Pneumatic Test Cell Upgrade Statement of Work .pdf

SOW – Test Cell System Upgrade – 23 October 2020 Page 1 of 82

STATEMENT OF WORK

For

Test Cell System

Upgrade

H1TC02

FSC: 4920

NAICS: 334419

Dated 23 October 2020

Air Driven Accessories

Overhaul and Test Facility

Tinker A.F.B., OK 73145

Prepared by:

76 CMXG/MXDEA

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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, design requirements, delivery, installation, and verification of replacement data acquisition systems and supply piping upgrades for six (6) existing Test Cells with equipment and accessories specified herein; and training on the maintenance, calibration, programming, and use of the replacement systems. The Test Cell System is currently used to functionally test B-1, B-2, B-52, C-5, C-130, KC-135, E-3, F-15, F-16, and

F-22 high pressure high temperature air Control Valves as required per relevant Technical Order (T.O.) instructions.

1.2. Background

1.2.1. The Test Cell System described in this document are intended for use in the Aerospace Repair Industry. The Data Acquisition Systems shall replace the existing data acquisition systems. The current system is comprised of a computer with Windows 2000 operating system, Agilent data acquisition components, MicroMod controllers, and programming. High

Temperature/High Pressure supply piping modifications are required to provide increased productivity of the test process and longevity of the system. The Test Cell System is operated in Building 200 at Tinker Air

Force Base (TAFB) OK 73145.

1.2.2. Each of the six (6) Test Cells is composed of an Operator Console, Transmitter Enclosure, and Overhead Interface Bulkhead Enclosure. Each

Test Cell has a dedicated high pressure high temperature piping system located above the Test Cell connected to a main air supply. Three different piping systems are configured. One type utilizes a three (3) inch orifice flow section, one type utilizes a four (4) inch flow section, and one type utilizes a six (6) inch orifice flow section.

2. Requirements

2.1. General

2.1.1. Period of Performance: The Contractor shall complete all work associated with this Statement of Work no later than thirty-six (36) months of contract award date.

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2.1.2. The Contractor shall demonstrate a knowledge of and experience in pneumatic theory and design, and software design and integration.

2.1.3. The six (6) Test Cells shall include Test Cell 1, Test Cell 2, Test Cell 6, Test Cell 7, Test Cell 11, and Test Cell 12.

2.1.4. The Test Cell System upgrade shall be new and unused and shall be based upon the design of the existing Test Cells and this SOW.

2.1.5. All Test Cell System components shall be available as commercial off the shelf (COTS) items.

2.1.6. The Government shall have unlimited rights on 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.

2.1.7. The Contractor may request the Contracting Officer (CO) provide a copy of photos taken during any site visit. 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.

2.1.8. 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).

2.1.9. Chemicals:

2.1.9.1. 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 four (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.

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2.1.9.2. The Contractor shall furnish all chemicals required for the Test Cell

System Upgrade. All other fluids required prior to test stand acceptance shall be provided by the Contractor and properly disposed of by

Contractor following acceptance.

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

2.1.9.4. 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.

2.1.10. Prohibited Materials:

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

2.1.10.2. Asbestos restriction: Asbestos and materials containing asbestos shall not be used on or in the Test Cell System.

2.1.10.3. Polychlorinated Biphenyl (PCB) restriction: The use of polychlorinated biphenyl on or in Test Cell System is prohibited.

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

2.1.11. 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.

2.1.12. Environmental Protection and Safety:

2.1.12.1. 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.

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

2.1.14. 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.

2.2. Design and Construction:

2.2.1. The six (6) Test Cells are utilized to performance test overhauled military aircraft components. The Test Cells utilize high pressure high temperature air to simulate jet engine bleed air conditions. The test cells are designed for operation and control of 350 psig air at 1000 degrees Fahrenheit with flows ranging from 0.5 to 600 pound per minute. These systems, combined with low pressure pneumatic and electrical systems, are required to provide performance testing of the End Items.

2.2.2. The Government will provide the original drawings for viewing during any solicitation site visits for review.

2.2.3. The Government will provide a hard copy of the original drawings for the Test

Cell System to the Contractor after award of the contract. The Contractor shall be responsible for making a copy of the drawings and retuning the original drawings to the Government.

2.2.4. The Contractor shall be responsible for verifying the accuracy of the drawings for the purpose of the design and installation of the Test Cell System Upgrade.

2.2.5. Construction:

2.2.5.1. The Test Cell System Upgrade shall utilize components that are new, without defects, commercial-off-the-shelf (COTS), and free of repairs.

2.2.5.2. Quality of materials used in the upgrade shall be equivalent to or superior than those used in the existing Test Cells.

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2.2.5.3. The Test Cell System Upgrade shall include all components, parts and features necessary to meet the performance requirements specified herein.

2.2.6. Labeling/Identification:

2.2.6.1. The Contractor shall provide label tags for each of the new high pressure high temperature process air components. The tags for all process piping components shall be fabricated from stainless steel and the identifying number stamped or laser etched onto the tag. The tag shall be connected to the hardware utilizing stainless steel wire. The tags shall be a minimum of 0.75 inches high by 2 inches wide. The lettering shall be a minimum of 0.25 inches high.

2.2.6.2. The Contractor shall provide label tags for each of the Test Cell upgrade components. The labels shall be black phenolic with white lettering.

The tag shall be attached utilizing stainless steel wire. The tags shall be a minimum of 0.75 inches high by 2 inches wide. The lettering shall be a minimum of 0.25 inches high.

