Revised SOW for Test Cell Upgrade.pdf

SOW – Test Cell System Upgrade Phase 2 – 16 July 2025 Page 1 of 106

STATEMENT OF WORK

For

Test Cell System Upgrade

Phase 2

H5TC04

FSC: 4920

NAICS: 334419

Dated 16 July 2025

Test Facility

Tinker A.F.B., OK 73145

Prepared by:

76 CMXG/MXDEA

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1. Scope of Work

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 existing Test Cell Pneumatic Test Console Systems or Test Cells with equipment and accessories specified herein, and training on the maintenance, calibration, programming, and use of the replacement systems. The Test Cell Systems are currently used to functionally test high pressure high temperature air control valves and turbines as required per relevant Technical Order (T.O.) instructions. The overall project shall be considered a whole and complete procurement, i.e. the project shall only be considered complete when final acceptance requirements have been met and approved by the appropriate Government POCs, and operational training has been conducted.

1.2. Background

1.2.1. The Test Cells 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 Cells are operated in at Tinker Air Force Base (TAFB) OK 73145.

1.2.2. Each of the 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. Two different piping systems are configured. Test Cells utilize a dual channel system that incorporates two separate and independent piping sources.

Test Cell utilize a single channel piping system. The size of the piping systems utilizes either a 4 inch or 6 inch piping 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 Test Cells to be upgraded shall include Test Cell , Test Cell , Test Cell , Test Cell , and Test Cell .

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

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 allowing 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 Test Cells are utilized for performance testing of 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. The original drawing is for reference only.

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 returning 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 to those used in the existing upgraded 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.

2.2.5.4. The Test Cell System Upgrades shall utilize identical data acquisition components, monitors, pressure transmitters, temperature transmitters, temperature sensors, power supplies, and programming languages based on the current upgraded Test Cells . Any deviations will require Government approval.

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 Pressure High Temperature Process Piping System

2.2.7.1. The Contractor shall upgrade each of the Test Cells to include one additional pressure control valve, one additional bleed control valve, one additional exhaust silencer and ductwork, and one plenum exhaust hood for each individual piping system for each upgrade. The existing piping schematics are shown in Figures 1.1 and 1.3. The upgraded system schematics are shown in Figures 1.2 and 1.4. The ‘- X’ in the valve identifying labels is replaced with the Test Cell Numbers. The ‘-YZ’ in the valve identifying labels is replaced with the Channel number for ‘Y’ and the upstream valve ‘A’ and

SOW – Test Cell System Upgrade Phase 2 – 16 July 2025 Page 7 of 106 downstream valve ‘B’ for ‘Z’. The programming identifying labels are shown in Appendix G. The Test Cell number is not required for programming, only the Channel number and upstream or downstream valve designation

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 individual piping systems for each of the 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 Test Cell upgrades as indicated in Tables 1.0, 1.1, 1.2, 1.3, and 1.4. 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.

2.2.7.3. 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 individual piping systems for each of the 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 Test Cell upgrades as indicated in Tables 1.0, 1.1, 1.2, 1.3, and 1.4. 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 individual piping systems for each of the 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 sound level at 200 ppm shall be less than 90 dBA at 3 feet. The silencer shall be Maxim Silencers part number VT1-14-4S1-13612. The silencer shall match the design of the existing upgraded Test Cells . The silencer shall be insulated and connected 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.

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The contractor shall cut the existing bleed line approximately inches from the existing 10-inch exhaust pipe connection. The Contractor shall install a schedule 40 stainless steel cap on the 2-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. Any deviations will require Government approval

2.2.7.5. The Contractor shall provide and install a dedicated stainless steel plenum exhaust hood for each of the individual piping systems for each of the Test Cell upgrades. The plenum exhaust hood shall match the design of the existing upgraded Test Cells . Any deviations will require Government approval.

2.2.7.6. 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.

