Nozzle Improvement Project.pdf

June 2, 2020

SCOPE OF WORK

LOW SPEED WIND TUNNEL and NOZZLE IMPROVEMENT PROJECT

1.0 CONTRACT PROJECT:

a. Project Number: _________________

b. Project Title: Low Speed Wind Tunnel and Nozzle Improvement Project at Southern

Plains Agricultural Research Center, College Station, Texas.

2.0 PROJECT CONTACT PERSONS:

a. CONTRACTING OFFICER (CO):

To be assigned

b. RESEARCH PROGRAM REPRESENTATIVES (RPR):

Dr. G. Wayne Ivie

USDA, ARS, PA, SPARC

Southern Plains Agricultural Research Center 2881 F&B Road College Station, Texas 77845 Phone: (979) 260-9372 FAX: (979) 260-9377

c. Location Site Monitor

Mark Buxkemper

USDA, ARS, PA, SPARC

Southern Plains Agricultural Research Center 2881 F&B Road

Phone: (979) 260-9262 FAX: (979) 260-9377

d. Research Leader, Aerial Application Technology Research Unit Brad Fritz

USDA, ARS, PA, SPARC

Southern Plains Agricultural Research Center 3031 F&B Road

Phone: (979) 260-9176

e. Personal Property Management Specialist

Amber Smith

USDA, ARS, PA

Plains Area Office 2150 Centre Ave. Bldg D, Suite 300 Fort Collins, CO 80526 Phone: (970) 492-7031

f. Safety Officer Dwayne Cordray Plains Area Office 1001 Hollemann East

Phone: 979) 260-9480

3.0 SCOPE OF SERVICES:

The Contractor shall provide all professional services necessary for the accomplishment of the contract project and such required services shall be in accordance with requirements as described herein.

a. The Contractor shall provide Services for the following tasks marked by an “X”:

[X] Provide a technical and cost proposal for the design and construction uniform airflow atomization test section with integrated airspeed measurement sensors and spray nozzle traversing mechanism for low-speed wind tunnel to include an air scrubber system for a low-speed wind tunnel.

[X] Provide a technical and cost proposal for the design and construction of a uniform airflow outlet nozzle with integrated airspeed measurement sensors and spray boom traversing mechanism for high-speed wind tunnel.

4.0 PROJECT REQUIREMENTS:

a. The Contractor will provide technical proposal for the both items: Low-speed Wind Tunnel and the Nozzle Improvement for the High-speed Wind Tunnel.

b. The Contractor will provide past performance for similar projects.

c. Low-Speed Wind Tunnel: Place and anchor the Government provided low-speed wind tunnel and perform operational check. To include design and installation of nozzle duct outlet test area and atomization test section, traversing mechanisms for spray nozzle and laser systems, an air scrubber for the low-speed wind tunnel. The

Contractor will design and install a wind tunnel inlet duct to provide best possible conditions. The Contractor will design and install the wind tunnel control and monitoring system that provides for user control system to set fan speed, control spray nozzle traversal and liquid spray activation and monitoring and recording of air and liquid flow parameter data to integrated Data Acquisition System. The Contractor will perform flow checks at outlet of the atomization test section.

d. Nozzle Improvement High-Speed Tunnel. The Contractor will design, construct, and install an outlet nozzle with uniform airflow and a specified test area. The Contractor will install sensors to measure and monitor air velocity and temperature at the outlet, integrating sensor outputs into the high-speed wind tunnel’s data acquisition system.

The Contractor will evaluate turbulence intensity and flow uniformity the outlet area and develop report of performance. The Contractor will design, construct, and install a spray boom traversing mechanism with speed and position control that can be monitored and controlled through interface with LabView software.

e. The project is located at the Southern Plains Agricultural Research Center at the Coulter Air Field in Bryan, Texas.

f. The Contractor’s proposal shall adhere to the criteria stated within these project requirements, drawings, and specifications. All construction shall comply with applicable federal, state, and local code requirements as well as current industry standards, (ie., UBC, UPC, NFPA, UL, ASTM, ACI, NEC, NEMA, etc.) and health and safety codes, in effect at the time of contract award.

g. The Contractor will provide a safety plan for the project.

h. Davis Bacon Wage Rates apply to all construction contracts in excess of $2,000.