2.2.6.3. The Contractor shall provide a new nameplate affixed to the front upper right side of the Operator Console. 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.

2.2.7. High Temperature High Pressure Process Piping System

2.2.7.1. The Contractor shall upgrade each of the six (6) Test Cells to include one additional pressure control valve, one additional bleed control valve, and one additional exhaust silencer and ductwork. The existing piping schematic is shown in Figure 1.1. The upgraded system schematic is shown in Figure 1.2.

2.2.7.2. The Contractor shall install a second pressure control valve (PCV) with new stainless steel ANSI Class raised face weld neck flanges immediately downstream of the expansion joint for each of the six (6)

Test Cell upgrades. The flange ANSI Class rating shall match the existing control valve ratings. The new pressure control valves shall be identical to the existing Mark IX pressure control valves for each of the six (6) Test Cell upgrades as indicated in Tables 1.0, 1.1, 1.2, 1.3, 1.4, and 1.5. All required modifications to the system and all components

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ASME 31.3 Process Piping. All components shall be rated for a minimum 350 psig at 1000 degrees Fahrenheit.

2.2.7.3. The Contractor shall install a second new bleed control valve (BCV) with new stainless steel ANSI Class raised face weld neck flanges immediately downstream of the existing bleed control valve for each of the six (6) Test Cell upgrades. The flange ANSI Class rating shall match the existing control valve ratings. The new bleed control valve shall be identical to the existing bleed control valve for each of the six

(6) Test Cell upgrades as indicated in Tables 1.0, 1.1, 1.2, 1.3, 1.4, and

1.5. All required modifications to the 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 a minimum 350 psig at 1000 degrees Fahrenheit.

2.2.7.4. The Contractor shall provide and install a new dedicated silencer for connection to the bleed line for each of the six (6) Test Cell upgrades.

The silencer shall be constructed of stainless steel. The silencer shall have a 2 inch nominal pipe size inlet. The silencer shall be rated for 350 pipe inlet pressure. The silencer shall be rated for 200 pounds per minute (ppm) flow with a maximum 10 psig back pressure. The silencer shall be insulated. The sound level at 200 ppm shall be less than 90 dBA at 3 feet. The silencer shall connect to the existing facility exhaust plenum using stainless steel duct. The stainless steel duct shall be insulated. The Contractor shall provide required support for the silencer and ductwork. The contractor shall cut the existing bleed line approximately six (6) inches from the existing 10 inch exhaust pipe connection. The Contractor shall install a schedule 40 stainless steel cap on the two inch pipe. The Contractor shall modify the existing bleed line as required to connect to the silencer. The location of the new silencer shall not interfere with any of the existing piping system, process piping, electrical conduit, or wire ways located on the Test Cell

Mezzanine. All required modifications to the 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 a minimum 350 psig at 1000 degrees Fahrenheit.

2.2.7.5. All piping connections shall be welded. All welds shall comply with the latest version of ASME 31.1 Power Piping, ASME 31.3 Process Piping, ANSI/AWS Structural Welding Code D1.1, and ASME Section IX, part

QW.

2.2.7.6. The Contractor shall replace all flange gaskets connections for each of

SOW – Test Cell System Upgrade – 23 October 2020 Page 8 of 82 the six (6) Test Cell upgrades. The gaskets shall be high temperature high pressure spiral round gaskets rated for 350 psig at 1000 degrees

Fahrenheit. The gaskets shall be the designed for the ANSI Class flanges being utilized.

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Figure 1.1 – Existing Piping / Valve Schematic

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Figure 1.2 – Upgrade Piping / Valve Schematic

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2.2.7.7. Flange Bolts

2.2.7.7.1 The Contractor shall use threaded studs and nuts for all ANSI

Class flange connections. All studs and nuts shall conform to the latest version of ASTM A193.

2.2.7.7.2 All threaded studs shall be sized based on the ANSI Class flange connection hole diameter.

2.2.7.7.3 All threaded studs shall have a minimum of four threads exposed on each side of the flange nuts.

2.2.7.7.4 The Contractor shall not use hex head bolts.

2.2.7.8. Process Piping Insulation

2.2.7.8.1 The Contractor shall remove the existing black rubber piping insulation covering on each of the six (6) Test Cell upgrades.

The removal shall consist of the ambient and hot branch lines for each of the six (6) Test Cells starting at the main air supply line connections.

2.2.7.8.2 The Contractor shall provide and install new banded aluminum jackets to cover the pipe insulation exposed by the removal of the black rubber piping insulation cover.

2.2.7.8.3 The Contractor shall not install aluminum jackets on manual valves, control valves, orifice sections, or expansion joints.

2.2.7.9. Process Piping Valve and Joint Insulation Blankets

2.2.7.9.1 The Contractor shall provide new removable insulation blankets for all control valves, orifice sections, and expansion joints for each of the six (6) Test Cell upgrades.

2.2.7.9.2 The Contractor shall provide one inner and one outer insulation blanket for each of the control valves, orifice sections, and expansion joints.

2.2.7.9.3 The insulation blankets shall match the existing Test Cell insulation blanket material and construction utilizing stainless steel connectors and wire.

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2.2.7.9.4 The Contractor shall not insulate the ambient or hot manual isolation valves.

