TRD_E1.pdf

Rev I

APPENDIX E1

MCKINLEY CLIMATIC LABORATORY (MCL)

1.0 PURPOSE. The purpose of the MCL is to provide controlled simulations of worldwide environmental conditions for static and dynamic testing of aircraft, weapon systems, electronic systems, support systems, equipment, and hardware.

2.0 GENERAL.

2.1. The MCL is located on Eglin main base between Eglin Boulevard and Second Street.

The systems, facilities, instrumentation, and test chambers are located in buildings 430, 438, 440, 441, 450, 466, and 486.

2.2. Main Machinery Room (MMR). The MMR is located on the south side ground floor of building 440. The machinery and equipment required to produce and control the test environment in the Main Chamber (MC) and Equipment Test Chamber (ETC) and provides refrigerant to the four heat exchangers in the two Air Make-Up (AMU) systems. The MMR includes three refrigeration units. Each unit has a 1,000 horsepower (HP) electric-motor-driven five-stage turbo compressor compounded with a 1,250 HP electric-motor-driven three-stage turbo compressor. The refrigerant is R-22, and temperature control is accomplished by varying the drive motor speed and the pre-rotational vanes. Test space temperature control is accomplished by circulating the cold liquid R-22 through air-to-refrigerant heat exchanger coils.

Each unit is mated to two sets of heat exchange coils. Cold liquid R-22 is circulated by a 75 HP centrifugal pump mated to each coil. Coils are located in plenums with a 100 HP centrifugal fan circulating air across the coil surface. A manifold condensing water system circulates cooling water through the unit condensers and back to an evaporative cooling tower. These main refrigeration units are used to control temperature in the MC and ETC, and to cool stage I (calcium chloride) and stage II (methylene chloride) brines for the two air makeup units.

2.3. Air Makeup Units (AMUs). AMU 1 and AMU 2 are used to condition and supply temperature-controlled air to the MC and the ETC to support operation of aircraft engines. The AMU systems use two brines for cooling the makeup air—Stage I (calcium chloride) and Stage II (methylene chloride). Stage I and Stage II brines are both cooled by any available refrigeration unit. Brines are stored in insulated tanks and circulated through air-cooling coils as required to provide cold air down to -65 degrees Fahrenheit (F). Similarly, steam coils are used to provide hot air up to 125 degrees F. The air supply for AMU 1 is supplied by two 1,000 HP constant speed fans. A 1,500 HP variable speed fan with a liquid drive system supplies the supply air for AMU 2.

2.4. Evaporative Cooling Tower. Condenser cooling water is cooled by means of an induced-draft three-cell evaporative cooling tower. A chemical feed system monitors and distributes the required levels of chemicals into the water to prevent calcium and other contaminants from building up and causing equipment damage.

2.5. Plenums and Air Ducts. The air cooling/heating coils are located in plenum chambers.

Each plenum has a 100 HP centrifugal fan for air circulation. Air is drawn from the test space by the fans, and is passed through the air coils, then discharged into a supply duct manifold supplying air to the test spaces. The duct manifold provides the ability to use any cooling plenum for controlling either the MC or the ETC. There are six cooling plenums and three

FA9200-05-C-0001, P00121

Attachment 3

Page E1-1 heating plenums. Two of the heating plenums are dedicated to the MC and one is dedicated to the ETC. The ducts and plenums are insulated and have stainless steel thermal vapor barriers.

Remotely operated dampers on the inlets and outlets of the plenums control airflow. Air duct manifold flexibility permits utilizing all or any portions of the three-refrigeration-unit capacity on either the MC or the ETC. Thus it is possible to concurrently use one unit on the MC, one unit on the ETC, and the third unit for cooling brine.

2.6. Control Room. The central control room for the MMC is located on the ground floor, adjacent to the main refrigeration units. Basic monitoring and control of the complex is performed in the control room.

2.7. Variable Speed Motors, Synchronous Drive. Three pairs of 1250 HP motors can vary their speed at nearly constant torque, from 100 to 1928 revolutions per minute. This is a load-commutated inverter system, implemented with discrete components to the medium scale integration microcircuit level. Demands for torque are current limited and horsepower is proportional to the phase angle firing point of the inverter stage. After filtering, direct current (DC) from the inverter is applied, always in synchronism, to the synchronous motor; speed proportional to frequency. Peripheral systems include protection from overcurrent, overheat, condensation, and refrigeration system interlocks. All are controlled by Sigma Programmable Controllers through digital and analog I/O boards. Sigma is programmed using a portable computer with Alstom Pilot Program. The drives have HMI (Human Machine Interface), an LCD touch screen PC, to allow monitoring, maintenance and troubleshooting of drive components, digital inputs and outputs for speed reference, speed feedback and exciter voltage/current.

