SOW_Altitude_Chamber_TS_Upgrade_V(5).pdf

STATEMENT OF WORK

For

Altitude Chamber Test Stand Upgrade

H8TC09

FSC: 4920

NAICS: 334419

Air Driven Accessories Tinker A.F.B., OK 73145

Dated 09 August 2018

Prepared by:

76 CMXG/ENA

ALTITUDE CHAMBER Test Stand Upgrade Statement of Work 25 May 2017

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TABLE OF CONTENTS

1. SCOPE OF WORK:

1.1. SCOPE:

1.1. BACKGROUND:

2. APPLICABLE DOCUMENTS AND DEFINITIONS:

2.1. GOVERNMENT STANDARDS:

2.2. NON-GOVERNMENT STANDARDS:

2.3. ORDER OF PRECEDENCE:

3. REQUIREMENTS:

3.1. GENERAL:

3.2. DESIGN AND CONSTRUCTION:

3.3. CALIBRATION:

3.4. WARRANTY:

3.5. TEST PLAN:

4. BUILD SEQUENCE AND SCHEDULE:

4.1. INSTALLATION SCHEDULE:

5. QUALITY ASSURANCE PROVISIONS:

5.1. RESPONSIBILITY FOR INSPECTIONS:

5.2. RESPONSIBILITY FOR COMPLIANCE:

5.3. DESIGN REVIEWS AND EVALUATION:

5.4. ACCEPTANCE TESTING:

6. TECHNICAL DATA:

6.1. MANUALS, INSTRUCTIONS, AND PROCEDURES:

6.2. AS-BUILT DRAWINGS:

6.3. OPERATION INSTRUCTIONS:

6.4. MAINTENANCE INSTRUCTIONS:

6.5. PROGRAMMING INSTRUCTIONS:

6.6. CALIBRATION INSTRUCTIONS:

6.7. DOCUMENTATION:

7. TRAINING/FAMILIARIZATION:

8. SPECIAL PROVISIONS:

8.1. RECEIPT AND ACCEPTANCE:

8.2. SAFETY, FOREIGN OBJECT DEBRIS (FOD), DROPPED OBJECT PREVENTION (DOP) & QUALITY CONTROL:

8.3. FOD AND DOP:

8.4. HOUSEKEEPING:

8.5. TOOL CONTROL AND ACCOUNTABILITY:

8.6. CONTRACTOR QUALIFICATIONS:

8.7. CONTRACTOR PERSONNEL:

9. GOVERNMENT FURNISHED PROPERTY AND SERVICES:

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9.1. GOVERNMENT FURNISHED PROPERTY:

9.2. GOVERNMENT FURNISHED SERVICES:

APPENDIX A: EQUIPMENT LIST

APPENDIX B: GOVERNMENT FURNISHED PROPERTY (GFP)

APPENDIX C: SAFETY SPECIFICATION

APPENDIX D: END ITEMS TESTED ON STAND

APPENDIX E: TEST STAND TRANSDUCERS

APPENDIX F: PROTECTION CIRCUITS

APPENDIX G: TEST SCREEN LAYOUTS

APPENDIX H: ENVIRONMENTAL COMPLIANCE

HAZARDOUS MATERIAL (HAZMAT):

SAFETY DATA SHEET (SDS) AND LABELING:

HAZARDOUS WASTE:

DISCHARGES:

OFF-SITE DISCHARGES:

SPILLS:

ENVIRONMENTAL TRAINING:

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1. SCOPE OF WORK:

1.1. Scope:

1.1.1. This Statement of Work (SOW) establishes the minimum requirements for the purchase, delivery, and installation of one (1) Altitude Chamber Test Stand Upgrade with equipment and accessories specified herein; and training on the maintenance, calibration, programming, and use of test stand. The test stand shall be used to test B-52, C-5, C-130, KC-135, E-3, F-15, and F-16 Cabin Air Pressure Control Valves as required and per relevant Technical Orders (T.O.’s) instructions. The overall project shall be considered “turnkey” type procurement.

1.1. Background:

1.1.1. The test stand described in this document is intended for use in the Aerospace

Repair Industry. The equipment shall be installed in the same industrial footprint as existing Altitude Chamber Test Stand operating in Building 200, room 188 of Tinker Air Force Base (TAFB) OK 73145-5990. This shop operates on an 8 hour basis, Monday through Friday, with possible overtime hours Monday through Saturday.

2. APPLICABLE DOCUMENTS AND DEFINITIONS:

The contractor, at a minimum, is required to comply with the current editions of the following requirements for design, construction, installation and safety as applicable. The term “most recent edition” shall be understood to mean, “most recently released edition as of date of issuance of contract.”

2.1. Government Standards:

The following documents form a part of this purchase description to the extent stipulated herein.

2.1.1. U.S. DEPARTMENT OF LABOR

2.1.1.1. 29 CFR 1910 – General Industry, OSHA Safety and Health Standards (29 CFR 1910), 2010 or most recent edition (available at http://www.osha.gov/). Application for copies should be addressed to the U.S. Department of Labor, 200 Constitution Ave, Washington, D.C.

20210)

2.1.2. ENVIRONMENTAL PROTECTION

http://www.osha.gov/

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2.1.2.1. 40 CFR 82 – Protection of Stratospheric Ozone, 2010 or most recent edition. (Application for copies should be addressed to the U.S.

Department of Labor, 200 Constitution Ave, Washington, D.C. 20210)

2.1.2.2. Tinker Air Force Base (TAFB) Supplement to Air Force Instruction (AFI) 32-7086, “Hazardous Materials Management”, Tinker AFB procedures per Tinker Air Force Base Instruction (TAFBI) 32-7004, “Hazardous Waste Management”, and Complex procedures per Oklahoma City Air Logistics Complex (OC-ALC) Sup to AFI 32-7086, “Hazardous Material Management” and OC-ALCI 32-101 “Air Quality Record Keeping Procedure”. Publications are available digitally on e- Publishing website at www.e-publishing.af.mil for downloading or ordering.