2.2.7.10. Flange Alignment

2.2.7.10.1 The Contractor shall remove the existing inlet flanges from the

Test Cell piping on Test Cells 2, 7, and 12 and install new stainless steel ANSI Class 600 slip joint flanges. The

Contractor stall ensure that the inlet and outlet Test Cell flanges are coplanar within plus or minus 0.5 degrees.

2.2.8. Test Cell Insulation

2.2.8.1. The Contractor shall provide sound deadening insulation in the existing ceiling strut channel for each of the six (6) Test Cell upgrades.

The existing strut channel is continuous and allows sound to transfer between cells.

2.2.8.2. The Contractor shall install the insulation on each side of the Test Cell ceiling at all locations the ceiling strut channel for each of the six (6)

Test Cell upgrades.

2.2.9. Orifice Plate Flow Sections

2.2.9.1. The Contractor shall provide new orifice plates and ring joint seals for each of the six (6) Test Cell upgrades.

2.2.9.2. The orifice plates and ring joint seals shall be stainless steel and designed to work with the existing orifice plate flow section assemblies.

2.2.9.3. The existing ring joint orifice assemblies are Crane ring joints with flange taps R45 Type 590 304SS Schedule 40.

2.2.9.4. The orifice plates shall be 0.25 inches thick square edged and beveled.

2.2.9.5. The orifice plates shall be designed according to the recommendations of

ANSI/API 2530-92. The Contractor shall provide the orifice certifications.

2.2.9.6. The Contractor shall provide two (2) each orifice plates with an orifice bore of 2.25 inches for the 4 inch nominal ring joint orifice plate flow section assembly for Test Cell 1.

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2.2.9.7. The Contractor shall provide two (2) each orifice plates with an orifice bore of 2.25 inches for the 4 inch nominal ring joint orifice plate flow section assembly for Test Cell 2.

2.2.9.8. The Contractor shall provide two (2) each orifice plates with an orifice bore of 1.250 inches for the 6 inch nominal ring joint orifice plate flow section assembly for Test Cell 6.

2.2.9.9. The Contractor shall provide two (2) each orifice plates with an orifice bore of 1.500 inches for the 6 inch nominal ring joint orifice plate flow section assembly for Test Cell 7.

2.2.9.10. The Contractor shall provide two (2) each orifice plates with an orifice bore of 3.250 inches for the 8 inch nominal ring joint orifice plate flow section assembly for Test Cell 11.

2.2.9.11. The Contractor shall provide two (2) each orifice plates with an orifice bore of 3.250 inches for the 8 inch nominal ring joint orifice plate flow section assembly for Test Cell 12.

2.2.10. Tubing and Fittings:

2.2.10.1. 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.

2.2.10.2. All fittings shall be stainless steel. All fittings shall be rated for 350 psig working pressure and 200 degrees Fahrenheit. All tubing and fittings shall comply with the latest version of ASME 31.1 Power Piping and

ASME 31.3 Process Piping.

2.2.10.3. The Contractor shall utilize compression or 37 degree flare Joint Industrial

Council (JIC) type fittings.

2.2.10.4. The Contractor shall not use push on fittings for any application.

2.2.11. Hoses:

2.2.11.1. All hoses shall be rated for 3050 psig working pressure and 200 degree

Fahrenheit temperatures and utilize swivel JIC 37 degree flare or compression end connections. All hoses shall be labeled on each end

SOW – Test Cell System Upgrade – 23 October 2020 Page 14 of 82 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 air. 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.

2.2.11.2. The Contractor shall not use plastic hose for any application.

2.2.12. Valves

2.2.12.1. The Contractor shall replace all manual and control valves in each of the six

(6) Test Cells in accordance with Tables 1.0, 1.1, 1.2, 1.3, 1.4, and 1.5.

2.2.12.2. The Contractor shall provide the valve quantities and valve models specified in in accordance with Tables 1.0, 1.1, 1.2, 1.3, 1.4, and 1.5.

The existing valves have been tested and proven. Identical replacement valves are required to ensure no additional testing or development is required to verify the test system. Identical replacement valves are required to maintain form, fit, and function of the six (6) Test Cell systems.

2.2.12.3. Any deviation from the specified valves shall require the Contractor to perform a piping stress analysis of the entire high piping system to ensure compliance with the requirements of ASME 31.1 Power Piping Code and

ASME B31.3 Process Piping Code. The Contractor shall provide all piping stress analysis documentation to the Government for approval.

2.2.12.4. The Government will approve any alternate valves.

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Table 1.0 – Test Cell 1 – High Pressure High Temperature Valves