2.8. North Machinery Room (NMR). The NMR is located on the north side ground floor of the main building (440). The machinery and equipment required to produce and control the test environment in the All-Weather Room (AWR) and Temperature-Altitude (TA) chamber are located in this area, adjacent to the test chambers.

2.9. Steam generation/distribution system. This is a 125 pounds per square-inch gauge saturated steam system. The boilers are located in a dedicated boiler house (438) adjacent to the main building. Steam and condensate return lines run throughout the facility supplying steam wherever needed.

2.10. Air compression/distribution system. This is a general-purpose compressed air system.

Primary compressors and air dryers are located on the second floor of building 441, with the main storage receivers on the ground floor and an additional compressor, dryer, and receiver are located in the AMU #2 fan room. Distribution lines run throughout the facility.

2.11. Electrical Distribution System. Electric power enters the facility on eighteen cables which form six triplex bundles. All bundles travel overhead from the 4160-volt Wye connection at the main substation to underground conduit risers outside the facility. In case of power failure, emergency power is automatically generated by a 115 kilovolt-amperes (KVA), 440-480 volt alternating current (AC), 60 Hertz (Hz), three-phase generator driven by a natural gas-fueled engine. The electrical distribution system includes:

2.11.1. The 115 KV substation that feeds two 4160-volt transformers which in turn feed the MMR power distribution system and the 480-volt substation.

2.11.2. The 480 and 208/120 volt branch circuit panels/transformers which get energy from the 480-volt substation and its feeder circuit breakers.

FA9200-05-C-0001, P00121

Page E1-2

2.11.3. Eight portable transformer carts used for power distribution to solar frame lighting in the chambers.

2.11.4. Three uninterruptible power systems providing backup power for lights in the main chamber and equipment test chamber, the computer system in the north lean-to, and the south observation room.

2.12. Facility Monitoring and Control System (FMCS). The FMCS consists of an array of items to support both facility operations and climatic testing in all chambers. Items range from sensors and cabling to high-speed data acquisition systems. The FMCS is located throughout the facility in every major system and test chamber. The FMCS consists of five major areas which are plant instrumentation, test instrumentation, test video, facility LAN, and support equipment. The FMCS includes:

2.12.1. Plant instrumentation for facility operation and maintenance. Operators of the plant environmental simulation and control systems rely on the FMCS for real-time displays of related parametric data and post run analysis.

2.12.2. Test instrumentation to monitor and control test conditions in each of the six chambers.

This includes instrumentation for chamber climatic conditions, instrumentation placed on test items for operation verification and soak condition, and decommutation, display, record, and process of data streams from our customers test item. Fiber optics is also used to transmit data within the test chambers and facility.

2.12.3. High Speed Compact cRIO data acquisition system for acquiring, displaying and documenting chamber test conditions and parameters being monitored on items being tested when subjected to environmental conditions. This system complements current FMCS, increasing data acquiring, documenting and displaying capabilities.

2.12.4. Video to monitor and document testing. It is available for safety and surveillance purposes.

2.12.5. Facility LAN for transfer of test data throughout the facility. E-mail is also available through this network.

2.12.6. Support equipment required to perform the above-mentioned duties plus all required spares and test equipment to maintain, troubleshoot, and install FMCS.

2.13. Main Chamber (MC). The MC is an insulated hangar 252 feet wide, 201 feet deep, 70 feet high in center, sloping to 35 feet high at sidewalls. The floor is a 12-inch-thick concrete surface lying on an insulation bed.

2.14. Equipment Test Chamber (ETC). The ETC is 130 feet long, 30 feet wide and 25 feet high, and is supplied refrigeration from the same system that supplies the main chamber.

2.15. All-Weather Room (AWR). The AWR is 22 feet wide, 42 feet long, and 16 feet high.

Heat is supplied by two 24 kilowatt (KW) duct heaters, and humidity is provided by steam.

2.16. Altitude Chamber (AC). The AC chamber is constructed of welded steel and is 13 feet 6 inches long, 9 feet 6 inches wide, and 6 feet 10 inches high. This chamber is located in the main building adjacent to the All-Weather room on the north side ground floor.

FA9200-05-C-0001, P00121

Page E1-3

2.17. Salt Test Chamber (STC) Building 450. The STC is 54 feet 8 inches long, 16 feet wide, and 16 feet high. This building is separated from the main building due to extremely corrosive conditions created within the chamber.