2.1.3. FEDERAL STANDARDS

2.1.3.1. FED-STD-H28A – Screw Thread Standards for Federal Services, 1994

(R2001) or most recent edition

2.1.3.2. FED-STD-H28/21B – Screw Thread Standard for Federal Service, Metric Screw Threads, 1984 (R2006) or most recent edition

2.1.3.3. (Application for copies should be addressed to Superintendent of

Documents, Government Printing Office, Washington, D.C. 20402-001).

2.2. Non-Government Standards:

The following documents form a part of this document to the extent stipulated herein.

2.2.1. NATIONAL FIRE PROTECTION ASSOCIATION (NFPA)

2.2.1.1. NFPA 1 – Fire Code, 2010 edition or most recent edition

2.2.1.2. NFPA 70 – National Electrical Code, 2014 edition

2.2.1.3. NFPA 70E – Standard for Electrical Safety in the Workplace, 2011 edition or most recent edition

2.2.1.4. NFPA 79 – Electrical Standards for Industrial Machinery, 2007 or most recent edition

2.2.1.5. (application for copies should be addressed to National Fire Protection Association, 1 Batterymarch Park, Quincy, MA 02169) http://www.e-publishing.af.mil/

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2.2.2. TELECOMMUNICATIONS INDUSTRY ASSOCIATION (TIA)

STANDARD

2.2.2.1. EIA/TIA-232-F – Interface Between Data Terminal Equipment and Data

Circuit-Terminating Equipment Employing Serial Binary Data Interchange, 1997 (R 2002) or most recent edition

2.2.2.2. (Application for copies should be addressed to IHS International Inc., http://www.ihs.com, or call 1-800-854-7179 for U.S. and Canada)

2.2.3. NATIONAL ELECTRICAL MANUFACTURERS ASSOCIATION

2.2.3.1. NEMA MG 1 – Motors and Generators, 2009 (R2010) or most recent edition

2.2.3.2. NEMA ICS 6 – Industrial Control and Systems: Enclosures, 1993

(R2006) or most recent edition

2.2.3.3. (Application for copies should be addressed to National Electrical Manufacturers Association, 1300 N 17th Street, Suite 1752, Rosslyn, VA 22209)

2.2.4. AMERICAN NATIONAL STANDARD INSTITUTE

2.2.4.1. ASTM SI 10 – American National Standard for use of the International

System of Units (SI): The Modern Metric System, 2010 or most recent

2.2.4.2. (Application for copies should be addressed to American National

Standards Institute, Attn: Sales Department, 1430 Broadway, New York, NY 10018-3363)

2.2.5. AMERICAN WELDING SOCIETY INC (AWS)

2.2.5.1. AWS D14.4 – Specification for Welded Joints in Machinery and

Equipment, 1997 or most recent edition

2.2.5.2. (Applications for copies should be addressed to the American Welding Society, Inc. 550 North LeJeune Road, Miamie, FL 33126)

2.2.6. INTERNATIONAL ORGANIZATION FOR STANDARDIZATION

http://www.ihs.com/

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2.2.6.1. ISO 4413 – Hydraulic Fluid Power – General Rules and Safety Requirements for Systems and Their Components, 2010 or most recent

2.2.6.2. ISO 10816-3 – Mechanical Vibration – Evaluation of machine vibration by measurement of non-rotating parts, 2009 or most recent edition.

2.2.6.3. (Application for copies should be addressed to International Organization for Standardization, 1, ch. de la Voie-Creuse, Case postale 56, CH-1211 Geneva 20, Switzerland, e-mail central@iso.ch or IHS International Inc., http://www.ihs.com, or call 1-800-854-7179 for U.S. and Canada)

2.3. Order of Precedence:

2.3.1. In the event of a conflict between the test of this specification and the references cited herein, the test of this specification takes precedence. Nothing in this document, however, supersedes applicable laws and regulations unless a specific exception has been obtained.

3. REQUIREMENTS:

3.1. General:

3.1.1. The Contractor shall complete all work associated with this Statement of Work no later than twenty-four (24) months of contract award date.

3.1.2. In the event of conflicting requirements between this Statement of Work and the acceptance tested end item Technical Order test requirements, the Contractor shall provide for the stricter requirement.

3.1.3. The Altitude Chamber test stand utilizes a high volume high vacuum source and a low pressure high volume positive air pressure source to simulate aircraft altitudes from 5,000 feet below sea level to 60,000 feet above sea level.

3.1.4. The Contractor shall demonstrate a knowledge of and experience in pneumatic theory and design, software design and integration, and requirements outlined in Section 8.6 of this SOW.

3.1.5. The Altitude Chamber Test Stand upgrade shall be new and unused, not prototype, and shall be based upon the design of the existing stand.

3.1.6. All Altitude Chamber test stand components shall be available as commercial off the shelf (COTS) items.

mailto:central@iso.ch http://www.ihs.com/

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3.1.7. All items requiring calibration shall be listed in AFMETCAL as approved devices.

3.1.8. Software assurance shall be designed into the software and shown as part of the Software Acceptance Test Procedure.

3.1.9. The USAF shall have unlimited right or all technical data and non-COTS software developed for this effort. All non-COTS source code and technical data developed shall be delivered along with the COTS licenses at the end of the contract.

3.1.10. The Altitude Chamber Test Stand upgrade is required to perform final acceptance testing on military aircraft end item Cabin Air Pressure Regulators, Cabin Pressure Safety Valves, Cabin Pressure Relief Valves, and Cabin Air Pressure Outflow Valves. The test stand upgrade shall be capable of testing the end items listed in Appendix D in accordance with the required end item Air Force (AF) Technical Orders (T.O.) listed in Appendix D.

