Purchase Description - Rev.pdf

PURCHASE DESCRIPTION

For

FIVE (5) PNEUMATIC VALVE

TEST STANDS

Air Driven Accessories

550 CMMXS/MXDPAA

Tinker A.F.B., OK 73145

Dated 11 March 2009

Prepared by:

76 CMXG/QIA

1.0 STATEMENT OF REQUIREMENTS

1.1 General Operation: The test stand is required to perform final acceptance testing on several military aircraft end item control valves and performing pretests on several military aircraft end item control valves utilizing compressed air.

1.2 Design: The Contractor shall utilize commercial off the shelf equipment in the design of the Test Stand.

1.2.1 Enclosure: Each Test Stand shall be a single self-contained enclosure. The Test Stand shall be constructed of a minimum of 14 gauge steel. Each Test Stand shall be painted white on the interior and bright blue on the exterior. The Contractor shall provide color samples. The paint shall be approved by the Contracting Officer prior to purchase and application of the paint. Each Test Stand shall incorporate a work surface constructed of a minimum of 14 gauge stainless steel located on the front of the Test Stand. The work surface shall run the full length of each Test Stand and be a minimum of 36 inches and a maximum of 38 inches above the finished floor and a minimum of 22 inches and a maximum of 24 inches deep. Each Test Stand shall be equipped with locking swivel casters that support the entire weight of the test stand and that shall allow easy rolling of the Test Stand. Each Test Stand shall be equipped with interior equipment access doors on the back and front sides. The access doors shall allow for removal and installation of all interior components. The maximum depth of each Test Stand shall be 50 inches and the maximum height of each Test Stand shall be 82 inches. The width of each Test Stand shall be a minimum 65 inches and a maximum of 88 inches. The front panels of each Test Stand above the work surface shall be designed for standard 19 inch rack mount equipment.

1.2.2 Each Test Stand shall be equipped with an articulating arm that will house an LCD touch screen. The articulating arm shall be equipped with a mechanism to allow easy vertical, arm rotation, and monitor rotation adjustment by the test stand operator. The adjustable vertical travel shall be a minimum of 13 inches. The arm shall be located on the front left side of the test stand as viewed by the operator. The articulating arm shall allow for the LCD touch screen to be positioned in front of the safety enclosure on the left side of the test stand as viewed by the test stand operator.

1.2.3 The configuration/layout, size, and labeling of all the operator interface bulkhead connections shall match the current test stand (Honeywell P/N 295100-1). All bulkhead connections shall be JIC 37 degree flare.

1.2.4 The Test Stand labels for all components located on the front panel shall be the same as the current test stand (Honeywell P/N 295100-1).

1.2.5 Each test stand shall have a nameplate affixed to the front upper left. The nameplate shall be a corrosion resistant metal securely affixed to the test stand. The words and numbers shall be engraved, etched, embossed, or stamped in boldface print on a contrasting background. The words shall be a minimum of 0.25 inches in height and maximum of 0.5 inches in height.

The nameplate shall contain the following information: nomenclature, manufacturer’s name, manufacturer’s model designation, manufacturer’s serial number, date of manufacture, and contract number.

1.2.6 Each test stand shall be equipped with a supplemental light fixture. The light shall be a minimum four foot 2 bulb fixture. The fixture shall be equipped with the required hardware to ensure a light bulb does drop to the work surface. The fixture shall be oriented to illuminate the work surface.

1.2.7 Each test stand shall be equipped with a testing safety enclosure. The enclosure shall be the full depth and length of the test surface. The enclosure shall be the same height of the top of the test stand. The enclosure shall be constructed utilizing 3/8 inch thick Lexan on the front and sides. The front shall have two bi-folding doors that allow full access to the test surface with a pocket hinge configuration to allow the doors to be recessed into the safety enclosure. The hinges, latches, fastening, and other associated hardware shall be stainless steel. The top shall not use Lexan but shall be covered with woven, welded, crimped, or molded wire cloth with square 1/4 inch spacing and a minimum wire diameter of 0.06 inches and a maximum wire diameter of 0.08 inches. The wire cloth shall be stainless steel.

1.2.8 The Contractor shall ensure that equipment is properly guarded and properly marked to prevent personnel injury in accordance with AFOSH and OSHA regulations.

1.2.9 Each test stand shall be equipped with a supplemental light fixture. The light shall utilize a minimum of 2 four foot bulbs. The fixture shall be equipped with a wire cage below the light bulbs to ensure to a light bulb does drop to the test surface.