2.18. Sun, Wind, Rain, and Dust (SWRD). The SWRD is a chamber, separate from the main building, adjoining the test assembly building (430). The interior dimensions are 50 feet long by 50 feet wide by 30 feet high. Wind machines and large hoppers are used to dispense sand and dust, and a dust collector is provided to remove dust from the air.

2.19. There are instances where a test item is either too large for an inside test chamber, or an inside test chamber is not available and the temperature is not to be controlled. These tests would be conducted on the ramp area in front of the main chamber building and the area inside the main compound adjacent to the STC. Testing where the temperature does not need to be controlled is occasionally performed at Range A-22.

2.20. Equipment being tested and data collected may be classified IAW individual projects/systems security classification guidelines.

2.21. Principal features of the MC are:

1. Temperature range is from plus 165 degrees F to minus 65 degrees F.

2. Humidity range is from 10 percent to 98 percent with 100mm Hg being the maximum vapor pressure.

3. Air makeup capability of up to 1000 pounds mass of air per second.

2.22. Principal features of the ETC are:

1. Temperature range is from plus 165 degrees F to minus 65 degrees F.

2. Air makeup capability of up to 500 pounds mass of air per second.

3. Humidity can be controlled from 10 percent to 98 percent depending on temperature.

2.23. Principal features of the AWR are:

1. Temperature range is from ambient to plus 170 degrees F.

2. Maximum cooling rate is from plus 60 degrees F to minus 80 degrees F Rate is dependant on outside ambient conditions.

3. Access via a vertical lift door 14 feet one inch wide by 15 feet six inches high that opens to an outdoor ramp on the east end of the room.

2.24. Principal features of the AC chamber:

1. Temperature range from ambient to plus 140 degrees F.

2. Chamber pressure reduction to 87mm Hg (equivalent to 50,000 feet) in 12 minutes.

Pressure can be reduced further to 20mm Hg (80,000 feet).

3. Access via a 2 feet 2 inches by 5 feet 8 inches door.

2.25. Principal features of the STC are:

1. Temperature range is from plus 70 degrees F to plus 95 degrees F.

2. Humidity range is from 30 percent to saturation.

3. Access via end doors 15 feet wide and 15 feet high and a 3 feet by 6 feet 6 inch personnel door.

4. Heat is supplied by steam.

2.26. Principal features of the SWRD facility are:

FA9200-05-C-0001, P00121

Page E1-4

1. Temperature range is from plus 60 degrees F to plus 165 degrees F.

2. Humidity control is from 30 percent to 100 percent.

3. Dust concentration is from 0.1 to 0.8 grams per 0.028 cubic meters and is measured by an opaciometer.

4. Access via four vertical lift doors measuring 16 by 16 feet, each on four separate sides of the chamber, and two personnel doors.

2.27. Historically, approximately 1500 preventive maintenance actions that total 9,100 hours and 600 corrective maintenance actions that total 5,600 hours were performed annually. In addition, approximately 65 civil engineering preventive maintenance actions that total 700 hours and 90 civil engineering corrective maintenance actions that total 2100 hours were performed annually.