3.1.11. No manuals exist that identify the mechanical and electrical configurations for the stand. The Contractor shall use the solicitation site visit to correctly identity the configurations.

3.1.12. The Contractor may request the Contracting Officer (CO) provide a copy of photos taken during site visits. The request shall be by e-mail. The Contractor shall not disclose the data provided for any purpose or in any manner not specifically authorized or required by this SOW or the contract.

3.1.13. Dimensional Systems: U.S. Customary System of Units (US) shall be used in the design and construction. In this specification, all measurements, dimensions, sizes, and capacities are given in the U.S. Customary System of Units (US).

3.1.14. Measuring/Indicating Devices: All measuring and indicating devices, such as dial indicators, pressure gages, temperature indicators, depth stops, and other similar devices used on the machine, shall be in the SI unit system. Marking on all measuring and indicating devices shall be permanently and legibly engraved or etched on a non-glare background. All dials and other type indicating devices shall be securely mounted in place. Such devices shall be located to allow reading from the operator’s normal workstation.

3.1.15. Safety and Health: Covers, guards and other safety devices shall be provided for all parts of the machine that present safety hazards. The safety devices shall not interfere with the operation of the machine. The safety devices shall prevent unintentional contact with the guarded part and shall be removable to

SOW – 2017 – ALTITUDE CHAMBER TEST STAND UPGRADE Page 9 facilitate inspection, maintenance and repair of the parts. All machine parts, components, mechanisms and assemblies furnished on the machine shall comply with all the requirements of 29 CFR 1910.

3.1.16. Caution–Warning Plates: Corrosion resistant “Caution” or “Warning” Plates shall be securely attached to the equipment in visible locations with any safety precautions to be observed by the operator or maintenance personnel permanently marked on the plates.

3.1.17. Chemicals:

3.1.17.1. The Contractor shall furnish to the Government POC a list of all chemicals used in conjunction with installation and maintenance of the equipment, and their Safety Data Sheets (SDS) 90 days prior to delivery of equipment. If time frame specified does not match with expected delivery schedule, then the Contractor shall propose an alternate schedule that makes delivery of chemical information to the Government prior to installation with a minimum of 4 weeks for review of the data and comments by all interested Government parties. If necessary, the delivery of the equipment shall be delayed to allow for the chemical review and comment period. Additional delivery delays may be required if the Government requests alternative chemicals. The Contractor shall submit this proposed schedule at time of contract award for Government approval.

3.1.17.2. The Contractor shall furnish all chemicals required for the installation and start-up of the Altitude Chamber test stand. All other fluids required prior to test stand acceptance shall be provided by the Contractor and properly disposed of by Contractor following acceptance.

3.1.17.3. The government reserves the right to reject use of any chemicals and request alternative(s) be proposed for completion of the installation.

3.1.17.4. Proper use, storage and removal of any chemical required during commissioning of test stand shall be coordinated with the Tinker Unit Environmental Coordinator (UEC). UEC info will be made available to Contractor by Government POC, as needed.

3.1.18. Prohibited Materials:

3.1.18.1. Mercury restriction: The machine shall contain neither mercury nor mercury compounds, or be exposed to free mercury during manufacture.

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3.1.18.2. Asbestos restriction: Asbestos and materials containing asbestos shall not be used on or in the machine.

3.1.18.3. Polychlorinated Biphenyl (PCB) restriction: The use of polychlorinated biphenyl on or in the machine is prohibited.

3.1.18.4. Lithium restriction: Lithium batteries used in the computer system are exempt from this requirement.

3.1.19. ODC Restrictions: Class I ozone depleting substances in accordance with section 602(a) of the Clean Air Act Amendments 1990, 42 USC 7671a(a) as implemented by 40 CFR 82 Protection of Stratospheric Ozone, shall not be contained within or used on this equipment.

3.1.20. Environmental Protection and Safety:

3.1.20.1. The Contractor shall be knowledgeable of and comply with all applicable federal, state and local laws, regulations, instructions and requirements regarding environmental protection and occupational safety and health.

The Contractor shall comply with any laws, instructions or regulation changes during the term of this contract.

3.1.20.2. Contractors shall be compliant with instructions, publications and supplements listed in section 2.1.2.

3.1.21. Other Environmental Compliance: Contractor shall comply with all environmental requirements as stipulated in Appendix H.

3.1.22. Identification/Instruction Plates: All words on instruction and/or identification plates shall be in the English language. The plate(s) shall be corrosion resistant and securely affixed to the test stand. The words and numbers shall be engraved, etched, embossed or stamped in boldface print on a contrasting background. Lettering shall be a minimum of 18-point font and the plates shall be sized accordingly to accommodate all standard text in this point size.

3.2. Design and Construction:

3.2.1. The current Altitude Chamber Test Stand utilizes a vacuum source at 2.14 inches of mercury absolute (in-hg-abs) and 4500 actual cubic feet per minute (acfm) and a pressure source at 7 pounds per square inch gage (psig) and 1000 acfm. These systems, combined with low pressure pneumatic and electrical systems, are required to provide performance testing of the end items.

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3.2.2. The Contractor shall list major functional components by make and model, cut sheets, and expected operation life of components. Major functional components at a minimum shall include valves, pneumatic control system, transducers, encoders, motors, software packages, PLC’s, computers, computer peripherals, power sources, controllers, and meters.

3.2.3. Construction:

3.2.3.1. The Altitude Chamber test stand shall be constructed of parts that are new, without defects, commercial-off-the-shelf (COTS), and free of repairs.

3.2.3.2. Quality of materials used in construction shall be equivalent to or superior than those used in construction of the existing Altitude Chamber test stand located in building 200.