2.2.7.7. The Contractor shall replace all flange gaskets at Contractor disconnections for each of the Test Cell upgrades. The gaskets shall be high pressure high temperature Flexitallic or equivalent spiral round gaskets rated for air at 350 psig and 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 – Single Channel

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Figure 1.2 – Upgrade Piping / Valve Schematic – Single Channel

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Figure 1.3 – Existing Piping / Valve Schematic – Dual Channel

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Figure 1.4 – Upgrade Piping / Valve Schematic – Dual Channel

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2.2.7.8. Flange Bolts

2.2.7.8.1 The Contractor shall replace all valve studs and nuts for all valves and expansion joints.

2.2.7.8.2 The Contractor shall use threaded studs and heavy hex nuts for all ANSI Class flange connections. All studs shall conform to the latest version of ASTM A193 and be ASTM Grade B7.

All heavy hex nuts shall conform to the latest version of ASTM A194 and be ASTM Grade 7.

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

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

2.2.7.8.5 The Contractor shall not use any grade hex head bolts.

2.2.7.9. Process Piping Insulation

2.2.7.9.1 The Contractor shall remove the existing black rubber piping insulation covering on each of the Test Cell upgrades.

The removal shall consist of the ambient and hot branch lines for each of the Test Cells starting at the main air supply line connections. The removal shall consist of the vertical inlet supply piping in each of the Test Cell.

2.2.7.9.2 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.

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

2.2.7.10. Process Piping Valve and Joint Insulation Blankets

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

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

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

2.2.7.10.4 The Contractor shall remove the existing black rubber piping insulation covering the vertical Test Cell Inlet Supply piping inside the Test Cell on each of the Test Cell upgrades.

2.2.7.10.5 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 on the Inline Supply piping for each of the Test Cell upgrades.

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

2.2.7.11. Silencer Insulation

2.2.7.11.1 The Contractor shall utilize aluminum foil coated insulation for all new insulation for the silencer and ductwork to the exhaust plenum.

2.2.7.11.2 The Contractor shall use material to match the configurations in the upgraded Test Cells .

2.2.8. Test Cell Sound Insulation

2.2.8.1. The Contractor shall provide sound deadening insulation in the existing ceiling strut channel for each of the 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 ceiling strut channel locations for each of the Test Cell upgrades. The Contractor shall ensure all voids in the ceiling strut channel are filled.

2.2.9. Orifice Plate Flow Sections

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

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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 four (4) each orifice plates with an orifice bore of 1.250 inches for the two (2) each 4-inch nominal ring joint orifice plate flow section assemblies for Test Cell .

2.2.9.7. The Contractor shall provide four (4) each orifice plates with an orifice bore of 2.250 inches for the two (2) each 4-inch nominal ring joint

2.2.9.8. The Contractor shall provide four (4) each orifice plates with an orifice bore of 3.000 inches for the two (2) each 6-inch nominal ring joint

2.2.9.9. The Contractor shall provide two (2) each orifice plates with an orifice bore of 3.000 inches for the 6-inch nominal ring joint orifice plate flow section assembly for Test Cell .

2.2.9.10. The Contractor shall provide two (2) each orifice plates with an orifice bore of 3.000 inches for the 6-inch nominal ring joint orifice plate flow section assembly for Test Cell .

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. The tubing size and routing configuration for the high pressure high temperature control valves and mezzanine control enclosure for each of the Test Cell upgrades shall match the upgraded Test Cells

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2.2.10.3. 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.

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

Council (JIC) type fittings.

2.2.10.5. 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 a minimum 350 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 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. Strainers

2.2.12.1. The Contractor shall remove all debris for the ambient and hot air line strainers located at the manual isolation valves for each of the Test Cell upgrades.

2.2.12.2. The Contractor shall provide new Flexitallic spiral wound ANSI class high temperature gaskets rated for air at 1000 deg. Fahrenheit. The gaskets shall be the designed for the ANSI Class flanges being utilized.

2.2.13. High Pressure High Temperature Valves

2.2.13.1. The Contractor shall replace all manual and control valves in each of the Test Cells in accordance with Tables 1.0, 1.1, 1.2, 1.3, and 1.4.

2.2.13.2. The Contractor shall provide the valve quantities and valve models specified in accordance with Tables 1.0, 1.1, 1.2, 1.3, and 1.4. The existing valves have been tested and proven. Identical replacement valves based on the current valve serial numbers are required to ensure

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Identical replacement valves are required to maintain form, fit, and function of the Test Cell systems. Valves in Tables 1.0, 1.1, 1.2, 1.3, and 1.4 and identified as ‘Replace’ are new replacement valves.