2.28. The MCL fire protection deluge system and associated foam containment pond on Range A-22 are maintained by 96 CEG.

3.0 CAPABILITIES.

3.1. The Contractor shall operate and maintain the MCL and associated systems and equipment, including:

3.1.1. The MMR including the following major components:

1. Three 1,000 HP turbo refrigeration compressors.

2. Three 1,250 HP turbo refrigeration compressors.

3. Six gear drives (speed increasers) and coupling assemblies.

4. Six 75 HP hermetically sealed refrigerant circulating pumps.

5. Eighteen 1/2 HP auxiliary oil pumps.

6. Fourteen 5 in. by 24 in. oil cooling heat exchangers.

7. Three 6-9/16 in. by 7 ft heat rejection oil cooling heat exchangers.

8. Three 54 in. by 20 ft surge drums.

9. Three 36 in. by 18 ft refrigeration condensers.

10. Three 54 in. by 14 ft desuperheater pressure vessels.

11. Two 96 in. by 42 ft (1900 cu. ft.) refrigerant storage vessels.

12. Two 75 HP rotary screw, RXB pump-out compressors.

13. One 14 in. by 18 ft RXB refrigerant condenser.

14. One cooling tower assembly with three 50 HP two speed fans.

15. Three 100 HP, 2,000 gpm cooling water circulating pumps and one cooling tower chemical feed management system.

16. Nine plenums with eight 100 HP and one 150 HP fan motors.

17. Six sets of cooling coils.

18. Three sets of heating coils.

19. Ninety-eight remotely operated damper doors.

20. Ten ventilation fans (1/2 HP - 50 HP).

21. All tanks, piping, valves and controls associated with these systems.

3.1.2. Air Make-Up system #1 including the following major components:

1. Two 1,000 HP fans with inlet vane controls.

2. Five brine pumps varying from 2 HP to 350 HP.

3. One 956 sq ft calcium chloride cooling coil and one 1,000 sq ft methylene chloride cooling coil.

4. One 30 ft by 45 ft high temperature steam coil.

FA9200-05-C-0001, P00121

Page E1-5

5. Air makeup ducting and dampers.

6. Two brine conditioning heat exchangers.

7. An air compressor and receiver assembly.

8. System piping and insulation.

9. System valves, controls, safety devices, indicators, gauges, etc.

10. One calcium chloride brine filtration system with a dedicated filter pump.

11. Six brine storage tanks, manual and automated valves and associated piping.

3.1.3. Air Make-Up system #2 including the following major components:

1. One 1,500 HP hydraulic drive variable speed fan.

2. One stage 1 brine heat exchanger, 24 in. by 12 ft.

3. One stage 2 brine heat exchanger, 30 in. by 17 ft.

4. Four brine pumps -- two 300 HP, one 40 HP, and one 50 HP.

5. Two 27 percent CaCl2 527,238-gallon storage tanks.

6. Two (R-30) Methylene Chloride 552,424-gallon storage tanks.

7. One stage 1 (Calcium Chloride), 756 sq ft low temp cooling coil.

8. One stage 2 (Methylene Chloride), 930 sq ft low temp cooling coil.

9. One steam heating coil rated at 4,000,000 BTUs/hr at 42,000 scfm.

10. One 300hp natural gas fired boiler, condensate return pump, tank, automated and hand valves & piping and insulation.

11. One 75 HP, 325 scfm air compressor with dryer and receiver assembly.

12. All associated ducting, dampers, and controls.

13. All associated instrumentation and controls for monitoring and controlling system operation.

14. All piping and associated thermal insulation.

15. One calcium chloride brine filtration system with a dedicated filter pump.

3.1.4. NMR equipment, including:

1. Electric drive vacuum pump for test chamber altitude pressure control.

2. Electric drive air circulating fans.

3. Electric resistance heaters.

3.1.5. Steam generation/distribution system, including:

1. Three fire-tube packaged boilers fired with natural gas and having a combined steam generating capacity of 48,500 pounds per hour (PPH) saturated steam.

2. Three electric drive centrifugal boiler feed pumps.

3. One boiler feedwater deaereating heater.

4. Seven condensate return pumps.

5. Six condensate receiver tanks.

6. Steam distribution mains and branches including valves, traps, strainers, etc.

7. One boiler chemical feed management system.

8. One condensate return storage tank (800 gallons).

9. Natural gas supply system from point of gas main shut offs to the point of use.

10. Approximately 12,000 linear feet of steam and condensate return lines including valves, strainers, traps, checks, pressure regulators, controllers, insulation, hangers, pressure gauges, thermometers, etc.

11. Two each, 511,800 BTU, 5KW, electric boilers which provide heat source for comfort heat to north and south side office spaces.

3.1.6 Air compression/distribution system, including:

FA9200-05-C-0001, P00121

Page E1-6

1. Three electric-drive rotary-screw compressors—one 150 HP, one 75 HP, and one

40 HP.

2. Two self-purging air dryers.

3. Four compressed air storage receivers.

4. Compressed air distribution mains and branches. Approximately 3,500 linear feet of piping, valves, strainers, drain traps, dryers and filters, pressure regulators, etc.

3.1.7 Electrical distribution system, including:

1. The 115 KV/4160V substation from the secondary side of the 115

KV/4160Wye/2400V transformers to the laboratory complex. This includes all feeders from the 4160V transformers, all metering of power including the new Facility Monitoring and Control System (FMCS), the primary gear, and one oil-filled transformer supporting AMU 2.

2. The 480V substation including all feeders, bus duct, primary gear, and two oil-filled transformers.

3. Portable transformer carts.

4. An emergency power plant which includes the emergency generator and its associated equipment, the three new uninterruptible power systems, all feeders, and the primary transfer switching.

5. Electrical power distribution systems throughout the facility, both indoor and outdoor circuits, including wiring, conduit, trays, transformers, cubicles, circuit breakers (air, oil, and vacuum types), disconnect switches, fuse panels, relays, voltage regulators, contactors, controls, switches, capacitors, resistor banks, etc.