1.2.10 Transducers:

1.2.10.1 Each Test Stand shall be equipped with absolute, gage, and differential pressure transducers as listed in Appendix A. The transducers shall be rated for industrial conditions with built-in overload protection and utilize stainless steel construction for wetted parts and case.

1.2.10.2 Each Test Stand shall be equipped with temperature transducers as listed in Appendix B. The temperature transducers shall be Type J, 304SS with 1/8 inch diameter sheath, simplex, ungrounded with male plug and 6 inch length.

1.2.10.3 Each Test Stand shall be equipped with an AC Voltage transducer.

The AC Voltage transducer shall be true RMS voltage with 0-300 VAC 400 Hz input. The value shall be capable of being displayed on the LCD touch screen.

1.2.10.4 Each Test Stand shall be equipped with an AC Current transducer.

The AC Current transducer shall have a minimum accuracy of +/-

0.05 amps. The range shall be 0 to 10 amps. The value shall be capable of being displayed on the LCD touch screen.

1.2.11 Each Test Stand shall utilize six (6) independent orifice plate assemblies with interconnecting tubing or piping. The tubing or piping shall be stainless steel. The orifice assemblies and orifice plates shall be stainless steel. The orifice assemblies shall utilize ANSI 300 pound class flanges with flange tap pressure ports. The orifice flow sections shall be sized and configured according to the recommendations of ANSI/API 2530-92. The orifice plate sizes for each flow section are listed in Appendix C. Each orifice plate size shall correspond to a independent flow section. The orifice plates shall be designed according to the recommendations of ANSI/API 2530-92. The orifice size certifications shall be furnished. All flow sections will utilize a dedicated thermocouple for temperature measurement. The thermocouple requirements are indicated in Appendix B. The thermocouple readings shall be capable of being displayed on the LCD screen.

1.2.12 Each Test Stand shall utilize analog pressure gages as indicated in

Appendix D.

1.2.13 Pneumatic System: Each Test Stand shall utilize two automatic pressure regulators. One (1) shall be capable of an outlet pressure range from 0 to 300 psig with a maximum inlet pressure of 320 psig and flow up to 50 scfm and one (1) shall be capable of an outlet pressure range from 0 to 300 psig with a maximum inlet pressure of 320 psig and flow up to 100 scfm. Each pressure regulator shall be self venting. The pressure regulators shall replace the two manual pressure regulators utilized on the existing Test Stands. The Test Stand shall be equipped with two separate gauges for four different circuits. This deviates from Figure 4-1 of Technical Order 33D7-25-38-1 dated 31 January 1978 with Change 1 dated 15 August 1995. The four circuits shall be equipped with an analog gauge and a pressure transducer. The ID’s are indicated in Appendix A and Appendix D. All valves, regulators, piping, tubing, and hoses shall have the minimum inner diameter of the current test stand and be capable of the same minimum flows as the current test stand. The pneumatic system and all components shall be rated for a minimum 320 psig at 100 degrees Fahrenheit unless otherwise noted. All connections, tubing, hoses, piping, and components shall be bubble tight for leaks at the maximum operating pressures. The pneumatic system and all components shall comply with the latest version of ASME 31.1 Power Piping.

1.2.14 Vacuum System: Each Test Stand shall be equipped with a process vacuum circuit. The circuit is not indicated on Figure 4-1 of Technical Order 33D7-25-38-1 dated 31 January 1978 with Change 1 dated 15 August 1995. The vacuum circuit shall schematically match the current test stand. The inlet piping shall be schematically connected to Valves V1 and V2. The Valves shall be connected to the front panel bulkhead connectors V1 and V2. The vacuum system shall have two separate automatic vacuum regulators. The regulators shall allow automatic control of the vacuum pressures required by the test operator. Each automatic vacuum regulator shall have an outlet pressure range of 5 psig to 28 inches HG vacuum and be capable of 35 acfm flow. All valves, regulators, piping, tubing, and hoses shall have the minimum inner diameter of the current test stand and be capable of the same maximum flows as the current test stand. The vacuum system shall be rated for 28.0 inches HG local vacuum at 100 degrees Fahrenheit unless otherwise noted. All connections, tubing, hoses, piping, and components shall be bubble tight for leaks at the maximum operating pressures.

1.2.15 Touch Screen: Each Test Stand shall utilize two (2) LCD screens to display and set the test parameters. Each LCD shall be touch screen, 19 inch minimum, and capable of plus or minus 85 degree wide viewing angles with a minimum of 1024 x 768 resolution, 1000:1 contrast ratio, 1000 Nits brightness, and lifetime of 40,000 hours. One shall be mounted in the articulating arm and one shall be rack mounted in the front panel.