Valves in Tables 1.0, 1.1, 1.2, 1.3, and 1.4 and identified as ‘Add’ are new additional valves.

2.2.13.3. The Contractor shall ensure that all new Hot Control Valves (HCV) are equipped with fail close/air to open actuators. All HCV valves were originally configured with fail open/air to close actuators. The current operation of the HCV actuators is fail close/air to open.

2.2.13.4. 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. The Contractor shall provide performance testing of end items to verify the valve deviation meets or exceeds the original valve performance.

2.2.13.5. Any valve deviations will require Government approval.

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Table 1.0 – Test Cell – High Pressure High Temperature Valves

Valve ID Manufacturer Model Serial Number Size Signal Qty.

Channel 1

AISO-3-1 Flowserve Valdisc

Replace 162643.001-4

2 inch Manual 1

HISO-3-1 Flowserve Valdisc Replace 162643.004-5

3 inch Manual 1

ACV-3-1 Flowserve Mark I Replace 162643.008-5

2 inch 4–20 ma 1

HCV-3-1 Flowserve Mark I Replace 162643.010-5

2 inch 4–20 ma 1

PCV-3-1A Flowserve Mark IX Replace 186710.001-2

2 inch 4–20 ma 1

PCV-3-1B Flowserve Mark IX Add 186710.001-2

2 inch 4–20 ma 1

BCV-3-1A Flowserve MaxFlo Replace 162643.023-4

2 inch 4–20 ma 1

BCV-3-1B Flowserve MaxFlo New-Add 162643.023-4

2 inch 4–20 ma 1

Channel 2

AISO-3-2 Flowserve Valdisc

162643.001-4

2 inch Manual 1

HISO-3-2 Flowserve Valdisc Replace 8016204.001

3 inch Manual 1

ACV-3-2 Flowserve Mark I Replace 162643.008-4

2 inch 4–20 ma 1

HCV-3-2 Flowserve Mark I Replace 162643.010-4

2 inch 4–20 ma 1

PCV-3-2A Flowserve Mark IX Replace 292921.003

2 inch 4–20 ma 1

PCV-3-2B Flowserve Mark IX Add 292921.003

2 inch 4–20 ma 1

BCV-3-2A Flowserve MaxFlo Replace 162643.023-3

2 inch 4–20 ma 1

BCV-3-2B Flowserve MaxFlo Add 162643.023-3

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Table 1.1 – Test Cell – High Pressure High Temperature Valves

Valve Tag

ID

Manufacturer Model Serial

Number Size Signal Qty.

AISO-4-1 Flowserve Valdisc

162643.001-6

2 inch Manual 1

HISO-4-1 Flowserve Valdisc Replace 162643.004-7

3 inch Manual 1

ACV-4-1 Flowserve Mark I Replace 162643.008-7

2 inch 4–20 ma 1

HCV-4-1 Flowserve Mark I Replace 162643.010-7

2 inch 4–20 ma 1

PCV-4-1A Flowserve Mark IX Change and Replace 162643.014-1

2 inch 4–20 ma 1

PCV-4-1B Flowserve Mark IX Add 162643.014-1

2 inch 4–20 ma 1

BCV-4-1A Flowserve MaxFlo Replace 162643.024-2

2 inch 4–20 ma 1

BCV-4-1B Flowserve MaxFlo Add 162643.024-2

AISO-4-C2 Flowserve Valdisc

162643.001-5

2 inch Manual 1

HISO-4-C2 Flowserve Valdisc Replace 162643.004-6

3 inch Manual 1

ACV-4-2 Flowserve Mark I Replace 162643.008-6

2 inch 4–20 ma 1

HCV-4-2 Flowserve Mark I Replace 162643.010-6

2 inch 4–20 ma 1

PCV-4-2A Flowserve Mark IX Change and Replace 162643.014-1

2 inch 4–20 ma 1

PCV-4-2B Flowserve Mark IX Add 162643.014-1

2 inch 4–20 ma 1

BCV-4-2A Flowserve MaxFlo Replace 162643.023-4

2 inch 4–20 ma 1

BCV-4-2B Flowserve MaxFlo Add 62643.023-4

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Table 1.2– Test Cell – High Pressure High Temperature Valves

Valve ID Manufacturer Model Serial Number Size Signal Qty.