Employee payroll logs for the project will be required to verify wage rates are being adhered to.

i. Obtaining and the cost of these bonds is the responsibility of the Contractor.

j. Contractor is required to be registered in the Government’s System Award

Management (SAM) for the bid to be accepted.

k. The Contractor will be required to register in Government’s Invoice Payment

Platform (IPP) and submit invoice electronically for payment.

l. The Contractor is responsible for visiting the site prior to submitting a bid to observe existing conditions. No compensation will be provided for conditions that would be visible during an on-site visit for persons experienced performing this type of work.

m. The Contractor will use biobased products meeting the minimum standard for content as defined in ASTM D6866 (Biobased Content Testing). The Contractor must comply with Section 9002 of the Farm Security and Rural Investment Act of 2002 (FSRIA), Executive Order (EO) 13423, “Strengthening Federal Environmental, Energy, and Transportation Management,” and the Federal Acquisition Regulation to provide biobased products. The Contractor shall utilize products and material made from biobased materials (e.g., insulating foam, composite panels, and concrete and asphalt release fluids) to the maximum extent possible without jeopardizing the intended end use or detracting from the overall quality delivered to the end user. All supplies and materials shall be of a type and quality that conform to applicable Federal specifications and standards. All supplies and materials to be used in the performance of work described herein are subject to the approval of the Location Site Manager (LSM).

4.1 Base bid: Project Details

1. Low-speed Wind tunnel requirements.

a. The Contractor will provide a turnkey project satisfying all Local and State requirements.

b. The Contractor will provide engineered drawings for review by the Government to ensure drawing satisfy the Government’s need. CAD drawings will be provided to the Government as well.

c. The Contractor will position and anchor the low-speed wind tunnel fan and power unit. The unit will be positioned to allow for all parts of the wind tunnel and air scrubber to be inside the building and allow for access around the system’s perimeter. The unit will be firmly mounted but anchored to minimize vibration created from operating the unit. The unit will be mounted to facilitate easy of use and minimize employees working in awkward positions.

d. The Contractor will connect electrical serve to the 10hp, 240v motor for the Government provided variable frequency drive that is already mounted at the facility. The Contractor is responsible for installing all conduit, electrical wiring, and associated material to satisfy the electrical code. The Contractor will provide all material and labor for all 120v components

e. The building physical parameters include maximum door size in the building of 12 ft high and 12 ft wide. The complete wind tunnel and air scrubber setup will be contained inside the building.

f. The wind tunnel setup will include the wind tunnel inlet, flow conditioning sections, nozzle duct and exit test area with integrated spray nozzle traversal assembly, atomization test section to control conditions around the exit jet with an integrated traversing mechanism to locate the lasers at a desired height and distance from spray nozzle and, a scrubber to collect spray for disposal.

g. All components of the system are expected to be exposed to several levels of moisture. All materials will be rust resistance, have rust preventive coatings, and/or be painted.

h. The facility parameters include a 4 ft. x 4 ft. jet, centered 4 ft. above ground and with a maximum speed of 20 mph. The scrubber is required to collect spray particles for disposal and control mist inside the test area. The test volume includes areas 0 to 6 ft from the exit nozzle and 2 ft in height. The support equipment includes a traversing mechanism that fits inside an 8 x 8 ft area and moves through the test volume, the movement is not required to be automated.

i. Design: The design includes four main components.

1. Fan Inlet, Outlet Expansion and Flow Conditioning Sections. The provided fan is an axial fan 3 feet in diameter powered by a 10 hp motor.