Table 1.1 – Test Cell 2 – High Pressure High Temperature Valves

Table 1.2– Test Cell 6 – High Pressure High Temperature Valves

Valve ID Manufacturer Model Serial Number Size Signal Quantity

AISO-1 Flowserve Valdisc 162643.001-1 2 inch Manual 1

HISO-1 Flowserve Valdisc 162643.004-1 3 inch Manual 1

ACV-1 Flowserve Mark I 162643.008-1 2 inch 4–20 ma 1

HCV-1 Flowserve Mark I 162643.010-1 2 inch 4–20 ma 1

PCV-1 Flowserve Mark IX 162643.014-1 2 inch 4–20 ma 2

BCV-1 Flowserve MaxFlo 162643.023-1 2 inch 4–20 ma 2

AISO-2 Flowserve Valdisc 162643.001-2 2 inch Manual 1

HISO-2 Flowserve Valdisc 293573.001 3 inch Manual 1

ACV-2 Flowserve Mark I 162643.008-3 2 inch 4–20 ma 1

HCV-2 Flowserve Mark I 162643.010-3 2 inch 4–20 ma 1

PCV-2 Flowserve Mark IX 162643.014-2 2 inch 4–20 ma 2

BCV-2 Flowserve MaxFlo 162643.023-2 2 inch 4–20 ma 2

AISO-6 Flowserve Valdisc 162643.002-4 3 inch Manual 1

HISO-6 Flowserve Valdisc 162643.005-6 4 inch Manual 1

ACV-6 Flowserve Mark I 162643.007-3 3 inch 4–20 ma 1

HCV-6 Flowserve Mark I 162643.009-4 3 inch 4–20 ma 1

PCV-6 Flowserve Mark IX 186710.001-3 2 inch 4–20 ma 2

BCV-6 Flowserve MaxFlo 162643.025-2 2 inch 4–20 ma 2

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Table 1.3 – Test Cell 7 – High Pressure High Temperature Valves

Table 1.4 – Test Cell 11 – High Pressure High Temperature Valves

Table 1.5 – Test Cell 12 – High Pressure High Temperature Valves

AISO-7 Flowserve Valdisc 162643.002-5 3 inch Manual 1

HISO-7 Flowserve Valdisc 162643.005-7 4 inch Manual 1

ACV-7 Flowserve Mark I 162643.007-4 3 inch 4–20 ma 1

HCV-7 Flowserve Mark I 162643.009-5 3 inch 4–20 ma 1

PCV-7 Flowserve Mark IX 186710.001-4 2 inch 4–20 ma 2

BCV-7 Flowserve MaxFlo 162643.025-3 2 inch 4–20 ma 2

AISO-11 Flowserve Valdisc 162643.003-1 4 inch Manual 1

HISO-11 Flowserve Valdisc 162643.006-1 6 inch Manual 1

ACV-11 Flowserve Mark I 162643.007-5 3 inch 4–20 ma 1

HCV-11 Flowserve Mark I 162643.011-1 4 inch 4–20 ma 1

PCV-11 Flowserve Mark IX 162643.015-1 4 inch 4–20 ma 2

BCV-11 Flowserve MaxFlo 162643.026-1 2 inch 4–20 ma 2

AISO-12 Flowserve Valdisc 162643.003-2 4 inch Manual 1

HISO-12 Flowserve Valdisc 162643.006-2 6 inch Manual 1

ACV-12 Flowserve Mark I 162643.007-6 3 inch 4–20 ma 1

HCV-12 Flowserve Mark I 162643.011-2 4 inch 4–20 ma 1

PCV-12 Flowserve Mark IX 162643.015-2 4 inch 4–20 ma 2

BCV-12 Flowserve MaxFlo 162643.026-2 2 inch 4–20 ma 2

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2.2.13. Expansion Joints

2.2.13.1. The Contractor shall replace each of the high pressure high temperature piping expansion joints for each of the six (6) Test Cell Upgrades in accordance with Table 2.0.

2.2.13.2. The Contractor shall provide the expansion joint quantities and expansion joint drawing numbers specified in in accordance with Table 2.0. The existing expansion joints were utilized in the piping stress analysis and have been tested and proven. Identical replacement expansion joints are required to ensure no additional testing or development is required to verify the test system. Identical replacement expansion joints are required to maintain form, fit, and function of the six (6) Test Cell systems.

2.2.13.3. Any deviation from the specified expansion joints shall require the

Contractor to perform a piping stress analysis of the entire high pressure piping system to ensure compliance with the requirements of ASME 31.1

Power Piping Code and ASME B31.3 Process Piping Code. The

Contractor shall provide all piping stress analysis documentation to the

Government for approval.

2.2.13.4. The Government will approve any alternate expansion joints.

Test Cell Manufacturer Drawing Number Size Quantity

1 Senior Flexonics Pathway H84690-2 3 inch 1

2 Senior Flexonics Pathway H84690-2 3 inch 1

6 Senior Flexonics Pathway H84690-3 4 inch 1

7 Senior Flexonics Pathway H84690-3 4 inch 1

11 Senior Flexonics Pathway H84690-4 6 inch 1

12 Senior Flexonics Pathway H84690-4 6 inch 1

Table 2.0 – Expansion Joints

2.2.14. Air Pneumatic Control System

2.2.14.1. The Contractor shall replace existing stainless steel pneumatic control system interconnection stainless steel tubing for the new Pressure

Control Valves (PCV).

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2.2.14.2. All required modifications shall be rated for a minimum of 350 psig working pressure at 200 degrees Fahrenheit. The pneumatic system and all components shall comply with the latest version of ASME

31.1 Power Piping and ASME 31.3 Process Piping.

2.2.14.3. The Contractor shall provide new Proportion Air Controllers, Norgren regulators, and power supply for each of the Pressure Control Valves for each of the six (6) Test Cell upgrades. The new components shall be identical to the existing components.

2.2.14.4. The Contractor shall provide a new pneumatic control system for the additional Pressure Control Valve for each of the six (6) Test Cells.

The Contractor shall provide new Proportion Air Controllers, Norgren regulators, and power supplies for each of the additional

Pressure Control Valves for each of the six (6) Test Cell upgrades.

The Contractor shall provide and install a new NEMA 4 Enclosure to house the new components. The enclosure and mounting shall match the existing enclosure for the existing Pressure Control Valve.