1.2.16 Tubing and Fittings: All tubing shall be seamless stainless steel. All bulkhead fittings on the operator front panel shall be stainless steel with stainless steel caps and lanyard cables connected to caps and test stand front panel. All bulkhead fittings sizes on the operator front panel shall match the existing test stands.

1.2.17 Hoses: All hoses shall be rated for 320 psig working pressure and utilize swivel JIC 37 degree flare or Swagelok compression end connections.

1.2.18 Valves: All valves in the compressed air circuit shall be constructed to withstand 320 psig working pressure at 100 degrees Fahrenheit.

1.2.19 Pressure Regulators: Air pressure and vacuum regulators shall allow for automatic and/or manual control of pressures.

1.2.20 DC Power Supply: The power supply shall be a commercial off the shelf unit from a manufacturer that is in the business of producing power supplies. The power supply shall be operator variable from 0 to 50 VDC and 10 amps maximum output. The power supply shall be regulated with overload protection. The voltage and the current from the power supply shall be displayed on the LCD.

1.2.21 Data Acquisition: The Contractor shall use a computer with data acquisition cards or a programmable logic controller (PLC) for data acquisition system. The analog to digital converter shall be 16 bit or better.

1.2.22 Each Test Stand shall be equipped with a DC electrical circuit based on the current test stand Honeywell P/N 291500-1. The circuit shall utilize the variable power in Paragraph 2.3.19. The circuit shall duplicate the function, layout, and electrical connector on the current test stand Honeywell P/N 291500-1. The volt/amp selector switch shall not be required. The volts and amps shall be capable of being displayed on the LCD screen. The output voltage to the electrical connector shall be variable. The output voltage shall be controlled via a knob and/or the touch screen LCD.

1.2.23 Each Test Stand shall be equipped with a 220 VAC, 3 phase, 400 Hz electrical circuit based on the current test stand Honeywell P/N 291500-1.

The circuit shall utilize facility power and be rated for 10 amps. The circuit shall duplicate the function, layout, and electrical connector on the current test stand P/N 291500. The 1 phase/3 phase/amp selector switch shall not be required. The volts and amps shall be capable of being displayed on the LCD screen. The display shall be configurable for 1 phase or 3 phase voltage.

1.2.24 Each Test Stand shall be equipped with an auxiliary 120 VAC 60 Hz electrical circuit based on the current test stand Honeywell P/N 291500-1.

The circuit shall be rated for a 20 amps. The circuit shall duplicate the function and layout on the current test stand Honeywell P/N 291500-1.

The test stand shall be equipped with four single or two duplex receptacles in lieu of the current single receptacle.

1.2.25 Timer: Each test stand shall be equipped with a timer circuit that can be displayed on the LCD touch screen. The timer shall be capable of displaying 59 minutes, 59 seconds, 9 tenths of a second, and 9 hundredths of a second. The timer shall be controlled manually or automatically with a current detection system in the AC and DC voltage circuits. The manual control shall have a start, stop, and reset on the LCD touch screen. The automatic circuit shall have a manual reset. The automatic circuit shall be controlled with either the AC or DC off/forward/reverse switch and begin timing when current is detected and stop timing when current has stopped. The minimum current to begin and end timing shall be 0.05 milliamps.

1.2.26 Cycle Counter: Each Test Stand shall be equipped with two (2) counters.

The counters shall display the actual and target count and be capable of being displayed on the LCD touch screen. Each test stand shall be capable of automatically performing cycles based on the operation of an end item. The end items utilize single and three phase 400Hz power and 28 volt DC power. Operation is based on current until the end item reaches a position and a signal is given at that point. The end item reverses direction and current is applied until the end item reaches the original position. This shall constitute one cycle. The operator shall be capable of inputting the desired number of cycles. Each Test Stand shall be equipped with feedback to indicate a failed cycle. The indication shall be on the LCD touch screen.

1.2.27 Current Detection: Each Test Stand shall be capable of retaining and displaying on the LCD touch screen the maximum or peak current. The peak current shall be either single or three phase 400Hz power or 28 volt DC power. The display shall be capable of operator reset. The display shall be in addition to the other current displays.

1.2.28 Each Test Stand shall be equipped with a rack mounted four (4) channel, 100 MHz bandwidth digital storage oscilloscope to be used to display analog signals produced by the end items under test. The oscilloscope shall be mounted in the front panel.