An inlet section that provides for uniform air intake while providing screening or other protective measures to prevent debris or personnel from accessing the fan entry port. The expansion section will provide for transition from fan outlet area to the 4 ft x 4 ft flow conditioning and test section duct outlet. The flow conditioning section will be positioned at the fan exit and will be designed to provide adequate geometry and length to allow development of uniform air flow at the outlet leading into the atomization test section. Additionally, flow conditioning screens position near the fan inlet and/or outlet will be provided to enhance air flow uniformity. Attachment points to fan housing are standard bolt holes and arrangement and layout will need to be confirmed onsite.

2. Nozzle Duct and Exit Test Area and Integrated Spray Nozzle Traversal Assembly. The low-speed nozzle outlet test section will have a minimal functional test area of 4 ft x 4 ft. The total nozzle structure shall be constructed such that the plane of the nozzle exit area is 6-12 inches within the atomization test area. The air velocity at the outlet will span the range of 1 to 20 mph, with the top end speed by the output of the current installed fan and motor. The geometry of the nozzle should be such that edge effect are minimized. Automated sensors will be mounted within the nozzle outlet test area to provide for air velocity and temperature measurement, monitoring, and recording. The sensors should be pitot tubes of sufficient number and placement to provide for representative measure of air velocity at the exit test are. Electronic gauges, which convert the pitot analog data to electronic data shall be integrated into the high-speed tunnels Data Acquisition System and Electronic Control Station implemented in LabView. The nozzle outlet section shall use lightweight, structural materials where possible that are coated/painted as needed to prevent rust and corrosion and minimize the weight of the entire structure. Turbulence intensity at the nozzle outlet face should not exceed 5%, however this metric can be adjusted with valid reason and prior approval from the Government. The integrate spray nozzle traversal assembly should provide for a minimal range of traverse of approximately 4 ft, allowing for movement of the fluid line and nozzle assembly across the entire height of the nozzle exit test area.

The traversal assembly shall be attached securely to the face of the nozzle exit test area and be constructed such that there is minimal structural interference with the exiting air jet. The traversal assembly shall maintain rigidity and parallelism of the nozzle during stationary and traversing operations. Continuous traversal speed should allow for a range from 0.1 to 2 inches per second.

3. Atomization Test Section and Integrated Laser Traversing Mechanism.

The atomization test section is located immediately after the 4 ft x 4 ft nozzle duct exit area and should have a minimum working area of 8 ft square by 8 - 10 ft long, with the length established to provide sufficient distance for the laser traverse and scrubber components. The section will include a suspended linear bearing mounted rail system that is attached to the walls of the test section structure and allow for positioning the laser system from 1 to 6 ft from spray nozzle outlet and across a height range of 2 ft corresponding to the center 2 ft height of the nozzle duct area. The tunnel exit area is inserted into this section a minimum of 1 ft.

The materials for these sections will consists of structural steel for the frame, with standard sheet metal siding in the inside. The traversing mechanism will be constructed of structural steel with stainless steel parts for the motion rollers and position hardware. The bottom will be fiberglass grating supported by painted structural steel.

Provided fan

4. Scrubber for Spray Material Collection. The scrubber has a screen in front (4 inches inside) and an e-Hive Louver. The louver is 5.25 in deep and will cover the entire inside area. The louver is placed at a distance from the spray nozzle exit that is sufficient to allow for diffusion of air jet from duct exit and allow for efficient collection of spray particles.

The base of the section is a collection basin and should include a suction pump to remove the fluids for disposal. A sufficient number of 24 in fans shall be added to the back to provide enough suction such that air and suspended spray particles are forced to go through the scrubber louver face. The scrubber materials will be painted steel sheet metal, all structural steel will have corrosion resistance coatings. The collection basin will be made of stainless steel for corrosion resistance.

5. The E-Hive design will be utilized. It is limited to working at low face velocities which may require inclusion of a flow diffuser. The pressure drop is the critical design parameter, not flow quality.

j. Typical setup is shown below:

Full assembly

Typical wind tunnel chamber section

Previous duct area outlet with spray nozzle traverse and laser mount

E-Hive layout

Depth: 5.25” Width: 24” (nominal) Standard Lengths: 36 – 144”

Below is the pressure drop (in. wg.) / Face Velocity (fpm) Chart:

FACE VELOCITY

(fpm)

PRESSURE DROP

(in. wg.)

