PD002_Process_Air_System_3_May_2018.pdf

3 May 2018

DISTRIBUTION STATEMENT A. Approved for public release: Distribution is unlimited.

PD #002

Purchase Description (PD) for

PROCESS AIR SYSTEM FOR PNEUMATIC COMPONENT

TESTING

Prepared by:

COMMODITIES SUPPORT MAINTAINENCE GROUP

309TH CMXG

HILL AFB UT 84056

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THIS PAGE HAS BEEN INTENTIONALLY LEFT BLANK

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TABLE OF CONTENTS

1. SCOPE

1.1. Scope Statement

2. APPLICABLE DOCUMENTS

2.1. Government Documents

2.2. General Industry Regulations

3. REQUIREMENTS

3.1. General

3.2. Compressors

3.3. Air Quality

3.4. Piping

3.5. Heater

3.6. Storage

3.7. Safety

3.9. Hose Requirements

3.10. Life Cycle Sustainment

Appendix A

Appendix B. Thickness Test Report

Appendix C. Air Testing Requirements and Hypothetical Day

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1. SCOPE

1.1. Scope Statement. The purpose of this Purchase Description (PD) is to define the technical requirements for the process air system for pneumatic component testing.

2. APPLICABLE DOCUMENTS

2.1. Government Documents. The following specifications, standards, and handbooks of the exact revision listed below form a part of this specification to the extent specified herein.

2.1.1. Department of Defense Standards. None.

2.2. General Industry Regulations. Test stand design shall conform to the following:

2.2.1. NFPA 70: National Electric Code (NEC), latest edition

2.2.2. 29 CFR 1910 Occupational and Health Administration (OSHA) General Industry Regulations

3. REQUIREMENTS

3.1. General. The air system shall connect to the two Air Turbine Starter (ATS) test stands defined in PD #001 and two existing pneumatic component test stands in room 112. The air system shall be capable of meeting the requirements listed in appendices B through K of PD #001. Additionally, the air system shall meet the requirements of the pneumatic test stands (room

112) listed in Appendix C. The air system shall also be able to keep up with the workload of the “Hypothetical Day” listed in Appendix C. The air system design shall consist of new piping from the location of the compressors up to the test stand connection points. The design shall include isolation valves close to each test stand.

3.2. Compressors. The air system shall include a minimum of two (2) compressors. The compressors shall be staged with pressure switches so that they run on demand. The compressor controller shall allow the compressors to alternate being the primary supply to keep operating hours more even. Each compressor shall have the ability to be isolated for maintenance while the other(s) remain in operation.

3.3. Air Quality. The air system shall be clean, oil free (< 4ppm), and dry (<0°F dew point at system pressure). The system shall include a 25 micron or better air filter between each test stand

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and each test stand shall have an isolation valve upstream of the filter to facilitate filter maintenance.

3.4. Piping. Air supply piping, and valves, shall be non-corrosive material (e.g. stainless steel, anodized aluminum IAW the latest revision of ASME B31.3) rated for all expected temperatures and pressures. Piping shall be adequately sized to accommodate the flow requirements of the test procedures listed in PD #001 and match the existing line sizes of the existing pneumatic component test stands.

3.5. Heater. The air system design shall include one electric heater for the two existing pneumatic component test stands in room 112. The heater shall be capable of heating 150 pounds per minute of air from 0°F up to 100°F for a ½ hour continuous period. The heater shall have a temperature controller accessible to the test operators and a shutoff switch. The system shall include a flow switch to disable the heating elements when there is no air flow.

3.6. Storage. The air system shall include a minimum of 15,000 gallons of storage. The air system design may include reusing the three existing 5,000 gallon storage tanks. Each storage tank shall have a new relief valve. The storage system shall include a new adjustable automatic condensate drain valve. Each tank shall have a manual drain isolation valve. A thickness test has been done on the current storage tanks. The test report is included in Appendix B.

3.7. Safety. The air system shall conform to the General Industry Requirements listed in paragraph 2.2.

3.8. Energy Efficiency. To fullest extent possible, the contractor shall incorporate energy efficiencies into the test system design and function (e.g. expected process time, pre-heat, state of equipment during idle time, etc.).

3.9. Hose Requirements. Hoses shall only be used where a flexible connection is required. The hose pressure rating shall be greater than the system operating pressure. The test stands shall include a set of production drawings for the hoses in the drawing package. The hoses shall be tagged with the hose number (to match the schematic), rated pressure, and date of manufacture.

3.10. Life Cycle Sustainment. The overall system design (e.g. components, hardware, software, etc.) shall be reliable, accessible, and maintainable and also allow the Government to competitively select service providers for all future repairs without involving the original manufacturer of the system. Wherever possible, the contractor shall use components that are commercially available, commonly used in comparable industry equipment, interchangeable with other brands, and competitively priced. The ATS system design shall not force the Government into a sole-source condition with the original manufacturer of the system when repairs or replacement parts are required. The system design shall not require the Government or a Government contractor to perform any reverse engineering in order to make system repairs.

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APPENDIX A. ACRONYMNS AND ABBREVIATIONS

ATS Air Turbine Starter NEC National Electric Code

OSHA Occupational and Health Administration PD Purchase Description

PPM Pound (mass) per minute PSIG Pounds per Square Inch – Gauge

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APPENDIX B. THICKNESS TEST REPORT

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APPENDIX C. AIR TESTING REQUIREMENTS AND HYPOTHETICAL DAY

The test stands shall meet the air requirements, listed in the following table, while also meeting the listed production numbers in the “Hypothetical 8 Hour Day Scenario” listed below.

Part Number Flow (lbs/min)

Pressure

(PSIG)

Temp (°F)

Approximate Time Per Run (sec)

UUTs Per

Month

ATS100-138

See Appendix B in PD #001

13.7 4

ATS100-302

See Appendix C in PD #001

32.7

ATS100-97C See Appendix D in PD #001

18 12 ATS100-395B See Appendix E in PD #001

29.2 10

36E84-18QF See Appendix F in PD #001

ATS100-421 See Appendix G in PD #001

40 4 ATS100-422 See Appendix H in PD #001

46 4 36E153-6E See Appendix I in PD #001

24 12 ATS100-440 See Appendix J in PD #001

23 4 36E84-2QC See Appendix K in PD #001

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Production and Air Requirement for the Pneumatic Cell in Room 112 109576 Actuator Supply Pressure 120±2 36±.5 80°±40° 600 3

109756 Opening and Closing Time 136±10 40±2 NA 60 3

Hypothetical 8 Hour Day Part Number Quantity 36E153-6E 2

ATS100-97C 1

ATS100-395B 1

109576 1 109756 1