2.2.15. Sensors, Transmitters, and Transducers

2.2.15.1. Pressure Transmitters

2.2.15.1.1 The Contractor shall provide new pressure transmitters for each of the six (6) Test Cell upgrades in accordance with Table 3.0. Table

3.0 indicates the quantity of pressure transmitters required for each Test Cell upgrade.

2.2.15.1.2 The Contractor shall provide new pressure transmitters for dedicated use with Flow Channel 2 for each of the six (6) Test

Cell upgrades in accordance with Table 3.1. The new pressure transmitters shall be mounted in the existing Transmitter

Enclosures. The Contractor shall provide number 4 male 37 degree flare JIC bulkhead pressure connections at the side of the

Overhead Interface Bulkhead Enclosure for each of the new pressure transmitters for each of the six (6) Test Cells. The

Contractor shall provide and install all interconnect hoses. The

Contractor shall provide programming and hardware for display on the LED display of the pressure transmitters.

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2.2.15.1.3 The Contractor shall provide a new pressure transmitter for each of the six (6) Test Cell upgrades in accordance with Table 3.2.

The new pressure transmitters shall be mounted in the existing

Transmitter Enclosures. The Contractor shall provide number 4 male 37 degree flare JIC bulkhead pressure connections at the side of the Overhead Interface Bulkhead Enclosure for each of the new pressure transmitters for each of the six (6) Test Cells. The

Contractor shall provide and install all interconnect hoses. The

Contractor shall provide programming and hardware for display on the LED display of the pressure transmitters.

2.2.15.1.4 Each pressure transmitter shall be rated for industrial conditions with built-in overload protection and utilize stainless steel construction for wetted parts.

2.2.15.1.5 The pressure transmitter update response time shall be a minimum of 100 milliseconds.

2.2.15.1.6 Each pressure transmitters shall be Highway Addressable

Remote Transmitter (HART) capable. Each pressure transmitter each shall be equipped with a digital readout on the pressure transmitter. The pressure transmitters shall be

Siemens SITRANS P series, Foxboro IAP10 and IGP10 series, GE RTX1000H series, or equivalent.

2.2.15.1.7 Each pressure transmitter 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 transmitter.

2.2.15.1.8 Each pressure transmitter shall be rated for a minimum of ten percent (10%) over pressurization from maximum designed working pressure.

2.2.15.1.9 The accuracy in Tables 3.0, 3.1, and 3.2 reflects the square root of the sum of the squares of the Non-Linearity, Hysteresis, and

Repeatability specifications of each transmitter.

2.2.15.1.10 The Contractor shall provide automatic isolation to ensure the

Low Differential Orifice H2O pressure transmitter (DPOAB) does not exceed 10% over pressurization.

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2.2.15.1.11 The Contractor may utilize the existing pressure transmitter’s air and electrical connections.

2.2.15.1.12 The Contractor shall provide a total of one each spare pressure transmitter for each transmitter listed in Table 3.0, 3.1, and 3.2.

2.2.15.2. Pressure Transmitter Relocation

2.2.15.2.1 The contractor shall relocate pressure transmitters EB, PGOA, DPOAA, and DPOAB from the current location in the Transmitter

Enclosure to the orifice section locations on the Test Cell mezzanine for each of the six (6) Test Cell upgrades.

2.2.15.2.2 The contractor shall provide and install a new NEMA 4 enclosure and support hardware for each of the six (6) Test Cells. The enclosures shall be located between 48 inches and 72 inches above the mezzanine finished floor.

2.2.15.2.3 The contractor shall provide electrical disconnects and mounting hardware designed for ease of removal and installation. The transmitters shall be capable of being be removed and temporarily installed in the Transmitter Enclosure for calibration. The transmitter shall be re-installed in the new enclosure for operation.