6. Portable and fixed power supplies.

7. Lighting circuits within the laboratory complex, including controls, fixtures, and lamps (incandescent, fluorescent, and high-intensity discharge).

3.1.8. FMCS plant instrumentation, including all equipment required to process, record, and display real-time and post-time data. This includes sensors, gauges, switches, controllers, transmitters, valves, displays, converters, on all systems such as the AMU 1, AMU 2, heat exchangers, transfer system, refrigeration system, north machinery room, steam and cooling water system, plenums, electrical substation and gear, and all test chambers, MC, ETC, AWR, TA, SWRD, and STC. This includes work stations, electronics cabinets, power supply cabinets, printers and storage devices. The FMCS is used to gather, monitor, and record plant data and up to 650 channels of test data. A LAN ties all cabinets together, and individual cabling ties each sensor to its respective cabinet. The FMCS also includes all control and display devices in the refrigeration control room, for operator control and display.

3.1.9. FMCS test instrumentation, including all equipment required to measure, process, record, and display real-time and post-time data. This includes sensors, transmitters, converters, connected to commutators, dataloggers, stripcharts, and/or customer-provided systems. This also includes all equipment used to process data such as decommutators, load cell system, and computers. Other equipment includes printers, analog and digital recording devices, and equipment associated with retrieving and displaying IRIG time.

3.1.10. FMCS video equipment, including all equipment required to provide video capability to the customer and facility. This equipment includes cameras, pan and tilt systems, switchers, controllers, recorders, quad systems, twisted pair video systems, time code inserters, monitors, and associated cabling.

FA9200-05-C-0001, P00121

Page E1-7

3.1.11. FMCS facility LAN, including all equipment required to support the facility local area network, which is a node on the ECONET. This includes monitors, servers, switchers, bridgers, repeaters, computers and peripherals, and associated cabling.

3.1.12. FMCS support equipment, including all equipment required to test, checkout, and maintain the other FMCS components.

3.1.13. MC including chamber and MC doors. MC door maintenance includes corrosion control and maintenance of:

1. Structural steel.

2. Sheet metal.

3. Insulation.

4. Electromechanical seals, clamping, and drive systems.

5. Vertical lift door electromechanical opening/closing and sealing systems.

6. Swinging door seals, hinges, and latches.

7. Seventeen (17) 480v motors.

3.1.14. ETC including chamber, doors and adjacent offices. Door maintenance includes corrosion control and maintenance of:

1. Structural steel.

2. Sheet metal.

3. Insulation.

4. Electromechanical seals, clamping, and drive systems.

5. Vertical lift door electromechanical opening/closing and sealing systems.

3.1.15. AWR and associated environmental control systems (in reduced maintenance category B), including:

1. Two sets of 24 KW electric duct heaters.

2. Pipe and equipment thermal insulation.

3. Electric motors, electric power circuits, and controls associated with the systems.

3.2. AC and associated environmental control systems (in reduced maintenance category B), including:

1. One 40 HP vacuum pump and oil separating system.

2. One 20 KW electric heater.

3. One electric drive centrifugal fan.

4. Pipe thermal insulation and equipment thermal insulation.

3.2.2. STC and associated equipment, including:

1. Salt water mixing tank.

2. General test support equipment.

3. Water system.

4. Air system.

5. Water pump, valves and mixing board.

6. Steam piping and valves.

7. Two vertical lift doors and associated operating equipment.

3.2.3. SWRD and associated equipment, including:

1. Sand test system.

2. Air distribution system.

3. Rotating dust dispenser.

FA9200-05-C-0001, P00121

Page E1-8

4. Dust collector.

5. Cooling coils and associated piping and valves.

6. Four electrical powered vertical lift doors.

3.2.4. Climatic simulation equipment, including:

1. Solar radiation simulation system, including 120 each 5-foot by 10-foot modular lamp banks, 72 each 150-watt spotlights per bank, and associated equipment.

2. Rain simulation system, including 45 each 10-foot by-12 foot modular rain frames, 16 nozzles per frame, and associated equipment.

3. Super cooled fog icing system, including 6 each 11-foot by 11-foot air-atomized and hot water modular spray frames with approximately 120 spray system nozzles and bodies per frame and 2 each 10-foot by 12-foot air-atomized and water modular spray frames with approximately 16 spray system nozzles and bodies per frame. Two valve boxes to control the icing cloud consisting of dozens of valves, solenoids, electronic pressure controllers, pressure transducers etc.

4. Instrumentation and control system for the icing system consisting of Labview graphical user interface with computers, customized software, and hundreds of instrumentation parameters.