1.2.29 Pressure Settings: Each of the four (4) test pressure regulators shall be

LCD screen selectable for either closed or open loop control schemes. The Closed loop scheme shall allow input values to be entered via the LCD touch screen. The open loop scheme shall allow an operator to input values via knobs for each of the two (2) compressed air circuits and each of the two (2) vacuum circuits. The PLC or computer shall be programmed to ensure all electrical control to the pressure regulators shall be disabled after 30 minutes of LCD touch screen inactivity. The system shall be designed to ensure no pressure is released to any front panel bulkhead fitting, calibration port, pressure transducer, or pressure gage upon disabling of the electrical control.

1.2.30 Flow Calculations: Each Test Stand shall continuously perform of at least two (2) times per second flow calculations on all six flow sections. The flows shall be capable of being displayed on the LCD touch screen as required for the test and calibration screens. Flow calculation methods shall be according to ANSI/AP2530-92 of current issue.

1.2.31 Test Screens: The Test screens shall be capable of displaying different pressure, flows based on the end item under test. The screens shall be configurable for a minimum of 300 different screens. The LCD screen shall have a blank screen saver after 15 minutes of inactivity.

1.2.32 Test Thermocouples: The Test Stand shall duplicate the front panel connections for external thermocouples of the existing test stand. The Test Stand shall be configured for J-Type thermocouples. The thermocouples shall be capable of being displayed on the LCD touch screen.

1.2.33 Each Test Stand shall be equipped with two emergency stop buttons. One shall be located at the upper left on the front panel and the other shall be located outside the safety enclosure at the middle left. Both buttons shall isolate the compressed air and vacuum supplies from the facility and shut off power to the Test Stand.

1.2.34 Facility Utilities: Each test stand shall operate on 120 VAC 60 Hz electrical power. The test shall have connections for a three phase 220 Volt 400 Hz 10 amp facility input. The test stand shall have a minimum one (1) inch schedule 40 pipe connection for 300 psig compressed air facility input.

The Test Stand shall have a minimum one (1) inch schedule 40 pipe connection for 28 inches HG process vacuum facility input.

1.2.35 Electrical

1.2.35.1 The label or listing of the Underwriters Laboratories, Inc., shall be accepted as evidence that the materials or equipment conform to the applicable standards of that agency. In lieu of this label or listing, a statement from a nationally recognized, adequately equipped testing agency indicating that the items have been tested in accordance with required procedures and that the materials and equipment comply with all contract requirements will be accepted.

Materials and equipment shall be approved based on the manufacturer's published data.

1.2.35.2 For other than equipment and materials specified to conform to UL publications, a manufacturer's statement indicating complete compliance with the applicable Federal Specification, or standard of the American Society for Testing and Materials, National Electrical Manufacturers Association, or other commercial standard, is acceptable.

1.2.35.3 Cables: Contractor shall label both ends of all cables with plastic sleeves or similar material describing wire list reference. Wire/cable identifiers shall be installed within 2 inches of each connector or terminal.

1.2.35.4 The Contractor shall use multiple colored wires for the different types of wiring circuits in accordance with standard industry practices.

1.2.35.5 The Contractor shall ensure compliance with the latest versions of the National Electrical Code (NEC), National electric Manufacturers association (NEMA) Stands, and National Fire Protection Agency

(NFPA) 70.

1.2.35.6 Each Test Stand shall have all electrical circuits equipped with ground fault interruption.

1.2.36 Software: The Computer and/or PLC programming software shall be commercial off the shelf type. All software versions shall be the latest available unless approved by the Government in writing. The Contractor shall be in compliance with T.O. 00-5-16 and 00-5-17 for Computer Program Identification Number (CPIN) updates. No custom proprietary software shall be used unless approved by the Government in writing.

1.2.37 Standard Products/Service Availability

1.2.37.1 Materials and equipment furnished shall be new and standard products of a manufacturer regularly engaged in the manufacture of such products, which are of a similar material, design and workmanship. The standard products shall have been in satisfactory commercial and/or industrial use for two years prior bid opening and still be in production.

1.2.37.2 Products having less than two years field service record shall be acceptable, if a two year extended warranty is provided to correct any design defects or problems. The products shall be approved by the Government.

1.2.37.3 The equipment items shall be supported by a service organization.

These service organizations shall be reasonably convenient to the equipment installation and able to render satisfactory service to the equipment on a regular and emergency basis during the warranty period of the contract.

1.2.37.4 The Contractor shall use, when possible, test measurement diagnostic equipment (TMDE) that is already in the Air Force inventory and normally found in a Class II precision measurement equipment laboratory. If the equipment is not in the inventory, the Contractor shall provide required calibration equipment as part of the contract.