3.2.3.3. Metals shall be of corrosion resistant materials unless suitably protected to resist corrosion.

3.2.3.4. The construction of stand shall include all components, parts and features necessary to meet the performance requirements specified herein. The machine shall be capable of withstanding all forces encountered during operation of the machine at its maximum rating and capacity without distortion or failure. All parts subject to damage from environmental hazards shall be sealed or otherwise protected.

3.2.3.5. Welding, plugging, or filling with solder or paste shall not be employed as repair or reclamation measures for defective parts.

3.2.3.6. All screws, pins, bolts and similar parts shall be installed with means of preventing loss of tightness.

3.2.3.7. All parts subject to removal or adjustment, shall not be swaged, peened, staked or otherwise permanently deformed.

3.2.4. Castings and Forgings: All castings and forging shall be free from defects, scale or mismatching. Processes such as welding, peening, plugging, or filling with solder or paste shall not be used on casting and forgings for reclaiming any parts of the machine. Such processes may only be used for enhancing surface finish and appearance.

3.2.5. Welding, brazing and soldering: Welding, brazing or soldering shall be employed only where those operations are included in fabrication of the original design. These operations shall not be employed as repair or reclamation measures for defective parts. Any excess material used for such

SOW – 2017 – ALTITUDE CHAMBER TEST STAND UPGRADE Page 12 operations shall be thoroughly removed from the part(s) upon completion of the operations. Weldments shall comply with AWS D14.4.

3.2.6. Surface Finish: All surfaces of castings, forgings, molded parts, stampings and welded parts shall be clean and free from sand, dirt film, sprues, flash, scale flux and other harmful or extraneous materials. External surface edges shall be either rounded or beveled unless sharpness is required to perform a necessary function. Except as otherwise specified herein, the condition and finish of all surfaces shall be commensurate with the manufacturer’s standard commercial practice.

3.2.7. Gears: All gears and pinions, if applicable, shall be designed and manufactured of a suitable ferrous material with proper width and size to transmit full-rated torque and horsepower throughout the speed ranges without failure for the expected service life of the machine.

3.2.8. Painting: Test stand shall be painted Air Force Blue or equivalent. Yellow or orange safety color-coding shall be used for designated physical hazards.

3.2.9. Screw Threads: All threaded parts used on the machine and its related attachments and accessories shall conform to FED-STD-H28 or FED-STD- H28/21B.

3.2.10. Interchangeability: To provide for replacement of worn parts, all parts bearing the same part number shall be functionally interchangeable and dimensionally identical within the manufacturer’s tolerance limits. Records, including detailed parts drawings, shall be maintained by the equipment supplier by part number throughout the life of the equipment in order than any replacement part can be supplied to the customer.

3.2.11. Maintainability: The machine shall be designed and constructed to permit effective maintenance. The machine shall be equipped with access covers (if applicable) to facilitate inspection, cleaning, repair, and replacement of parts.

3.2.12. Lubrication: Means shall be provided to insure adequate automatic lubrication for all moving parts. Recirculating systems shall include filters which are cleanable or replaceable. Each lubricant reservoir shall have visible or mechanical means for determining fluid level. All oil holes, grease fittings and filler caps shall be accessible. Parts consuming fluids shall be clearly identified as such along with the recommended periods of additions and the type of fluid that should be used.

3.2.13. Altitude Chamber Test Stand Components:

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3.2.13.1. The current Altitude Chamber Test Stand consists of two (2) 7.5-foot diameter by 12.5 feet long pressure chambers (Chamber 1 and Chamber 2), control valves, seven (7) orifice flow sections, an operator console, a climate controlled operator console enclosure, and interconnect piping.

3.2.13.2. The Contractor shall remove the existing 120 VAC duplex outlet and provide two (2) new 120 VAC quadplex outlets ergonomically located within range of the technician(s) standard location. One quadplex shall be located on each side of operator console.

3.2.13.3. The Contractor shall relocate the 120 VAC light switches for the operator console lights and altitude chamber lights to a location above the operator console work surface.

3.2.13.4. The Contractor shall remove the existing 28 VDC connections from the operator console.

3.2.13.5. The Contractor shall remove the existing 115 VAC 400 Hz connections from the operator console.

3.2.13.6. The Contractor shall Remove the existing surface fluorescent light fixture in the climate controlled operator console enclosure. The Contractor shall provide at least two (2) new surface mount high efficiency 4 foot LED or 4 bulb fluorescent light fixtures for the climate controlled operator console enclosure as sufficient for appropriate visibility. The light fixtures shall be capable of a minimum of two (2) brightness levels controlled by a light switch.

3.2.13.7. Contractor shall provide new sealing gaskets and shall restore the mating door surface of the exterior doors on Chamber 1 and Chamber 2 to ensure leak free sealing. The contractor shall provide mechanisms to ensure the four (4) latches on each door shall engage at the same time without any other latches inadvertently releasing during setup and depressurization and pressurization test cycles. The Contractor shall not weld or drill into the existing Chamber doors.

3.2.14. Emergency Stops:

3.2.14.1. The Contractor shall provide a minimum of six (6) emergency stop buttons.

3.2.14.2. One (1) shall be located inside the cabin side of each of the test chambers, one (1) shall be located inside the altitude side of each of the test

SOW – 2017 – ALTITUDE CHAMBER TEST STAND UPGRADE Page 14 chambers, one shall be located on the right side of the operator console, and one shall be located on the left side of the operator console.

3.2.14.3. The emergency stop buttons shall remove all power from the system and relieve all pressures in the test chambers.

3.2.14.4. The Contractor shall provide new sirens and warning lights for the emergency stops. Siren(s) shall sound when the four (4) emergency stop buttons located in Chambers are pressed. The two (2) emergency stop buttons in the Operator Console shall not sound the sirens

3.2.14.5. One (1) siren and warning light shall be mounted on each test chamber.

The siren shall be UL listed to standard 464 (60G3). The siren shall have a minimum sound rating of 100 dB(A) based on UL Standard 464. The siren and lights shall be rated for outdoor use.