5. Icing cloud measuring equipment consisting of two laser interferometer systems, two hot wire liquid water monitoring devices, heated aerodynamic measuring equipment.

6. Three thrust stands and associated equipment and instrumentation to measure engine thrust.

7. Three snow machines.

8. Three wind machines.

9. Seven high speed fans, synchronous variable frequency drives, and associated equipment.

10. Compressed air system for icing consisting of two 500 SCFM compressors, dryers for each of the compressors, six 81 ft long by 12 ft diameter air storage tanks, and associated piping, valves, and controls.

11. Icing booth (20 ft x 12 ft) with associated air and water controls.

12. Over 200 ft of specialized icing cloud delivery ducting.

13. Two fans for high speed cruise missile testing, synchronous variable frequency drives and associated equipment.

14. Multiple cruise missile support structures and ducting.

15. Specialized icing, rain, and start air equipment for cruise missile testing which includes hundreds of components (valves, piping, controls, etc.).

16. Six catch net systems for cruise missile testing.

17. Two air compressors and dryers specific for cruise missile testing.

3.2.5. Aircraft rigging system, including:

1. Cutting tools, swage tools, hydraulic swage.

2. Equipment for installing tie-down systems, exhaust ducting, and climatic simulation equipment.

3.2.6. General support equipment, including

1. Exhaust duct support stands.

2. Refueling system including tanks, pumps, filtering system, and chilling system.

3. Pallet handlers and numerous trailers.

4. Seven walk-in test booths with air conditioning, heater, and nitrogen purged windows.

FA9200-05-C-0001, P00121

Page E1-9

5. Two bottomless booths.

6. Chains, wire ropes, nylon straps, and manual hoists with lifting capabilities varying from 550 to 6,600 pounds.

7. Electrically operated hoists.

8. Various sized aircraft jacks.

3.2.7. Mechanical support equipment including, but not limited to:

1. Lathes.

2. Milling machines.

3. Drill presses.

4. Bench drills.

5. Grinders.

6. Saws.

7. Presses.

8. Metal shears.

9. Metal brake.

10. 16-gauge lockformer.

11. Sheet metal roller.

12. Welding machines.

13. Automatic acetylene/oxygen torch.

14. Metalizing machine.

15. 1/2-inch metal plate nibbling machine.

3.2.8. Electrical support equipment including:

1. Electrically operated doors.

2. Digital Test and Facility Communications Network including 6 main circuits, 100 secondary circuits, and more than 1,600 electrical and electronic connections.

3. Facility public address system.

4. Portable power carts.

5. Approximately 600 electric motors ranging from 1,500 HP to fractional horsepower, both wound-rotor induction type and synchronous drives, including controls, some of which are solid state.

3.2.9. One 1500-gallon liquid nitrogen system. (operated by site personnel, maintenance performed by vendor)

3.3. The Contractor shall provide test assembly and test conduct support IAW tasks and test directives, including:

3.3.1. Assemble the required test fixtures, aircraft cables, other support cables and chains, and associated hardware.

3.3.2. Rig test assemblies including chains, cables, steel and aluminum trusses up to 84 feet in length, and one and a half-ton hoists. The final assembly may be suspended as high as 70 feet above the chamber floor.

3.3.3. Position, with a forklift or crane, large steel ducting of a nominal size of 108 inches in diameter and up to 60 feet in length to within one inch of aircraft tail assembly while the aircraft is positioned on jacks.

FA9200-05-C-0001, P00121

Page E1-10

3.3.4. Place and position test items within the test chamber in preparation for tie down, affix cables or chains to the test items, and secure all attachment points per the recommended and accepted guidelines.

3.3.5. Install tie downs on aircraft and other test equipment per government test engineer design and instructions and per MCL safety requirements.

3.3.6. Operate fuel pumps, oxygen servicing carts, air compressors, snow machines, ground heaters, and similar items.

3.3.7. Winterize and de-winterize mobile support equipment.

3.3.8. Inspect the test items using special rail-mounted personnel baskets at heights up to 80 feet above the chamber floor.

3.3.9. Configure and install rain, solar radiation, and icing frames or spray bars to meet test requirements. Simultaneously operate three forklifts, one crane and one 120’ man-lift to accomplish these installations. Measure and adjust required rainfall rates, dust emissions, water temperatures, flow rates, and perHydrion (pH) readings.

3.3.10. Provide a single point of contact and a mission controller for environmental tests.

3.4. The Contractor shall provide mechanical support, including:

3.4.1. Provide field engineering support to plan, design, fabricate, modify and install test support fixtures or special unique tooling and prototype equipment.

