Updated FAA Statement of Work - CT-23-00030-A1.pdf

STATEMENT OF WORK

FOR

Environmental Simulation System for Electric Propulsion Unit Testing

Federal Aviation Administration

William J. Hughes Technical Center

Structures & Propulsions Branch (ANG-E28)

Atlantic City International Airport

1.0 Introduction/Background

The Federal Aviation Administration’s (FAA) Structures & Propulsion Branch (ANG-E28) has a requirement for an Environmental Simulation System (ESS) for Electrical Propulsion System Testing. The components under test will be exposed to a range of temperatures and altitudes to explore their effects on the power distribution systems.

The Structures & Propulsion Branch located at the William J. Hughes Technical Center (WJHTC) in

Atlantic City, New Jersey requires an Environmental Simulation System (ESS) that can perform environmental testing. This ESS is to perform testing on electric propulsion units and other electrical components for the use in aerospace applications. The FAA requires the capability to perform combined temperature and altitude (pressure) simulation. The ESS must have the capability to support testing of electrical components under simulated altitudes and temperatures of up to 100,000 ft. above sea level, a minimum temperature of -60℃, maximum temperature of +170℃, and humidity of 5% to 95% RH at site-level pressure.

2.0 Scope of Work

This Statement of Work outlines the requirements for an Environmental Simulation System for Electrical

Propulsion Unit Testing. The contractor must provide design, manufacturing, delivery, start-up/commissioning, documentation, and warranty of an Environmental Simulation System that can provide testing capabilities for altitude, humidity, and temperature in compliance with the minimum technical specifications listed in Section 3.0, Minimum Specifications.

2.1 Schedule Work

The contractor must coordinate the work schedule with the COR/TOR, Site access is secure and additional times should be allowed for personnel and equipment to pass through

FAA Security Operations Center (SOC).

2.2 Additional Requirements and Considerations

Contractor must have all materials necessary on-site before they start work.

3.0 MINIMUM SPECIFICATIONS

The contractor must provide all services, equipment, software, user guide and manuals, and commissioning, safety and startup training for an Environmental Simulation System (ESS) for electrical propulsion system testing.

3.1 Technical Requirements

3.1.1 Controlled Chamber Parameters

The ESS must simultaneously control the humidity, pressure, and altitude within the working area, as well as the temperature output by the ESS itself.

3.1.2 Temperature

The ESS operational temperature range must be -60 °C to +170°C with a control tolerance of ±3.0

°C as measured at the control sensor after stabilization.

3.1.3 Heating and Cooling

The chamber must be capable of performing the following temperature transitions with a UUT radiated heat output of an estimated 200W:

Maximum

Transition Time

Starting

Temperature

Ending

Temperature

Approximately 40

Minutes

85℃ -40℃

Approximately 40

Minutes

-40℃ 85℃

3.1.4 Altitude

The chamber must be capable to structurally support altitude ranging from site level to 100,000 feet. The chamber must have all ports, connections, sensors, software to support the mechanical system that would provide altitude capabilities. The altitude range must be site level to 100,000 feet in 40 minutes or less, 50,000 feet in 20 minutes or less (clean and dry chamber). The system must allow altitude profiles to be programmed as ramp steps for controlling climb and dive rates at any desired rate less than the maximum chamber capacity rating. The system must control altitude to within 500 feet of the set point of altitudes below 50,000 and within 1% of altitudes above

50,000 feet.

3.1.5 Combined Environment

ESS must provide both cycling and steady-state altitude and temperature capability between +80

°C and - 40 °C at any altitude between site level and 65,000 feet.

3.2 Environmental Chamber

The environmental chamber will be primarily used to provide specific environments for high-voltage wires and components as the units under test (UUT). The conditioned space portion of the chamber will be positioned in a manner as to surround the UUT and place it in the specific environment. The chamber may also be used for environmental testing of other electrical components. The environmental chamber will seat on a concrete floor.

3.2.1 Interface

Must provide:

1. Three (3) 6” or larger flange type penetrations for installation of user defined pass-through fittings.

3.2.2 Chamber Interior Dimensions

Minimum internal dimensions (working area) must be L 36” x W 36” x H 36”.

3.2.3 Available Space Dimensions

The available floor space for the chamber is 6ft x 6ft. A maximum height restriction of 10 feet exists in possible locations for the chamber.

3.2.4 Internal Liner

The chamber liner must be constructed of corrosion resistant materials and must ensure a hermetic seal preventing moisture migration into the chamber during low-temperature operation. All liner seams and corners must be designed to allow for thermal expansion during temperature cycling operation. All interior parts exposed to the chamber environments must be fabricated of corrosion-resistant materials. The floor must be sloped in a manner to direct all condensates toward a drain.

The chamber vessel insulation must be isolated from the working space.

3.2.5 Chamber Exterior

Panels covering serviceable components must be equipped with quick release fasteners for ease of access. Removable panels must be equipped with gasket seals to prevent ambient air and moisture migration into the insulation space during low temperature operation to prevent frost build-up and subsequent saturation of the insulation. The chamber exterior must be finished with a coating resistant to typical corrosive agents present in an industrial application per best commercial practices. The chamber must include an emergency stop on the control panel, a run time meter, a main power disconnect switch, a padlock to prevent chamber opening during operation and an adjustable control screen with the option to move both vertically and horizontally.

3.2.6 Conditioning System

Cooling, heating, and other related conditioning components must not protrude into the workspace other than the area specifically allocated for ESS and its supporting equipment. The air circulation system must assure proper air distribution and prevent air stratification throughout the chamber.