200 0.03 300 0.04 400 0.05 500 0.07 600 0.10 700 0.14 800 0.20 *Not to exceed 800 fpm

E-Hive specs.

k. The Contractor may utilize other construction material provided they provide equal or better structural integrity and corrosion resistance properties.

2. Nozzle Improvement for High-speed Wind Tunnel

a. The Contractor will provide a turnkey project satisfying all Local and State requirements.

b. The Contractor will provide engineered drawings for review by the Government to ensure drawing satisfy the Government’s need. CAD drawings will be provided to the Government after final designs are approved and construction is completed.

c. The Contractor will remove the current tunnel outlet nozzle and install newly designed and constructed outlet nozzle test section. The new outlet nozzle is expected to fit within the confines of the current test area such that spray discharge is within the capture region of the existing scrubber.

d. The Contractor will connect the electronic controls and air velocity monitoring sensors to existing LabView control software and data acquisition systems. The Contractor is responsible for installing all conduit, electrical wiring, and associated material to satisfy the electrical code. The Contractor will provide all material and labor for all 120v components.

e. The outlet nozzle test area will also include an electronically controlled traverse mechanism that provides for secured support and vertical movement of the spray boom and liquid dispersal system. This mechanism shall allow for precise control of the speed of the vertical traverse as well as for precision placement of the boom at any point across the height.

f. All components of the system are expected to be exposed to several levels of moisture. All materials will be rust resistant, have rust preventive coatings, and/or be painted.

g. Design: The design includes three main components:

1. Nozzle Duct and Exit Test Area. The high-speed nozzle outlet test section will have a functional test area of 9 x 19 in (1.19 sq.ft.). The total nozzle structure shall be constructed such that the plane of the nozzle exit area is 5’ from the fan entry duct. The air velocity at the outlet will span the range of 50 to 180 mph, with the top end speed limited to 180 mph by the output of the current installed fan. The geometry of the nozzle should be such that edge effect are minimized.

Automated sensors will be mounted within the nozzle outlet test area to provide for representative air velocity and temperature measurement, monitoring, and recording. The sensors should be pitot tube of sufficient number and placement to provide for representative measure of air velocity at the exit test are. Electronic gauges, which convert the pitot analog data to electronic data shall be integrated into the high-speed tunnels Data Acquisition System and Electronic Control Station implemented in LabView. The nozzle outlet section shall use lightweight, structural materials (i.e. aluminum) where possible that are coated/painted as needed to prevent rust and corrosion and minimize the weight of the entire structure. Turbulence intensity at the nozzle outlet face should not exceed 5%, however this metric can be adjusted with valid reason and prior approval from the Government.

2. Flow Conditioning Section. A flow conditioning section with a minimal length of 20 inches shall be position inline, and upstream of the duct and exit test area. The conditioning section should allow for the placement and adjustment of up to five screens to adjust flow uniformity and turbulence intensity. The Flow Condition Section will be mounted immediately to the fan exit using existing bolt holes. All sections shall be installed with gasket material at joints to minimize air flow leakage.

The dimensions and bolt hole patterns are shown in Figure 1. These should be confirmed onsite prior to construction.

Figure 1. Fan Exit Dimensions and Bolt Hole Placement.

3. Boom Traversal Assembly. The traversal assembly should provide for a minimal range of traverse of approximately 40 inches, allowing for movement of the boom and nozzle assembly across the entire height of the nozzle exit test area as well as 10 inches above and below the same area. The traversal assembly shall provide mounting brackets allowing for secure attachment of the existing spray boom assembly. The traversal assembly shall be attached securely to the face of the nozzle exit test area and be constructed such that there is minimal structural interference with the exiting air jet. The traversal assembly shall maintain rigidity and parallelism of the boom during stationary and traversing operations. Continuous traversal speed should allow for a range from 0.1 to 2 inches per second.

h. The Contractor may utilize other construction materials provided they provide equal or better structural integrity and corrosion resistance properties.

i. Flow uniformity analysis shall be completed after construction is final and a report of the results provide to the Government.

j. Typical nozzle assembly is shown in Figure below.