3.4.2. Perform technical feasibility studies of mechanical and welding modifications to existing environmental test equipment and systems.

3.4.3. Conduct engineering analysis needed to propose solutions, corrections, and improvements for operation and maintenance of plant equipment to include the interpretation of blueprints and piping schematics.

3.4.4. Perform field measurements on aircraft and other test items using precision instruments to engineer and fabricate tie-downs, restraints, and other specialty items.

3.4.5. Evaluate the effects of mechanical and welding modifications on equipment performance.

3.4.6. Understand structural loads, to calculate size requirements in the fabrication of hardware, and to understand the principles of metallurgy.

3.4.7. Operate machine shop equipment and machine metals to close tolerances.

3.4.8. Perform TIG, MIG, acetylene/oxygen and arc welding on alloys, carbon steel, stainless steel, cast steel and aluminum to close tolerances and in close proximity to aircraft and other test items located in an environmental test chambers.

3.4.9. Conduct field measurements on plant equipment, aircraft, supporting structural equipment, and a variety of test items for welding fabrication when engineering drawings or blue prints may not be available.

FA9200-05-C-0001, P00121

Page E1-11

3.4.10. Conduct qualitative assessments and engineering analysis to determine the impact of various welding techniques on material suitability, structural design, and structural integrity.

3.4.11. Troubleshoot, repair, install, align, and calibrate refrigeration compressors, air compressors, water pumps, chemical processing pumps, torque converters, chain drives, gear boxes, electric motors, electric valves, pneumatic valves and other such equipment or subsystems used in the operation and maintenance of plant equipment.

3.4.12. Conduct and interpret vibration analysis performed on rotating equipment.

3.4.13. Provide technical specifications for procurement of components and subsystems to meet task requirements.

3.5. The Contractor shall provide electrical (including high voltage) and electronic, technical support, including:

3.5.1. Field engineering to plan, design, fabricate, modify and install electrical, digital, and electronic equipment or fixtures to meet test support and power distribution requirements.

3.5.2. Technical feasibility studies of electrical modifications to existing environmental test equipment and systems.

3.5.3. Engineering analyses needed to propose solutions, corrections, and improvements for operation and maintenance of plant equipment to include the interpretation of blueprints, drawings, and schematics.

3.5.4. Field measurements on aircraft and other test items using precision instruments to engineer and fabricate electrical, digital, or electronic specialty items.

3.5.5. Evaluation of the effects of electrical, digital, and electronic modifications on equipment performance using such instruments as digital multimeters, signal generators, semiconductor testers, and oscilloscopes.

3.5.6. Identification, acquisition, and installation (sometimes in extreme environments) of electrical, electronic, digital, or high voltage equipment according to industry standards.

3.6. The Contractor shall provide equipment and instrumentation support, including:

3.6.1. Design, fabricate, install, calibrate, troubleshoot, and checkout special instrumentation to support test and plant operations.

3.6.2. Modify existing plant instrumentation and install upgraded systems to improve equipment performance.

3.6.3. Evaluate the effects of modifications to plant instrumentation on equipment performance.

3.6.4. Install test and plant instrumentation in extreme environmental conditions; in the vicinity of high voltage equipment; in high noise areas; in high and hard to reach locations; and around large rotating machinery.

FA9200-05-C-0001, P00121

Page E1-12

3.6.5. Provide engineering and system analysis support to design, modify, and install environmental test software packages; data collection and reduction software packages; and LabView Control software packages for facility upgrades.

3.6.6. Develop software interfaces and generate computer programs to meet plant instrumentation and customer test support requirements. This capability will include incorporating software modifications to existing programs, documenting program changes, and providing operations guidelines IAW Government-furnished procedures.

3.6.7. Provide technical support for improvement and modernization efforts associated with the FMCS. This capability will include activities such as development of acceptance tests, systems specifications (both hardware and software), interface and maintainability requirements, and technical risks.

3.6.8. Conduct engineering analyses and fabricate and install chemical, mechanical, and electro-mechanical equipment to support operation, maintenance, and improvement of the Steam Generation and Distribution System, AMUs, and Evaporative Cooling Tower. This capability includes providing technical advice and consultation to test and plant engineers, chemical treatment technicians, and environmental specialists to ensure Government and commercial guidelines are met.

3.6.9. Conduct analyses as necessary to determine the amount of conditioned air required to support aircraft engine operations. Operate the Air Make-Up System instrumentation to meet the requirements for various test scenarios and environmental conditions, including two simultaneous tests in two different chambers.