AISO-5-1 Flowserve Valdisc

162643.002-3

3 inch Manual 1

HISO-5-1 Flowserve Valdisc Replace 162643.005-5

4 inch Manual 1

ACV-5-1 Flowserve Mark I Replace 162643.007-2

3 inch 4–20 ma 1

HCV-5-1 Flowserve Mark I Replace 162643.009-3

3 inch 4–20 ma 1

PCV-5-1A Flowserve Mark IX Replace 186710.002-2

3 inch 4–20 ma 1

PCV-5-1B Flowserve Mark IX New-Add 186710.002-2

3 inch 4–20 ma 1

BCV-5-1A Flowserve MaxFlo Replace 162643.024-4

2 inch 4–20 ma 1

BCV-5-1B Flowserve MaxFlo Add 162643.024-4

AISO-5-2 Flowserve Valdisc

162643.002-2

3 inch Manual 1

HISO-5-2 Flowserve Valdisc Replace 162643.005-4

4 inch Manual 1

ACV-5-2 Flowserve Mark I Replace 162643.007-1

3 inch 4–20 ma 1

HCV-5-2 Flowserve Mark I Replace 162643.009-2

3 inch 4–20 ma 1

PCV-5-2A Flowserve Mark IX Replace 186710.002-3

3 inch 4–20 ma 1

PCV-5-2B Flowserve Mark IX Add 186710.002-3

3 inch 4–20 ma 1

BCV-5-2A Flowserve MaxFlo Replace 162643.024-3

2 inch 4–20 ma 1

BCV-5-2B Flowserve MaxFlo Add 162643.024-3

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Table 1.3 – Test Cell – High Pressure High Temperature Valves

Valve ID Manufacturer Model Serial

AISO-13-1 Flowserve Valdisc

162643.002-1

3 inch Manual 1

HISO-13-1 Flowserve Valdisc Replace 162643.005-1

4 inch Manual 1

ACV-13-1 Flowserve Mark I Replace 162643.007-7

3 inch 4–20 ma 1

HCV-13-1 Flowserve Mark I Replace 162643.009-1

3 inch 4–20 ma 1

PCV-13-1A Flowserve Mark IX Replace 162643.016

3 inch 4–20 ma 1

PCV-13-1B Flowserve Mark IX New-Add 162643.016

3 inch 4–20 ma 1

BCV-13-1A Flowserve MaxFlo Replace 162643.026-3

2 inch 4–20 ma 1

BCV-13-1B Flowserve MaxFlo Add 162643.026-3

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Table 1.4 – Test Cell – High Pressure High Temperature Valves

2.2.14. Expansion Joints

2.2.14.1. The Contractor shall replace each of the high-pressure high temperature piping expansion joints for each of the Test Cell Upgrades in accordance with Table 2.0.

2.2.14.2. 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 Test Cell systems.

2.2.14.3. 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.

Valve ID Manufacturer Model Serial

AISO-14-1 Flowserve Valdisc

100915.5

3 inch Manual 1

HISO-14-1 Flowserve Valdisc Replace 162643.005-2

4 inch Manual 1

ACV-14-1 Flowserve Mark I Replace 100915.2

3 inch 4–20 ma 1

HCV-14-1 Flowserve Mark I Replace 100915.1

3 inch 4–20 ma 1

PCV-14-1A Flowserve Mark IX Replace 186710.002-1

3 inch 4–20 ma 1

PCV-14-1B Flowserve Mark IX Add 186710.002-1

3 inch 4–20 ma 1

BCV-14-1A Flowserve MaxFlo Replace 162643.026-4

2 inch 4–20 ma 1

BCV-14-1B Flowserve MaxFlo Add 162643.026-4

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2.2.15.9. The enclosure shall house 2 each panel mount USB connections on the exterior.