3.2.14.6. All emergency stops shall be hard wire controlled.

3.2.15. Labeling/Identification:

3.2.15.1. The Contractor shall provide new labeling of all the operator interfaces to be in accordance with section 3.1.21.

3.2.15.2. The test stand shall be equipped with labels on the front test panel which identify every air, and electrical connection point, valves, switches, gauges, indicators and instrumentation. The labels and mounting shall be resistant to the test fluid and not degrade as a result of exposure to the test fluid. The labels shall be fabricated in accordance with paragraph 3.1.21.

3.2.15.3. The test stand shall have a new nameplate affixed to the front upper right.

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 upgrade and contract number.

3.2.16. High Volume – High Vacuum System:

3.2.16.1. The Contractor shall provide and install new components for the existing high volume – high vacuum system.

3.2.16.1.1 The new components include orifice plate flow section assemblies, orifice plates, orifice plate flow section assembly flow control valves, pressure control valves, pressure transducers, temperature

SOW – 2017 – ALTITUDE CHAMBER TEST STAND UPGRADE Page 15 transducers, and interconnect wiring and tubing. The new components shall be utilized with a new Contractor provided data acquisition and control system. The control system shall have the capability to control the new system components as required to maintain the parameters necessary for testing the end items listed in Appendix D. The control system shall include all programming and data acquisition system hardware needed to work in conjunction with new system components to control the high volume – high vacuum circuits. All required modifications to the high volume – high vacuum system and all components shall comply with the latest version of ASME 31.1 Power Piping and ASME 31.3 Process Piping. All components shall be rated for the pressures.

3.2.17. High Volume – Low Pressure System:

3.2.17.1. The Contractor shall provide and install new components for the existing high volume – low pressure system.

3.2.17.1.1 The new components shall include isolation valves, pressure control valves, pressure transducers, temperature transducers and interconnect wiring and tubing. The new components shall be utilized with the new Contractor provided data acquisition and control system. The control system shall have the capability to control the new system components as required to maintain the parameters necessary for testing the end items listed in Appendix D. The control system shall include all programming and the data acquisition system hardware needed to work in conjunction with new system components to control the high volume low pressure circuits.

3.2.17.2. The Contractor shall provide controls that enable the operator to start and stop the high volume – low pressure system blower from the operator display.

3.2.17.1. The start/stop functions shall automatically start/stop the pressurization blower and open/close the supply (PSV_1) and bleed (PBV_1) valves.

The Contractor shall provide controls to ensure the supply (PSV_1) and bleed (PBV_1) valves are fully open before starting the pressurization blower.

3.2.17.2. All required modifications to the high volume – low pressure system and all components shall comply with the latest version of ASME 31.1 Power

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Piping and ASME 31.3 Process Piping. All components shall be rated for the maximum supply pressure.

3.2.18. Low Volume Pressure System:

3.2.18.1. The Contractor shall provide and install new components for the existing low volume pressure system.

3.2.18.2. The system components shall include isolation valves, pressure regulators, pressure transducers, and interconnect tubing to replace the existing manual controlled low volume pressure system. The Contractor shall provide one system for Chamber 1 and one system for Chamber 2.

3.2.18.3. The system shall be capable of displaying and controlling a set point pressure on the operator display. The system shall be capable of manual control using an encoder.

3.2.18.4. The Contractor shall use stainless steel tubing and fittings for all interconnections.

3.2.19. Orifice Plate Flow Section Assemblies:

3.2.19.1. The Contractor shall provide seven (7) new orifice plate flow section assemblies.

3.2.19.2. The orifice plate flow section assemblies shall be Daniel Simplex Orifice Plate Holders type or equivalent for nominal pipe sizes from 2 to 8 inches. The assemblies shall be capable of changing orifices by removing a top plate that secures and seals the orifice, orifice holder, and seals.

3.2.19.3. The orifice plate flow section assemblies shall be Daniel Junior Orifice

Plate Holders type or equivalent for nominal pipe sizes larger than 8 inches. The assemblies shall be capable of changing orifices by removing a top plate that secures and seals the orifice, orifice holder, and seals.

3.2.19.4. The orifice plate flow section assemblies shall be Daniel Orifice Flange

Union Plate Holders type or equivalent for nominal pipe sizes smaller than 2 inches.

3.2.19.5. The orifice plate flow section assemblies shall be steel.

3.2.19.6. The orifice flow sections shall be sized and configured according to the recommendations of the latest version ANSI/API 2530-92.

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3.2.19.7. The Contractor shall provide and install dedicated upstream pressure transducers and differential pressure transducers for pressure measurement of each flow section. The pressure transducers requirements are indicated in Appendix E. The pressure transducers shall be utilized for the flow calculations. The pressure transducers readings shall be capable of being displayed on the LCD screen.

3.2.19.8. The Contractor shall provide and install dedicated temperature sensors for temperature measurement for each flow section. The RTD requirements are indicated in Appendix E. The RTD shall be utilized for the flow calculations. The RTD readings shall be capable of being displayed on the LCD screen.

3.2.19.9. The Contractor shall provide one (1) each 10 inch nominal orifice plate flow section assembly.

3.2.19.10. The Contractor shall provide one (1) each 6 inch nominal orifice plate

3.2.19.11. The Contractor shall provide one (1) each 4 inch nominal orifice plate

3.2.19.12. The Contractor shall provide three (3) each 2 inch nominal orifice plate flow section assemblies.

3.2.19.13. The Contractor shall provide one (1) each 1 inch nominal orifice plate

3.2.20. Orifice Plates and Seals:

3.2.20.1. The Contractor shall provide spare orifice plates and seals.

3.2.20.2. The orifice plates and seals shall be designed to work with the Contractor provided orifice plate flow section assemblies.