Figure. Typical Nozzle Assembly.

5.0 GENERAL REQUIREMENTS:

5.1 Permits: Where governing regulations and imposed codes and standards require notices, permits, licenses, inspections, tests, and similar items or actions in order to lawfully proceed with the required work, the Contractor shall obtain items and take those actions in accordance with the regulations of the governing authority. The costs of such permits, licenses, inspections, etc., are the obligation of the Contractor.

5.2 Installation: It shall be the responsibility of the Contractor to complete work in accordance with the manufacturer’s recommendations and Industry Standards.

Additional procedures and materials may be required than is indicated herein. If any item specified herein conflicts with the applicable codes and recommendations, the Contractor shall bring it to the attention of the Contracting Officer for immediate resolution.

5.3 Submittals: Provide manufacturer’s descriptive literature/shop drawings for all materials to the LSM for review. The descriptive literature shall be annotated/highlighted to show its conformance with contract requirements. Submittals are required for all building materials and equipment and will be stamped by the general contractor prior to submission to the Government. Any work\material completed before approval of a submittal is at the contractor’s own risk.

5.4 Quality Control: The work performed under this contract shall be subject to continuous audit by the LSM. Quality control is the exclusive responsibility of the Contractor with all required manufacturer’s inspection requirements being performed.

5.5 Protection of Work and Property/Safety Requirements:

a. The Contractor shall protect the work, the site, and all existing property and structures within the limits of the construction activities or that may be affected thereby until acceptance of the work. Any damage to property shall be repaired at the Contractor’s expense, to pre-damaged condition to the satisfaction of the LSM.

b. Safety and health matters, as they relate to the work, are the exclusive responsibility of the Contractor. The Contractor shall furnish, erect, and maintain barricades, warning lights, signs, guards, or take other precautions as may be required by law or local authorities for protection and security.

c. The Contractor will provide a safety plan for the project.

5.6 Temporary Facilities:

a. Temporary utilities (water and electricity) may be furnished to the Contractor by the Government, if so requested. The Contractor shall maintain and protect all such utilities during the course of construction and shall repair or replace any items damaged through its own negligence.

b. Should the Contractor require any power or utility shutdowns during construction, the Contractor shall obtain approval for such shutdown from the LSM three working days prior to the need.

5.7 Materials and Equipment:

a. The material and equipment to be furnished under these contract documents shall be the standard products of manufacturers regularly engaged in the production of such materials and equipment and shall be the manufacturer’s latest standard design.

b. All materials and equipment to be incorporated in the work shall be handled and stored by the manufacturer, fabricator, supplier and\or contractor before during and after shipment in a manner to prevent warping, twisting, breaking, chipping, rusting and any injury, theft or damage of any kind to the materials and equipment. All materials and equipment furnished by the Contractor shall be subject to inspection and approval by the LSM.

5.8 Cleanup: The construction site shall be kept clean and free of debris at all times. Upon completion of the project, and prior to final inspection, the Contractor shall remove from the premises all unused material, trash, and debris resulting from the work to the satisfaction of the LSM.

5.9 Warranty:

a. Provide one-year general contractor’s warranty for areas repaired.

b. Provide material’s warranty.

5.10 Final Payment/Contract Closeout: The following submittals are REQUIRED PRIOR

TO FINAL PAYMENT:

a. General and Subcontractors one (1) year warranty on work.

b. All warranties from manufacturers covering equipment\material.

c. O&M manuals for all equipment.

d. As-built drawings.

e. Release of liens.

f. Payroll sheets

g. Any other documents as required by the contract.

6.0 PROJECT SCHEDULE: The contract time for this project is 270 calendar days from the Contractor’s Notice to Proceed.