2.2.15.2.4 The Contractor shall provide all new wiring and air connections to the relocated pressure transmitters.

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Current

ID

Description Range Accuracy Quantity

Per Each

Test Cell

EB Pressure Transmitter 16-32 in HgA ±0.10% of Full Scale 1

PGOA Pressure Transmitter 0-350 psig ±0.10% of Full Scale 1

DPOAA Pressure Transmitter 0-240 in H2O ±0.10% of Full Scale 1

DPOAB Pressure Transmitter 0-24 in H2O ±0.10% of Full Scale 1

CPI-A Pressure Transmitter 0-350 psig ±0.10% of Full Scale 1

PG1 Pressure Transmitter 0-350 psig ±0.10% of Full Scale 1

PG2 Pressure Transmitter 0-350 psig ±0.10% of Full Scale 1

PG3 Pressure Transmitter 0-350 psig ±0.10% of Full Scale 1

PG4 Pressure Transmitter 0-350 psig ±0.10% of Full Scale 1

DP1 Pressure Transmitter 0-5 psid ±0.10% of Full Scale 1

DP2 Pressure Transmitter 0-30 psid ±0.10% of Full Scale 1

DP3 Pressure Transmitter 0-30 psid ±0.10% of Full Scale 1

DP4 Pressure Transmitter 0-30 psid ±0.10% of Full Scale 1

Table 3.0 – Existing Test Pressure Transmitters

ID Description

Range Accuracy Quantity

Per Each

Test Cell

PT-PGU-C2 Pressure Transmitter 0-350 psig ±0.10% of Full Scale 1

PT-DPOL-C2 Pressure Transmitter 0-24 in H2O ±0.10% of Full Scale 1

PT-DPOH-C2 Pressure Transmitter 0-240 in H2O ±0.10% of Full Scale 1

Table 3.1 – Flow Channel 2 Additional Pressure Transmitters

SOW – Test Cell System Upgrade – 23 October 2020 Page 22 of 82

ID Description Range Accuracy Quantity

Per Each

Test Cell

PT-PA1 Pressure Transmitter 0-50 in HgA ±0.10% of Full Scale 1

PT-PG5 Pressure Transmitter 0-150 psig ±0.10% of Full Scale 1

PT-DP5 Pressure Transmitter 0-5 psid ±0.10% of Full Scale 1

Table 3.2 – Additional Test Pressure Transmitters

2.2.15.3. Resistance Temperature Detector Sensors

2.2.15.3.1 The contractor shall provide new Resistance Temperature

Detector (RTD) temperature sensors in accordance with Tables

4.0 and 4.1 for each of the six (6) Test Cell upgrades. Tables 4.0 and 4.1 indicates the quantity of temperature sensors required for each Test Cell upgrade.

2.2.15.3.2 The RTD temperature sensors shall be Tolerance Class A.

2.2.15.3.3 The contractor shall provide panel mount connections for calibration of the test temperature transducers at the rear of the

Operator Console or in the Transducer Enclosure.

2.2.15.3.4 The contractor shall provide new transmitters for each RTD in

Tables 4.0 and 4.1 for each of the six (6) Test Cell upgrades.

2.2.15.3.5 The Contractor shall provide a total of three (3) spare RTD temperature sensors and transmitters.

2.2.15.3.6 The RTD/transmitters shall be capable of being displayed on the

End Item test screens.

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Current ID Temperature Sensor Range Quantity

COLD-1 RTD 0 – 1000 deg. F 1

HOT-1 RTD 0 – 1000 deg. F 1

BLND-1 RTD 0 – 1000 deg. F 1

TDCTP RTD 0 – 1000 deg. F 1

CONTP RTD 0 – 1000 deg. F 1

Table 4.0 – Existing Test Temperature Sensors

ID Temperature Sensor Range Quantity

BLND-2 RTD 0 – 1000 deg. F 1

Table 4.1 – Additional Channel 2 Test Temperature Sensor

2.2.15.4. Thermocouples

2.2.15.4.1 The Contractor shall provide hardware and software to connect the eight (8) existing J-Type thermocouple connections in the Overhead

Interface Bulkhead Enclosure in each of the six (6) Test Cell upgrades to the new data acquisition system.

2.2.15.4.2 The Contractors shall provide new transmitters for each of the eight

(8) J-Type Thermocouple connections in each of the six (6) Test

Cell upgrades.

2.2.15.4.3 The Contractor shall provide a total of six (6) spare transmitters.

2.2.15.4.4 The thermocouples/transmitters shall be capable of being displayed on the End Item test screens.

2.2.15.5. Operator Interface Control Panel

2.2.15.5.1 The Contractor shall provide a new operator interface control panel for each of the six (6) Test Cell upgrades.

2.2.15.5.2 The new operator interface panel be constructed utilizing a 5U rack mount enclosure.

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2.2.15.5.3 The Contractor shall provide eight (8) each encoders for automatic and manual control of pressure and temperature, DC voltage control, and manual bleed control for each of the six (6)

Test Cells. The encoders shall be BEI part number H20DB-25-

SS-1024-ABC-28V/V-EM16 or encoders with equivalent or better mechanical and electrical specifications. Alternate encoders shall be approved by the Government.

2.2.15.5.4 The operator interface control front panel shall be designed in accordance with Figure 2.0. The operator interface front panel shall utilize a minimum 1/8 inch thick unfinished brushed aluminum rack mount panel. Each operator interface control panel shall be labeled in accordance with Figure 2.0. The lettering shall be engraved in the panel. The lettering shall be identical to the existing operator interface panel. The engraved lettering shall be gloss black.

2.2.15.5.5 The panel design shall ensure that only the 1/4 inch encoder shaft and not the bearing housing protrudes through the operator interface panel.

2.2.15.5.6 The contractor shall provide and install a green LED light next to each encoder. The light shall be on when the encoder is active.

2.2.15.5.7 The “On” and “Off” buttons shall be momentary and have an internal light. The light shall be on when the button is in an active state.

2.2.15.5.8 The “Emergency Stop” button shall be a red mushroom type button with a twist or pull required to disengage. The button shall have an internal light. The light shall be on when the button is in an active state.

2.2.15.5.9 The contractor shall utilize ten (10) bulkhead connectors on the rear of the operator interface control panel. The connectors shall be Amphenol part number MS3102R16S-1P or equivalent.

The connectors shall be utilized for connection to the new data acquisition system.

2.2.15.5.10 The design shall duplicate the Government prototype.

2.2.15.5.11 The Contractor shall provide a total of eight (8) each spare encoders.

SOW – Test Cell System Upgrade – 23 October 2020 Page 25 of 82

Figure 2.0 – Operator Interface Control Panel Layout

2.2.16. Power Supplies

2.2.16.1. End Item DC Power Supplies

2.2.16.1.1 The Contractor shall provide one (1) each new DC power supply for each of the six (6) Test Cell upgrades. The power supplies shall be utilized for End Item testing.

2.2.16.1.2 The DC power supply shall be capable of 0-300 VDC output. The power supply shall be capable of delivering 16 amps at 300 VDC.

The DC power supply shall have a maximum line regulation voltage of 3 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. The power shall be mounted in the existing 19 inch rack Test

Cell console. The DC power supply shall be Ametek Programmable

Power Model SGX300X17C-0ASAR.