2.0 CONTRACTOR QUALIFICATIONS

2.1 The contractor shall have been actively and successfully designing and building process and/or test equipment over the past ten (10) years in accordance with industry codes and standard practices.

2.2 The Contractor shall have an on-staff of at least one each registered electrical engineer, software engineer, and mechanical engineer. Their resumes and professional engineer certifications must be submitted with the contractor’s bid.

2.3 These engineers must have expert knowledge of industry standards and codes and experience relative to the design, calibration, maintenance, and operation of process and control equipment. The equipment includes electrical and electronic systems, pneumatic systems, piping and tubing materials, control valves, analog instrumentation logic, computer based control systems, data acquisition systems and analysis, system safety, and operator interface.

2.4 The Contractor shall employee personnel with expert knowledge in the technologies, software products, methodologies, and disciplines necessary for the design, fabrication, calibration, and operation of the Pneumatic Valve Test Stand. Specific areas include equipment documentation including Process and Instrument Diagram development and operating procedures, process flow analysis including process modeling, valve sizing, piping sizing, tubing sizing, and piping design, hazard analysis, industry codes and standards, and process design including control parameters, component sizing, fluid velocities, pressure drops, and capacities.

Appendix A

Pressure Transducers

ID Description Range Accuracy

G1 Pressure Transducer 0-300 psig +/- 0.1% F.S

G2 Pressure Transducer 0-300 psig +/- 0.1% F.S

G3 Pressure Transducer 0-300 psig +/- 0.1% F.S

G4 Pressure Transducer 0-300 psig +/- 0.1% F.S

G5 Pressure Transducer 0-160 psig +/- 0.1% F.S

G6 Pressure Transducer 0-160 psig +/- 0.1% F.S

G7 Pressure Transducer 0-160 psig +/- 0.1% F.S

G8 Pressure Transducer 0-200 in HgA +/- 0.1% F.S

G9 Pressure Transducer 0-200 in HgA +/- 0.1% F.S

G14 Differential Pressure Transducer 0-60 in Hg +/- 0.1% F.S

G15 Differential Pressure Transducer 0-60 in Hg +/- 0.1% F.S

G16 Differential Pressure Transducer 0-60 in Hg +/- 0.1% F.S

G17 Differential Pressure Transducer 0-100 in Hg +/- 0.1% F.S

G18 Differential Pressure Transducer 0-60 in H2O +/- 0.1% F.S

G19 Differential Pressure Transducer 0-60 in H2O +/- 0.1% F.S

G20 Differential Pressure Transducer 0-60 in H2O +/- 0.1% F.S

G21 Differential Pressure Transducer 0-100 in H2O +/- 0.1% F.S

Appendix B

Flow Section Temperature Transducers

ID Description Range Accuracy

T1 Temperature Transducer 0-150 Deg F +/- 1 Deg F

T2 Temperature Transducer 0-150 Deg F +/- 1 Deg F

T3 Temperature Transducer 0-150 Deg F +/- 1 Deg F

T4 Temperature Transducer 0-150 Deg F +/- 1 Deg F

T5 Temperature Transducer 0-150 Deg F +/- 1 Deg F

T6 Temperature Transducer 0-150 Deg F +/- 1 Deg F

Appendix C

Orifice Assemblies

Description Orifice Size Orifice Thickness

Orifice Plate Assembly 0.0312 0.125 inch

Orifice Plate Assembly 0.0625 0.125 inch

Orifice Plate Assembly 0.1250 0.125 inch

Orifice Plate Assembly 0.2000 0.125 inch

Orifice Plate Assembly 0.3125 0.125 inch

Orifice Plate Assembly 0.6250 0.125 inch

Appendix D

Pressure Gauges

ID Description Size Range Accuracy

G10 Pressure Gauge 2-1/2 in dia. 0-300 psig 1% F.S

G11 Pressure Gauge 2-1/2 in dia. 0-300 psig 1% F.S

G12 Pressure Gauge 2-1/2 in dia. 0-30 psig 1% F.S

G13 Pressure Gauge 2-1/2 in dia. 0-30 psig 1% F.S

G1 Pressure Gauge 6 in dia. 0-300 psig 0.25% F.S

G2 Pressure Gauge 6 in dia. 0-300 psig 0.25% F.S

G5 Pressure Gauge 4-1/2 in dia. 0-160 psig 0.5% F.S

G8 Pressure Gauge 8-1/2 in dia. 0-200 in HgA 0.25% F.S