2.2.15.10. The Contractor shall provide a door activated light in the enclosure.

2.2.15.11. The Contractor shall provide a spare 120 VAC duplex receptacle in the enclosure.

2.2.15.12. The Contractor shall provide all tubing, hose, connections and electrical hardware for connection of all hardware in the enclosure.

2.2.15.13. The enclosure shall match the design of the existing Test Cells

2.2.15.14. Any deviations will require Government approval.

2.2.16. Valve Pneumatic Control Systems

2.2.16.1. Pressure Control Valves

2.2.16.1.1 The Contractor shall provide a new pneumatic control system for each of the existing and new additional Pressure Control Valves for each of the Test Cell upgrades.

2.2.16.1.2 The Contractor shall remove the existing pressure control valve enclosures for each of the Test Cell upgrades.

2.2.16.1.3 The Contractor shall replace existing stainless steel pneumatic control system interconnection stainless steel tubing for the new Pressure Control Valves (PCV).

2.2.16.1.4 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.

2.2.16.1.5 The Contractor shall provide one each Proportion Air

Controller, Part Number QB1SANICZP320PSG, Norgren pressure regulator, Part Number 11-008-130, Norgren mounting bracket, Part Number 18-001-003, and required power supplies and stainless steel interconnect connections and tubing for each of the Pressure Control Valves (PCV) for each of the Test Cell upgrades. The new components shall be identical to the configurations in Test Cells

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2.2.16.1.6 The Contractor shall provide one each new isolation solenoid valves, Asco Part Number 8262H260 – 120 VAC, Asco Part Number 8262H232 – 120 VAC, and mounting brackets for each Pressure Control Valve for each of the Test Cell upgrades. The Contractor shall provide all stainless steel tubing and piping connections. The new components shall be identical to the configurations in Test Cells

. Any deviations will require Government approval.

2.2.16.1.7 The Contractor shall use stainless steel connections that match the configurations in Test Cells 1, 2, 7, and 11, and 12. Any

2.2.16.2. Temperature and Bleed Air Control Valves

2.2.16.2.1 The Contractor shall provide one each new 100 psig instrumentation control air solenoid valve, Asco Part Number 8136G064 – 120 VAC, mounting bracket, and stainless steel silencer for each of the piping channels for each of the Test Cell upgrades. The new components shall be identical to the configurations in Test Cells . Any

2.2.16.2.2 The Contractor shall install stainless steel tubing for interconnection to the pneumatic control system for the new Temperature and Bleed Air Control Valves.

2.2.16.2.3 The Contractor shall use stainless steel connections that match the configurations in Test Cells .

2.2.17. Sensors, Transmitters, and Transducers

2.2.17.1. Pressure Transmitters

2.2.17.1.1 The Contractor shall provide new replacement pressure transmitters for each of the Test Cell upgrades in accordance with Tables 3.0 and 3.1. Table 3.0 indicates the required pressure transmitters for each of the Single Channel Test Cell upgrades. Table 3.1 indicates the required pressure transmitters for each of the Dual Channel Test Cell upgrades.

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2.2.17.1.2 The Contractor shall provide new additional pressure transmitters for dedicated use with Flow Channel 2 for each of the two (2) Single Channel 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 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.

2.2.17.1.3 The Contractor shall provide new additional pressure transmitters for each of the Test Cell upgrades in accordance with Table 3.3. Pressure transmitter PT-AV-1 shall be mounted in the Mezzanine Enclosure. The remaining 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 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.

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

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

2.2.17.1.6 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.

2.2.17.1.7 The pressure transmitters shall be Siemens SITRANS P series and shall duplicate the part numbers in Test Cells . The part numbers are listed in Table 3.4. Any

SOW – Test Cell System Upgrade Phase 2 – 16 July 2025 Page 27 of 106

2.2.17.1.8 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.

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

2.2.17.1.10 The accuracy in Tables 3.0, 3.1, 3.2, and 3.3 reflects the square root of the sum of the squares of the Non-Linearity, Hysteresis, and Repeatability specifications of each transmitter.

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

2.2.17.2. Pressure Transmitter Relocation

2.2.17.2.1 The contractor shall relocate pressure transmitters EB, PGOA, DPOAA, DPOAB, and CPI-A from the current location in the Transmitter Enclosure to the Mezzanine Enclosure on the Test Cell mezzanine for upgrades to Test Cell and .