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2.2.16.1.3 The Contractor shall provide all necessary hardware for a rack mount installation in the Operator Console.

2.2.16.1.4 The Contractor shall remove the existing DC power supply and install the new DC power supply in place.

2.2.16.1.5 The Contractor shall modify existing wiring as required to connect to the new DC power supply.

2.2.16.1.6 The Contractor shall install blank panels and relocate existing components to ensure no gaps in the console.

2.2.16.1.7 The Contractor shall provide and install new hardware to measure the DC voltage supplied to the End Item. The range shall be between 0 and 320 VDC. The accuracy shall be 0.25% full scale.

2.2.16.1.8 The Contractor shall provide and install new hardware to measure the DC amperage supplied to the End Item. The Contractor shall provide hardware for three (3) ranges. The ranges shall be 0 to 500 milliamps, 0 to 5 amps, and 0 to 15 amps. Each shall have an accuracy of 0.25% full scale.

2.2.16.1.9 The DC power supply shall interface with the data acquisition system to enable the required voltage to be set and automatically controlled for End Item testing.

2.2.16.1.10 The Contractor shall provide a total of one (1) each spare DC

Power Supply.

2.2.16.2. Control DC Power Supplies

2.2.16.2.1 The Contractor shall provide one (1) each control DC power supply for each of the six (6) Test Cell upgrades.

2.2.16.2.2 The DC power supply shall connect to the existing wiring for control.

2.2.16.2.3 The DC power supply shall be capable of 0-40 VDC output. The power supply shall be capable of delivering 10 amps at 40 VDC.

The DC power supply shall have a maximum load regulation voltage of less than 0.01% of maximum output for a 90% load change. The power supply shall have a maximum output ripple less than 2 mVrms and a maximum output noise peak to peak of

10 mV. The power supply shall have a maximum transient response time of 50 ms. The power supply shall conform to UL

SOW – Test Cell System Upgrade – 23 October 2020 Page 27 of 82 publications UL61010-1. The power supply shall have front panel adjustment controls. The power supply shall have front readouts to display the output voltage and current simultaneously.

The power supply shall be mounted in the existing 19 inch rack

Test Cell console. The DC power supply shall be Ametek

Programmable Power Model XPH42-10.

2.2.16.2.4 The Contractor shall provide all necessary hardware for a rack

2.2.16.2.5 The Contractor shall remove the existing control DC power supply and install the new control DC power supply in place.

2.2.16.2.6 The Contractor shall modify existing wiring as required to connect to the new DC power supply.

2.2.16.2.7 The Contractor shall install blank panels and relocate existing

2.2.16.2.8 The Contractor shall provide a total of one (1) each spare control

DC Power Supply.

2.2.16.3. AC Power Supply

2.2.16.3.1 The Contractor shall provide one (1) AC Power Supply for each of the six (6) Test Cell upgrades. The power supply shall be utilized for

End Item testing.

2.2.16.3.2 The AC power supply shall be rated for a minimum of 500 VA output. The power supplies shall be capable of a minimum output voltage range of 5 to 400 VAC rms. The power output shall be single phase. The power supplies shall be capable of an adjustable minimum output sine wave frequency range of 16 to 1,200 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 0.06% of the maximum frequency and shall be capable of a minimum resolution of 0.1 Hz. The power supplies shall be capable of operating within all required parameters with a single phase input voltage of 100 to 125 VAC or 200 to 240 VAC and an input frequency of 47 to 440 Hz. The AC power supply shall be Ametek Programmable Power Model AST0501A1B-E000A0A.

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2.2.16.3.3 The Contractor shall provide all necessary hardware for a rack

2.2.16.3.4 The Contractor shall remove the existing AC power supply and install the new AC power supply in place.

2.2.16.3.5 The Contractor shall install blank panels and relocate existing

2.2.16.3.6 The Contractor shall provide and install new hardware to measure the AC voltage supplied to the End Item. The range shall be between 0 and 130 VAC. The accuracy shall be 0.25% full scale.

2.2.16.3.7 The Contractor shall provide and install new hardware to measure the AC frequency supplied to the End Item. The range shall be between 0 and 450 Hz. The accuracy shall be 0.25% full scale.

2.2.16.3.8 The Contractor shall provide and install new hardware to measure the AC amperage supplied to the End Item. The Contractor shall provide hardware for two ranges. The ranges shall be 0 to 500 milliamps and 0 to 5 amps. Each shall have an accuracy of 0.25% full scale.

2.2.16.3.9 The Contractor shall provide a total of one (1) each spare AC

Power Supply.

2.2.16.4. Vibration Sensor

2.2.16.4.1 The Contractor shall interface with one each (1) existing Bruel &

Kjaer accelerometer Part Number 4371V for each of the six (6)

2.2.16.4.2 The hardware shall provide for a minimum range of 0 to 15 G’s indication.

2.2.16.5. Speed Sensor

2.2.16.5.1 The contractor shall provide all required hardware and programming to interface with one each existing Honeywell Part

Number 901114-1-2 magnetic speed sensor for each of the six (6)

2.2.16.5.2 The hardware shall provide for a minimum range of 0 to 150,000 rpm indication.

SOW – Test Cell System Upgrade – 23 October 2020 Page 29 of 82

2.2.17. Emergency Stops:

2.2.17.1. The Contractor shall connect to the existing of three (3) emergency stop circuits.

2.2.17.2. The emergency stop buttons shall remove all power from the system identical to the current emergency stop functions.