3.2.20.3. The orifice plates shall be stainless steel.

3.2.20.4. The orifice plates shall be designed according to the recommendations of ANSI/API 2530-92. The orifice size certifications shall be furnished.

3.2.20.5. The Contractor shall provide two (2) each orifice plates with an orifice bore of 6.5625 inches for the 10 inch nominal orifice plate flow section assembly.

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3.2.20.6. The Contractor shall provide two (2) each orifice plates with an orifice bore of 3.6875 inches for the 6 inch nominal orifice plate flow section

3.2.20.7. The Contractor shall provide two (2) each orifice plates with an orifice bore of 2.0625 inches for the 4 inch nominal orifice plate flow section

3.2.20.8. The Contractor shall provide two (2) each orifice plates with an orifice bore of 1.1250 inches for one of the 2 inch nominal orifice plate flow section assembly.

3.2.20.9. The Contractor shall provide two (2) each orifice plates with an orifice bore of 0.6875 inches for one of the 2 inch nominal orifice plate flow

3.2.20.10. The Contractor shall provide two (2) each orifice plates with an orifice bore of 0.3750 inches for one of the 2 inch nominal orifice plate flow

3.2.20.11. The Contractor shall provide two (2) each orifice plates with an orifice bore of 0.1875 inches for the 1 inch nominal orifice plate flow section

3.2.20.12. The Contractor shall provide two (2) sets of spare seals for each orifice plate flow section assembly.

3.2.21. Tubing and Fittings:

3.2.21.1. All tubing shall be seamless stainless steel. All tubing shall be rated for the required maximum working pressure of the required highest end item test pressures and temperatures in a required circuit. All tubing and fittings shall comply with the latest version of ASME 31.1 Power Piping and ASME 31.3 Process Piping.

3.2.21.2. All fittings shall be stainless steel. All fittings shall be rated for the required maximum working pressure of the required highest end item test pressures and temperatures in a required circuit. All tubing and fittings shall comply with the latest version of ASME 31.1 Power Piping and ASME 31.3 Process Piping.

3.2.21.3. The Contractor shall replace all existing copper tubing with stainless steel tubing.

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3.2.21.4. The Contractor shall utilize compression type fittings.

3.2.21.5. The Contractor shall utilize tubing for all connections between all orifice plate flow section assemblies and pressure transducers. The Contractor shall utilize tubing for all connections between all pressure transducers and calibration ports.

3.2.21.6. All bulkhead pressure calibration ports shall be stainless steel. All calibration ports shall be supplied with caps.

3.2.22. Hoses:

3.2.22.1. All hoses shall be rated for the required maximum working pressure of the required highest end item test pressures and temperatures in a required circuit and utilize swivel Joint Industrial Council (JIC) 37 degree flare or Swagelok compression end connections. All hoses shall be labeled on each end with a metal band which indicates the maximum working pressure, size, material, material manufacturer, material manufacturer’s part number and length. All hose internal and external material shall be compatible with MIL-C-7024, Type II calibration fluid. All hoses shall comply with the latest version of the National Fluid Power Association, ASME 31.1 Power Piping and ASME 31.3 Process Piping.

3.2.23. Valves:

3.2.23.1. The Contractor shall replace all control valves in the existing system.

3.2.23.2. The Contractor shall provide two (2) each 24 inch nominal Chamber

Cabin Supply valves (CSV_1 for Chamber 1 and CSV_2 for Chamber 2).

The valves shall be open or closed and shall be controlled from the operator touchscreen display. The operator touchscreen display shall indicate open or closed.

3.2.23.3. The Contractor shall provide two (2) each 12 inch nominal Chamber

Atmosphere/Altitude Vacuum Control valves (VCV_1 for Chamber 1 and VCV_2 for Chamber 2). The valves shall be used for control.

3.2.23.4. The Contractor shall provide two (2) each 3 inch nominal Chamber Cabin to Ambient Low Flow Bleed Valves (BV3_1 for Chamber 1 and BV3_2 for Chamber 2). The valves shall be used for control.

3.2.23.5. The Contractor shall provide two (2) each 4 inch nominal Chamber Cabin to Ambient High Flow Bleed valves (BV4_1 for Chamber 1 and BV4_2 for Chamber 2). The valves shall be used for control.

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3.2.23.6. The Contractor shall provide one (1) each Pressure Control valve

(PCV_1). The valve shall be used for control.

3.2.23.7. The Contractor shall provide one (1) each Pressure Supply valve

(PSV_1). The valves shall be open or closed and controlled from the operator touchscreen display. The display shall indicate open or closed.

3.2.23.8. The Contractor shall provide one (1) each 2 inch nominal Pressure Bleed valve (PBV_1). The valves shall be open or closed and shall be controlled from the operator touchscreen display. The display shall indicate open or closed.

3.2.23.9. The Contractor shall provide one (1) each 2 inch nominal Flow Isolation valve (FIV_4). The valves shall be open or closed and shall be controlled from the operator touchscreen display. The display shall indicate open or closed.

3.2.23.10. The Contractor shall provide one (1) each 10 inch nominal Orifice Flow

Control Valve (FCV_1). The valve shall be used for control.

3.2.23.11. The Contractor shall provide one (1) each 6 inch nominal Orifice Flow Control Valve (FCV_2). The valve shall be used for control.

3.2.23.12. The Contractor shall provide one (1) each 4 inch nominal Orifice Flow

Control Valve (FCV_3). The valve shall be used for control.

3.2.23.13. The Contractor shall provide three (3) each 2 inch nominal Orifice Flow Control Valves (FCV_4A, FCV_4B, and FCV_4C). The valves shall be used for control.

3.2.23.14. The Contractor shall provide one (1) each 1 inch nominal Orifice Flow

Control Valve (FCV_4D). The valve shall be used for control.