2.2.17.2.2 The contractor shall relocate pressure transmitters EB, PGOA, DPOAA, DPOAB, CPI-A, PGOB, DPOBA, DPOBB, CPI-B from the current location in the Transmitter Enclosure to the Transmitter Enclosure on the Test Cell mezzanine for upgrades to Test Cell .

2.2.17.2.3 The Contractor shall install the new available air pressure (PT-AV-

1) transmitter in the enclosure on the Test Cell mezzanine for each of the Test Cell upgrades.

2.2.17.2.4 The contractor shall provide JIC flared connections at each pressure transmitter for calibration connections. The connections shall be stainless steel.

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

2.2.17.2.6 The Contractor shall provide new factory mounting brackets for each of the relocated and new pressure transmitters for each of the

Test Cell upgrades.

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2.2.17.2.7 The Contractor shall provide hose connections for the pressure transmitter that match the connections in the existing Transmitter Enclosure. The connections shall allow for disconnections and connections for Calibration.

Current

ID

New ID Description Range Accuracy Qty.

Test Cell

EB PT-AT-1

Pressure

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

PGOA PT-OP-C1

Pressure

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

DPOAA PT-OL-C1

Pressure

Transmitter 0-100 in H2O ±0.10% of Full Scale 1

DPOAB PT-OH-C1

Pressure

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

CPI-A PT-CP-C1

Pressure

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

PG1 PT-PG-1

Pressure

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

PG2 PT-PG-2

Pressure

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

PG3 PT-PG-3

Pressure

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

PG4 PT-PG-4

Pressure

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

DP1 PT-DP-1

Pressure

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

DP2 PT-DP-2

Pressure

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

DP3 PT-DP-3

Pressure

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

DP4 PT-DP-4

Pressure

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

Table 3.0 – Existing Test Pressure Transmitters

Test Cells

SOW – Test Cell System Upgrade Phase 2 – 16 July 2025 Page 29 of 106

New ID Description Range Accuracy

Qty.

Per Cell

EB PT-AT-1

Pressure

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

PGOA PT-OP-C1

Pressure

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

DPOAA PT-OL-C1

Pressure

Transmitter 0-100 in H2O ±0.10% of Full Scale 1

DPOAB PT-OH-C1

Pressure

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

CPI-A PT-CP-C1

Pressure

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

PGOB PT-OP-C2

Pressure

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

DPOBA PT-OL-C2

Pressure

Transmitter 0-100 in H2O ±0.10% of Full Scale 1

DPOBB PT-OH-C2

Pressure

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

CPI-B PT-CP-C2

Pressure

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

PG1 PT-PG-1

Pressure

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

PG2 PT-PG-2

Pressure

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

PG3 PT-PG-3

Pressure

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

PG4 PT-PG-4

Pressure

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

DP1 PT-DP-1

Pressure

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

DP2 PT-DP-2

Pressure

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

DP3 PT-DP-3

Pressure

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

DP4 PT-DP-4

Pressure

0-30 psid ±0.10% of Full Scale 1

Table 3.1 – Existing Test Pressure Transmitters

SOW – Test Cell System Upgrade Phase 2 – 16 July 2025 Page 30 of 106

Current ID New ID

Description

Range Accuracy Qty.

Per Cell

N/A PT-OP-C2

Pressure

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

N/A PT-OL-C2

Pressure

Transmitter 0-100 in H2O ±0.10% of Full Scale 1

N/A PT-OH-C2

Pressure

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

N/A PT-CP-C2

Pressure

0-350 psig ±0.10% of Full Scale 1

Table 3.2 – Flow Channel 2 Additional Pressure Transmitters

Current ID New ID Description Range Accuracy Qty.