2.2.17.3. All emergency stops shall be hard wire controlled.

2.2.17.4. All high pressure high temperature control valves shall close on activation of any emergency stop. All bleed valves shall open on activation of any emergency stop.

2.2.18. Data Acquisition

2.2.18.1. The Contractor shall provide one each (1) new data acquisition system for each of the six (6) Test Cell upgrades. Each system shall be standalone for each Test Cell upgrade.

2.2.18.2. The Contractor shall use a computer with data acquisition cards and/or a programmable logic controller (PLC) for the 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, displaying the test data on the LCDs, and printing the test screens to printer. The data acquisition system shall be capable of displaying all transmitter, sensor, and transducer inputs.

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

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

The motherboard of the computer shall be an ATX form.

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

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

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2.2.18.7. The Contractor shall provide three (3) USB connections on the

Operator Console and three (3) USB connections on the Transmitter

Console for each of the six (6) Test Cell upgrades.

2.2.18.8. The Contractor shall provide two (2) each computer keyboards, two (2) each computer mice, and two (2) computer mouse pads for each of the six (6) Test Cell upgrades.

2.2.18.9. The Contractor shall provide a total of one (1) each spare computer with duplicate components.

2.2.18.10. The Contractor shall provide eight (8) spare analog input channels for 4-

20 mA signals. The Contractor shall provide all wiring and terminals for connection to the inputs in the Transmitter Enclosure.

2.2.18.11. The Contractor shall provide eight (8) spare analog input channels for 0-

10 volt DC signals. The Contractor shall provide all wiring and terminals for connection to the inputs in the Transmitter Enclosure.

2.2.19. LED Touch Screen Displays

2.2.19.1. The Contractor shall provide two (2) each LED touch screen displays for each of the six (6) Test Cell upgrades.

2.2.19.2. 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 hundred sixty eight (1024 x 768) resolution. The displays shall have at a minimum seven hundred fifty to one (750:1) contrast ratio, seven hundred fifty (750) Nits brightness and lifetime of forty thousand

(40,000) hours. Each LED display shall be rack mountable for a standard nineteen (19) inch electronics cabinet.

2.2.19.3. One LED display shall be mounted in the Operator Console. The LED display shall be rack mountable for a standard nineteen (19) inch electronics cabinet and shall be capable of displaying the End Item test screens and calibration screens.

2.2.19.4. One (1) LED display shall be mounted in the Transmitter Enclosure in the Test Cell. The display will duplicate the Operator Console

Display.

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2.2.19.5. The Contractor shall not use panel mount displays.

2.2.19.6. The Contactor shall provide a total of two (2) each spare LED displays.

2.2.20. Printers

2.2.20.1. The Contractor shall provide one (1) each printer for each of the six (6)

2.2.20.2. The printer shall be capable of color printing with a minimum input paper tray size of 200 pages of 8-1/2 X 11 inch paper. The minimum ISO print speed for black and white shall be 8 pages per minute. The minimum ISO print speed for color shall be 6 pages per minute. The minimum print resolution shall be 600 x 600 dpi for both color and black and white. The manufacturer recommended monthly printed page volume shall be a minimum of 1500 pages. The printer shall have a Hi

Speed USB minimum 2.0 compatible connection.

2.2.20.3. The printer shall be located at the general location of the current Test Cell printer.

2.2.20.4. The Contractor shall modify the existing Operator Console to accommodate the printer. The modification shall include a rack mount enclosure for the printer to replace the current mount. The enclosure shall be fully open on the front to access the paper tray and printout. The enclosure shall have cutouts in the back to allow connection to power and communications. The enclosure shall be vented on the top, back, and sides for ventilation.

2.2.20.5. The printer shall be capable of printing the End Item test screens during

End Item testing or the standalone oscilloscope data during End item testing without switching printer cables. The Contractor shall provide all required hardware.

2.2.20.6. The Contractor shall provide one (1) each set of spare printer ink cartridges for each of the six (6) Test Cell upgrades.

2.2.20.7. The Contractor shall provide a total of one (1) each spare printer.

2.2.21. Cooling Fans

2.2.21.1. The Contractor shall replace the two (2) existing rack mount cooling fan units and filters for each of the six (6) Test Cell upgrades.

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2.2.21.2. The fan units shall consist of a rack mount support consisting of three (3)

4-12 inch fans on support for a total of six (6) fans per Test Cell upgrade.

The fans shall be manufacturer Middle Atlantic, model FAN. The fan mounts shall be manufacturer Middle Atlantic, model FP3. The fan guards shall be manufacturer Middle Atlantic, model GUARD. The filter shall be manufacturer Middle Atlantic, model FILTER. The interconnect cord shall be manufacturer Middle Atlantic, model

FANCORD-3X1. Equivalent components may be utilized. Equivalent components shall be equal or better to all mechanical and electrical specifications.

2.2.21.3. The filters shall be capable of being removed and shall be capable of being cleaned for reuse.

2.2.22. Power Distribution Units

2.2.22.1. The Contractor shall replace the two (2) each power distribution units for each of the six (6) Test Cell upgrades.

2.2.22.2. The Contractor shall provide two (2) each power distribution units for each of the six (6) Test Cell upgrades. The replacement units shall be manufacturer Pulizzi, model PC125-A-LTR or equivalent units.

Equivalent units shall be equal or better in all…