Condenser must be air cooled and must have the option to be located outside of the building on a concrete pad in which the ESS is contained as to not introduce excess heat into the working environment. The FAA will be responsible for creating the concrete pad on the exterior of the building. Alternatively, the condenser may be installed on the roof of the building in which the

ESS will be located. The FAA will be responsible for creating pass-through voids in existing walls or ceilings for electrical and plumbing routing. The Contractor will be responsible for installation and commissioning of the external condenser system, including rigging if the unit will be located on the roof of the building. The run length for the condenser interconnect will not exceed 40 feet.

3.2.7 Refrigeration System

The refrigeration system must use non-explosive and ozone-friendly refrigerants. Only ASME approved refrigerant vessels, over pressure limit cut-out switches, pressure relief valves must be used in the refrigerant systems (R-507 /R-508).

3.2.8 Electrical System

Motor starters, heater contactors, relays and other electrical components must be packaged enclosed in a power distribution panel and must include thermal and electrical overload protection.

The ESS must operate on no more than standard 480-volt 3-phase power. All electrical components and wiring must conform to National Electrical Manufacturers Association Standards.

All wiring must be clearly labeled and identified with wires and terminals labeled to correspond to the electrical schematic.

3.2.9 Instruments and Controls

The system must provide the following instruments and controls for both local and remote monitoring and control of the system including temperature, pressure, humidity, and user-defined data logging / text export of all control and indicator parameters. Instruments must be mounted and housed in a control panel enclosure allowing easy user access during chamber operation. The system must provide user–defined alarm notification and automatic system shutdown capabilities.

3.2.10 Electrical Overload Protection

The system must provide electrical and thermal overload protection for individual circuits and components.

3.2.11 Fan Openings

All fans with openings larger than three-eighths of an inch (3/8”) must have guard screens.

3.2.12 Over-Temperature Safety Limit

The system must have adjustable protection measures to protect the chamber from exceeding design limits.

3.2.13 Pressure Relief

The system must have a means for pressure relief to prevent excessive pressure build-up in the system.

3.2.14 Accessibility

All system hardware must be easily accessible for maintenance and removal.

4.0 Deliverables/Documentation

4.1 Operation Instruction Manual

Contractor must provide Operator instruction manuals. The manuals must include wiring and plumbing schematics.

4.2 Maintenance Instruction Manual

Contractor must provide Maintenance instruction manuals. The manuals must include wiring and plumbing schematics.

4.3 Spare Parts List

The contractor must provide a complete parts list for all systems and their sources.

4.4 Illustrated Parts Breakdown

The contractor must provide a complete illustrated parts breakdown for all systems.

4.5 Engineering Drawings

The contractor must provide a complete set of as-built engineering drawings including schematics of all systems. In addition, the contractor must provide a complete set of assembly drawings. All drawing packages must have sufficient detail to fully describe each system they represent.

4.6 Installation Drawings

Installation interconnection drawings must be furnished at the earliest possible time, but no later than 60 days after contract award to assist in facilities and installation planning. The contractor must provide procedures and system calibration requirements.

4.7 Calibration Manual

The contractor must provide calibration manuals.

4.8 Warranty

The Contractor must include a one (1) year warranty effective the day of Full Operational

Capability (FOC).

4.9 System Specification

The Contractor must include a system specification, which completely describes all system operational capabilities.

4.10 Engineering Drawings/Schematics

The Contractor must provide the following at FOC:

1. As-Built drawings including Bill of Materials (BOM)

2. Electrical wiring schematics including BOM

3. Mechanical drawings/schematics including BOM

4.11 Specifications

The Contractor must provide specifications for chamber and subsystems.

5.0 Delivery

5.1 Delivery and Installation

Delivery must be provided by the contractor. Utility hookups will be provided by the FAA.

Locations of these hookups will be finalized during the engineering phase of the project.

Contractor must make appropriate connections to the provided hookups.

5.2 Packaging

All shipments required for the ESS hardware must arrive in palletized packaging for ease of unloading at the location specified in Section 7.

5.3 Heavy Shipment

Any shipment exceeding four-thousand (4,000) pounds must be defined as a Heavy Shipment.

Each Heavy Shipment must adhere to the following:

1. Contractor must notify the Government not less than one (1) week in advance of shipment.

2. Contractor must schedule the specific date and time of delivery.

3. Contractor must notify the Government immediately upon any deviation to the delivery schedule.

6.0 Period of Performance

The period of performance will be 54 weeks from date of award.

7.0 Site Location

All work will be conducted at the FAA WJHTC, Building 214 Structures and Propulsions Branch, Atlantic

City International Airport, located in Egg Harbor Township, New Jersey. All personnel must be aware of and comply with COVID-19 safety protocols in place at the time the work is to be performed.

8.0 Access

Visiting contractor employees must comply with all Government escort rules and requirements. The contractor must be escorted by an FAA Technical Point of Contact (TPOC) (or a representative) and display all identification and visitor badges in plain view above the waist at all times, while performing services at the FAA, William J. Hughes Technical Center. All scheduling of services must be coordinated with the FAA TPOC.

9.0 Safety

To the greatest extent possible, all electrical work must be performed on de-energized material and equipment using appropriate lock-out/tag-out (LOTO) procedures, per FAA and OSHA requirements. All persons working on energized electrical equipment must wear appropriate personal protective equipment

(PPE) and follow safe electrical work practices of the latest version of the NFPA 70E.

10.0 Travel

The contractor will not be reimbursed for travel as a separate line item.