Per Cell

N/A PT-AV-1

Pressure

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

N/A PT-PA-1

Pressure

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

N/A PT-PG-5

Pressure

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

N/A PT-DP-5

Pressure

0-5 psid ±0.10% of Full Scale 1

Table 3.3 – Additional Pressure Transmitters

SOW – Test Cell System Upgrade Phase 2 – 16 July 2025 Page 31 of 106

Description Range Manufacturer Part Number

Pressure

0-150 psig Siemens 7MF03001QE015AM2-Z B20+C11+E00

Pressure Transmitter

0-350 psig Siemens 7MF03001TE015AM2-Z B20+C11+E00

Pressure Transmitter

0-100 H2O Siemens 7MF03401GN015AM2-Z B20+C15+E00

Pressure Transmitter

0-240 H20 Siemens 7MF03401HN015AM2-Z B20+C15+E00

Pressure Transmitter

16-32 HgA Siemens 7MF03201PE015AM2-Z B20+C15+E00

Pressure Transmitter

0-50 HgA Siemens 7MF03201PE015AM2-Z B20+C15+E00

Pressure Transmitter

0-5 psid Siemens 7MF03401HN015AM2-Z B20+C15+E00

Pressure

0-30 psid Siemens 7MF03401PN015AM2-Z B20+C15+E00

Table 3.4 – Pressure Transmitter Part Numbers

2.2.17.3. Resistance Temperature Detector Sensors

2.2.17.3.1 The contractor shall provide new replacement Resistance Temperature Detector (RTD) temperature sensors in accordance with Tables 4.0 and 4.1 for each of the Test Cell upgrades. Tables 4.0 and 4.1 indicate the quantity of temperature sensors required for each Test Cell upgrade. Table 4.0 indicates the required RTD temperature sensors for the Single Source Test Cell upgrades. Table 4.1 indicates the RTD temperature sensors required for the Dual Source Test Cell upgrades. The RTDs required for the 0-1000 deg. F temperature range applications shall be Duro-Sense Corporation Part Number 250616 to match the custom piping thermowells. Any deviations will require Government approval.

2.2.17.3.2 The Contractor shall provide new additional RTD temperature sensors for each of the Single Channel Test Cell upgrades in accordance with Table 4.2.

SOW – Test Cell System Upgrade Phase 2 – 16 July 2025 Page 32 of 106

2.2.17.3.3 The RTD temperature sensors shall be Tolerance Class A.

2.2.17.3.4 The contractor shall provide disconnections for calibration of the RTD temperature sensors at the rear of the Operator Console and in the Transducer Enclosure. The Contractor shall provide panel mount connections for calibration of the RTD temperature sensors on the Overhead Interface Bulkhead Enclosure and Mezzanine Enclosure. The connections shall be Omega Engineering part number OTP-U-M and part number TPJ-U-F or equivalent. Each part number set is required for four (4) each RTD connections.

The panel mount connections are required to facilitate calibration.

Any deviations will require Government approval.

2.2.17.3.5 The Contractor configuration shall match the upgraded Test Cell

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

End Item test screens.

New ID Temperature Sensor Range Quantity

COLD-1 TT-AT-C1 RTD 0 – 1000 deg. F 1 HOT-1 TT-HT-C1 RTD 0 – 1000 deg. F 1

BLND-1 TT-CT-C1 RTD 0 – 1000 deg. F 1 TDCTP TT-TR RTD 0 – 250 deg. F 1 CONTP TT-CO RTD 0 – 250 deg. F 1

Table 4.0 – Existing Test Temperature Sensors

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New ID Temperature Sensor Range Quantity

COLD-1 TT-AT-C1 RTD 0 – 1000 deg. F 1 HOT-1 TT-HT-C1 RTD 0 – 1000 deg. F 1

BLND-1 TT-CT-C1 RTD 0 – 1000 deg. F 1 COLD-2 TT-AT-C2 RTD 0 – 1000 deg. F 1 HOT-2 TT-HT-C2 RTD 0 – 1000 deg. F 1

BLND-2 TT-CT-C2 RTD 0 – 1000 deg. F 1 TDCTP TT-TR RTD 0 – 250 deg. F 1 CONTP TT-CO RTD 0 – 250 deg. F 1

Table 4.1 – Existing Test Temperature Sensors

ID New ID Temperature Sensor Range Quantity

N/A TT-CT-C2 RTD 0 – 1000 deg. F 1

Table 4.2 – Additional Channel 2 Test Temperature Sensor

2.2.17.4. Test Thermocouples

2.2.17.4.1 The Contractor shall provide hardware and software to connect the eight (8) existing J-Type test thermocouple connections in the Overhead Interface Bulkhead Enclosure in each of the Test Cell upgrades to the new data acquisition system. The Test Thermocouples are listed in Table 4.3.