3.7. The Contractor shall provide specialized technical support, including:

3.7.1. Technical expertise, guidance, and assistance in O&M decisions, priorities, and activities that directly support very large scale industrial heating, refrigeration, and air conditioning systems. This includes providing recommendations on code and policy.

3.7.2. Troubleshooting, repairing, installing, aligning, and calibrating specialized plant equipment.

3.7.3. Conducting qualitative assessments and engineering analyses to determine the impact of equipment suitability, structural design, and structural integrity.

3.7.4. Evaluation of and recommendations on Improvement and Modernization (I&M) efforts associated with plant equipment at the MCL. This includes development of acceptance tests, systems specifications, interface requirements, reliability and maintainability requirements, and logistical requirements.

3.7.5. Planning, scheduling, and coordinating plant maintenance schedules to ensure equipment availability in meeting test support requirements.

3.7.6. Maintaining and controlling the use of refrigerants and refrigerated brines. This includes proper sampling techniques, inhibitor maintenance, inventory control, and plant/industrial safety procedures.

FA9200-05-C-0001, P00121

Page E1-13

3.7.7. Preparing for, coordinating, and conducting the O&M of plant equipment and systems.

This includes electrical, electronic, pneumatic control, air moving or fan, pumping, steam generation and distribution, and low temperature refrigeration systems.

3.8. The Contractor shall provide quality, safety, and environmental expertise associated with MCL’s unique systems. This includes evaluating, inspecting, reviewing, and verifying environmental procedures relating to the use and storage of calcium chloride, methylene chloride, and refrigerants.

3.9. The Contractor shall provide logistics and supply capability specific to the MCL including:

3.9.1. Maintain a facility sub-supply account for dispensing consumable supplies unique to plant and test operations at the MCL.

3.9.2. Conduct facility inventory management of decentralized and decontrolled items including equipment and supplies.

3.9.3. Research and identify materials and equipment needed to support plant and test operations.

3.9.4. Perform a material coordination function for test programs, plant maintenance, and production shops.

3.9.5. Maintain a record of all facility supply transactions on an automated material management system.

3.9.6. Maintain accurate facility records of the location and disposition of all plant and test equipment at the MCL.

3.10. The Contractor shall operate and maintain the maintenance management system that is unique to the plant equipment installed at the MCL. The maintenance management system provides maintenance control, data collection, data analysis, and data reporting capabilities for MCL plant equipment.

3.11. The Contractor shall provide civil engineering support for the MCL (reference A4).

3.11.1. Maintain the eight buildings and seven temporary storage facilities associated with the MCL. This includes the 136,064 square foot main complex as well as the two electrical substations.

3.11.2. Operate and maintain the mechanical, interior and exterior electrical, and interior and exterior plumbing equipment and systems.

3.12. The Contractor shall perform necessary actions under extreme environmental and occupational hazardous conditions to include temperatures ranging from minus 105 degrees F to plus 165 degrees F, icy floors, limited visibility, proximity to high voltage lines, high noise levels, varying humidity, and close proximity to aircraft on jacks with engines operating, guns firing, and undergoing refueling operations.

3.13. The Contractor shall operate and support testing in the MC and ETC simultaneously and operate and support testing in any one of the remaining chambers at the same time when

FA9200-05-C-0001, P00121

Page E1-14 required. The Contractor shall also be required to support, when test requirements dictate, around-the-clock test customer support.

3.14. The Contractor shall provide chamber environmental control 24 hours per day, 7 days per week, 365 days per year.

3.15. The Contractor shall perform specialized maintenance for 8 hours per day, 5 days per week on all Climatic Laboratory equipment while simultaneously providing chamber environmental controls, during both testing and non-testing periods.

3.16. The Contractor shall operate three lathes/milling machines and four acetylene/oxygen or arc welding sets/machines, while simultaneously supporting environmental tests.

3.17. The contractor shall maintain and operate the vehicles identified in Table E1-1 in accordance with requirements established in TRD A3. Co-utilization of vehicles from and to other Contractor operated and maintained facilities is an acceptable means for satisfying vehicle shortages due to surge support requirements. Suitable substitute for vehicle type is acceptable.

TABLE E1-1

Mgt Code Nomenclature Qty Auth

B200 TRK PU CMPT 4X2 1

B204 TRUCK 1/2T REG CAB 4X2 1

D515 CRANE, 7.5 T 1

E801 TUG WHSE 4K 1

E829 TRK,FORKLIFT, 15K 1

E949 TRK FL 6K(COMMERCIAL) 1

L351 TOW TRACTOR, MB-4 1

FA9200-05-C-0001, P00121

Page E1-15