3.2.23.15. All valves shall be rated for the required maximum working pressure of the required highest end item test pressures and temperatures in a required circuit. All valves shall comply with the latest version of the National Fluid Power Association, ASME 31.1 Power Piping and ASME 31.3 Process Piping.

3.2.23.16. All valves shall be rated for Class IV leakage.

3.2.23.17. All valves shall be motor or air actuated.

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3.2.23.18. All valves used for control shall be default programmed for automatic control, but shall be capable of automatic and manual control.

Automatic and manual control shall be selectable through the operator touchscreen display. The control loops shall be capable of being enabled and disabled by the operator touchscreen display and capable of indicating the state of the loop. Automatic control shall be through set points that are input by the operator on the touchscreen display. Manual control shall be by means of encoders on the operator console.

3.2.23.19. The Contractor shall provide programming to allow the operator to select the desired orifice flow control valves utilized for the orifice plate flow section assemblies. The programming shall ensure that only one flow control valve can be selected at any given time. Selection of an orifice flow control valve shall enable control of the selected valve and close all of the other flow control valves.

3.2.23.20. All valves used for control shall be equipped with positon feedback. The position percentage of all valves used for control shall be displayed on the service screens.

3.2.23.21. The Contractor shall provide a replacement for the current manual isolation valve for each of the two (2) Chambers H2O differential pressure transducers. The Contractor provided components shall ensure automatic isolation of each of the H2O transducers to prevent over pressurization.

3.2.23.22. All air actuated valves shall utilize the current facility instrument air. All air actuated valves shall be capable of operation on 90 psig. All piping, tubing, and connections for air actuated valves shall be stainless steel.

The contractor shall provide stainless steel ball type isolation valves at all branch lines. The contractor shall provide a dedicated supply tap for the air actuated valves at the facility 4 inch schedule 40 stainless steel instrument air supply line located approximately 40 feet from Altitude Chamber 1 at an elevation of approximately 18 feet.

3.2.24. Shop Air Pneumatic Control System:

3.2.24.1. The Contractor shall provide a new shop air pneumatic control system for the test stand. The control system shall have the capability to control the current and Contractor provided shop air pneumatic system components.

3.2.24.2. All interconnections shall utilize stainless steel tubing and fittings.

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3.2.24.3. All required modifications shall be rated for a minimum of one hundred fifty (150) PSIG working pressure at two hundred (200) degrees Fahrenheit unless otherwise noted. The pneumatic system and all components shall comply with the latest version of ASME 31.1 Power Piping and ASME 31.3 Process Piping.

3.2.25. Transducers:

3.2.25.1. Test Pressure Transducers:

3.2.25.1.1 The Contractor shall provide new pressure transducers for each test stand upgrade.

3.2.25.1.2 The test stand upgrade shall be equipped with new gauge and differential pressure transducers as required to perform all functional end item tests for the end items listed in Appendix D.

The transducers shall include, but not be limited to the pressure transducers listed in Appendix E. The transducers shall be rated for industrial conditions with built-in overload protection and utilize stainless steel construction for wetted parts.

3.2.25.1.3 The update response time shall be a minimum of 100 milliseconds.

3.2.25.1.4 Each pressure transducer shall be Highway Addressable Remote

Transducer (HART) capable or otherwise be capable of communicating with the host computer or Human-Machine Interface (HMI) utilizing a digital readout on the pressure transmitter.

3.2.25.1.5 Each pressure transducer shall be capable of setup and adjustment without additional equipment or tools. The setup and adjustment buttons or controls shall be located on the pressure transducer.

3.2.25.1.6 Each pressure transducer shall incorporate a display to enable setup and maintenance activities with the transmitter.

3.2.25.1.7 Each pressure transducer shall be rated for ten percent (10%) over pressurization from maximum designed working pressure of the system.

3.2.25.1.8 The Contractor shall provide automatic isolation to ensure the differential H2O pressure gage connected to the Cabin and Atmosphere/Altitude side of each chamber do not over pressurize.

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3.2.25.1.9 The contractor shall provide shutoff valves for calibration that isolate the test pressure transducers from the system. Removed.

3.2.25.1.10 All new pressure transducers shall be located in a NEMA 4 electrical enclosure on the south wall of the Operator Console enclosure. All interconnect tubing and fittings shall be stainless steel. All communication cables shall be routed in metal conduit.

3.2.25.1.11 The Contractor shall provide one spare test pressure transducer for each type provided.

3.2.25.2. Test Temperature Transducers:

3.2.25.2.1 The contractor shall provide new Resistance Temperature Detector (RTD) temperature transducers as required to perform all functional end item tests for the end items listed in Appendix D.

The transducers shall include, but not be limited to the temperature transducers listed in Appendix E.

3.2.25.2.2 The RTD temperature transducers shall be Tolerance Class A.

3.2.25.2.3 The contractor shall provide panel mount connections for calibration of the test temperature transducers. The connections shall be located in a NEMA 4 enclosure. All communication cables shall be routed in metal conduit.

3.2.25.3. Service Pressure Transducers:

3.2.25.3.1 The Contractor shall provide new service pressure transducers for the test stand upgrade. As a minimum, the service transducers shall include those listed in Appendix E. The pressure transducer accuracies shall be a maximum of ±1.0% of full scale and the range shall be as required to monitor the test stand and to performance test the end items listed in Appendix D. The transducers shall be rated for industrial conditions with built-in overload protection and utilize stainless steel construction for wetted parts.

3.2.25.3.2 The contractor shall provide shutoff valves for calibration that isolate the service pressure transducers from the system.

3.2.25.3.3 All service pressure transducers shall be located in a NEMA 4 electrical enclosure. All interconnect tubing and fittings shall be

SOW – 2017 – ALTITUDE CHAMBER TEST STAND UPGRADE Page 24 stainless steel. All communication cables shall be routed in metal conduit.