2.2.17.4.2 The Contractors shall provide new data acquisition hardware for each of the eight (8) J-Type Thermocouple connections in each of the Test Cell upgrades.

2.2.17.4.3 Each of the thermocouples shall be capable of being displayed on the End Item test screens.

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Current ID New ID Temperature Sensor Range

TT-1 TT-T1 J-Thermocouple 0 – 1000 deg. F TT-2 TT-T2 J-Thermocouple 0 – 1000 deg. F TT-3 TT-T3 J-Thermocouple 0 – 1000 deg. F TT-4 TT-T4 J-Thermocouple 0 – 1000 deg. F TT-5 TT-T5 J-Thermocouple 0 – 1000 deg. F TT-6 TT-T6 J-Thermocouple 0 – 1000 deg. F TT-7 TT-T7 J-Thermocouple 0 – 1000 deg. F TT-8 TT-T8 J-Thermocouple 0 – 1000 deg. F

Table 4.3 – Test Temperature Sensors

2.2.17.5. Operator Interface Control Panel

2.2.17.5.1 The Contractor shall provide a new operator interface control panel for each of the Test Cell upgrades.

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

2.2.17.5.3 The Contractor shall provide ten (10) each encoders for automatic and manual control of pressure and temperature, and manual bleed control for each of the three (3) Dual Channel Test Cells, Test Cell 3, Test Cell 4, and Test Cell 5. The encoders shall be BEI part number H20DB-25-SS-1024-ABC-28V/V- EM16 and match the encoders in Test Cells .

Any deviations will require Government approval.

2.2.17.5.4 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 two (2) Single Channel Test Cells, Test Cell 13 and Test Cell 14. The encoders shall be BEI part number H20DB-25-SS-1024-ABC- 28/V-EM16 and match the encoders in Test Cells

2.2.17.5.5 The operator interface control front panel for Test Cells 13 and 14 shall be designed in accordance with Figure 2.0. The operator interface control front panel for Test Cells

SOW – Test Cell System Upgrade Phase 2 – 16 July 2025 Page 35 of 106 shall be designed in accordance with Figure 2.1. 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 or 2.1. 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.

2.2.17.5.6 The new operator control interface panels shall match the existing updated panels of Test Cells in design, manufacture, and hardware with the exception of the additional quantity of controls required for Test Cells

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

2.2.17.5.8 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.

2.2.17.5.9 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.

2.2.17.5.10 The contractor shall utilize BEI cable part number 31186-1610 to connect the encoders to the PLC system.

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Figure 2.0 – Operator Interface Control Panel Layout

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Figure 2.1 – Operator Interface Control Panel Layout

2.2.18. Power Supplies

2.2.18.1. End Item DC Power Supplies

2.2.18.1.1 The Contractor shall provide two (2) each new DC power supplies for each of the Test Cell upgrades. The power supplies shall be utilized for End Item testing.

2.2.18.1.2 One DC power supply shall be capable of 0-40 VDC output. The power supply shall be capable of delivering 15 amps at 40 VDC.

The DC power supply shall have a maximum line regulation voltage of 10 millivolts for 0–100% load variation, with constant nominal AC input voltage and temperature. The DC power supply shall have a maximum load regulation voltage 10 millivolts for 0–100% load variation, with constant nominal AC input voltage and temperature.

The power supply shall have a maximum output ripple and noise of 30 mV from 20 Hz to 10 MHz. The power supply shall have a remote voltage programming accuracy of 100 mV or better. The power supply shall conform to UL publications UL61010-1. The

SOW – Test Cell System Upgrade Phase 2 – 16 July 2025 Page 38 of 106 power supply shall be mounted in the existing 19-inch rack Test Cell console. The DC power supply shall be Sorensen Model DLM 40-15 R.

2.2.18.1.3 One DC power supply shall be capable of 0-300 VDC output. The power supply shall be capable of delivering 4 amps at 300 VDC.

The DC power supply shall have a maximum…