3.2.25.4. Service Temperature Transducers:

3.2.25.4.1 The temperature transducer accuracies shall be a maximum of ±3.0 degrees F. The temperature transducers shall be RTD type.

3.2.25.4.2 The contractor shall provide panel mount connections for calibration of the service temperature transducers. The connections shall be located in a NEMA 4 enclosure. All communication cables shall be routed in metal conduit.

3.2.25.5. Encoders:

3.2.25.5.1 The Contractor shall provide encoders for manual adjustment of the vacuum and pressure flow.

3.2.25.5.2 The contractor shall provide two (2) sets of encoders. One (1) set shall be for Chamber 1 and one (1) set shall be for Chamber 2.

3.2.25.5.3 The automatic or manual control option shall be selectable utilizing the operator touchscreen display. The operator shall have the ability to enable and disable the encoder loops from the touchscreen display.

3.2.25.5.4 The contractor shall provide encoders for manual control of the following valves and Chambers: VCV_1, BV3_1, BV4_1, PCV_1, FCV_1, FCV_2, FCV_3, FCV_4A, FCV_4B, FCV_4C, and FCV_4D for Chamber. VCV_2, BV3_2, BV4_2, PCV_1, FCV_1, FCV_2, FCV_3, FCV_4A, FCV_4B, FCV_4C, and FCV_4D for Chamber 2.

3.2.26. Power Supply:

3.2.26.1. DC Power Supply:

3.2.26.1.1 The Contractor shall provide two (2) new adjustable DC Power

Supplies for the test stand upgrade. One power supply shall be utilized for each Chamber.

3.2.26.1.2 The DC power supplies shall be capable of 0-300 VDC output.

The power supply shall be capable of delivering 5 amps at 300 VDC. The DC power supply shall have a maximum line

SOW – 2017 – ALTITUDE CHAMBER TEST STAND UPGRADE Page 25 regulation voltage of 20 mV from no load to full load, constant input voltage. The power supply shall have a maximum output ripple (rms, 300 kHz) of 30 mV and a maximum output noise (p-p, 20 MHz) of 200 mV. The power supply shall have a maximum transient response time of 4 ms. The power supply shall conform to UL publications UL61010-1, UL60950-1-(2nd Ed).

3.2.26.1.3 The DC power supplies output voltage shall be displayed on the operator touchscreen displays. The output voltage set point shall be adjustable from the operator touchscreen displays and shall be capable of enabling and disabling power to the end item from the operator touchscreen displays.

3.2.26.2. AC Power Supply:

3.2.26.2.1 The Contractor shall provide two (2) new adjustable AC Power

Supplies for the test stand upgrade. One power supply shall be utilized for each Chamber.

3.2.26.2.2 The adjustable AC power supplies shall be rated for a minimum of

1200 VA output. The power supplies shall be capable of a minimum output voltage range of 0 to 130 VACrms. The power output shall be single phase. The power supplies shall be capable of a minimum output sine wave frequency range of 50 to 450 Hz.

The power supplies shall be capable of a minimum voltage accuracy of plus or minus 0.3% and a minimum resolution of 0.1 Vrms. The maximum total harmonic distortion shall be less than 3% at 400 Hz. The power supplies shall have a minimum frequency accuracy of plus or minus 0.03% of the maximum frequency and shall be capable of a minimum resolution of 0.05 Hz. The power supplies shall be capable of operating within all required parameters with a single phase input voltage of 105 to 125 VAC and an input frequency of 47 to 63 Hz.

3.2.26.2.3 The AC power supplies output voltage and frequency shall be displayed on the operator touchscreen displays. The output voltage set point and frequency set point shall be adjustable from the operator touchscreen displays and shall be capable of enabling and disabling power to the end item from the operator touchscreen displays.

3.2.26.2.4 The Contractor shall remove the existing facility 115 VAC single phase 400 Hz facility power from the Altitude Chamber Test Stand.

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3.2.27. Data Acquisition:

3.2.27.1. The Contractor shall provide two (2) new data acquisition systems. One

(1) for Chamber 1 and one (1) for Chamber 2. Each system shall be standalone but have the ability to communicate to ensure only one chamber can be operated at any given time.

3.2.27.2. The Contractor shall use a computer with data acquisition cards and/or a programmable logic controller (PLC) for data acquisition system. The analog to digital converter shall be sixteen (16) bit or better. The data acquired shall be for automatically and manually controlling test parameters, calculating if the test results are pass/fail, displaying the data on the LCDs, and printing the test results to printer. The data acquisition system shall be capable of displaying all transducer inputs. The data acquisition system shall be capable of capturing the required maximum or minimum functional test parameters and displaying them on the LCD.

3.2.27.3. The minimum update response time of the data acquisition system shall be 100 milliseconds.

3.2.27.4. All computer components and computer data acquisition cards shall be mounted in a standard 19 inch rack mount enclosure with a minimum 4U height.

3.2.27.5. The Contractor shall ensure adequate ventilation of all computer components and PLC equipment.

3.2.27.6. The test stand shall use only a PLC or computer controller for all control loops.

3.2.27.7. The Contractor shall provide one (1) each spare computer system with duplicate hardware, software, and programming.

3.2.27.8. The Contractor shall provide at least three (3) USB connections on the Control Module and at least three (3) USB connections of the service Module.

3.2.27.9. The Contractor shall provide two (2) each computer keyboards and two

(2) each computer mice

3.2.28. LCD Touch Screen Displays:

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3.2.28.1. The Contractor shall provide four (4) new LED touch screen displays for the test stand upgrade.

3.2.28.2. Each LED displays shall be touch screen, nineteen (19) inch minimum and capable of plus or minus eighty-five (85) degree wide side to side viewing angles with a minimum of one thousand twenty four by seven…