Attachment_L-9 _Sample_Project_-_Hydraulic_System_Upgrade.pdf

FARM

FA9101-16-R-0100

Attachment L-9

FA9101-16-R-0100

Attachment L-9

Sample Project:

Hydraulic System Upgrade

28 January 2016

Sample Task Order #0001 RD

NOT SENSITIVE

Dated January 28, 2016

REQUIREMENTS DOCUMENT

For

Hydraulic System Upgrade

Sample Task Order # 0001

NOT SENSITIVE

REQUIREMENTS DOCUMENT

For

Sample Task Order # 0001

1.0 SCOPE

1.1 BACKGROUND

The Propulsion Wind Tunnel (PWT) Model Installation Building (MIB) hydraulic system is used to supply hydraulic power to the test carts for model support system operation during pre-test checkout in the MIB. Once the test carts are installed in the 16T or 16S tunnel circuits, the test section hydraulic system is used to provide hydraulic power. The existing PWT MIB hydraulic system does not have the same system performance, operating characteristics, system safety design, or same hydraulic components as the 16T and 16S test section hydraulic systems. This results in different operating characteristics for the MIB hydraulic system with reduced rates for model movement during pretest checkout.

1.2 STATEMENT OF NEED

This project will replace the entire MIB hydraulic system with a new system modeled after and comparable in operation and performance to the 16T and 16S test section hydraulic systems. The objectives are to:

• reduce checkout duration in the test facilities,

• reduce the cost of maintenance,

• increase spare parts availability,

• reduce the number of spare parts needed by system commonality, and

• provide consistent system operation and performance.

1.3 JUSTIFICATION

The existing hydraulic pumps have been in service for more than twenty years in the PWT MIB. Prior to this they were used at the Engine Test Facility (ETF) and in the 16T and 16S test section hydraulic systems. The pumps are no longer manufactured or quoted and rebuild parts are costly with long lead times. In the MIB hydraulic system, a single electric motor is coupled with two hydraulic pumps for normal system operation.

Two of these arrangements exist so that backup capability exists should a motor, pump, or set of pumps fail. Currently, two of the four pumps installed are no longer operational.

Thus no backup capability currently exists in the PWT MIB. The failure of the PWT MIB hydraulic system, coupled with the lack of spare parts and the long lead time to rebuild components, would necessitate the pretest checkouts be conducted in 16T or 16S. This will make for an inefficient test process and will decrease the amount of test time available for other test entries.

NOT SENSITIVE

1.4 SYSTEM DESCRIPTION

1.4.1 DESCRIPTION

The existing MIB hydraulic system is used to supply 3500 psi Mobil DTE 24 hydraulic fluid to the 16T and 16S test cart systems for model support system movements during pre-test buildup/checkout prior to installation into the tunnel. The system consists of hydraulic pumps, electric motors, reservoirs, piping, heat exchangers, hydraulic valves and other components and electrical control stations. The current system is configured for 70 gallons/minute at 3200 psig in a one motor/two pump configuration. The fluid is sent to four different connection points in the MIB (i.e. Bays 201, 202, 203, and 204) for use with the 16T and 16S test carts.

NOT SENSITIVE

1.4.2 Diagram of Existing MIB (MIB) Hydraulic System

F1

AV1

(100 psi MIB Shop Air)

RES1

PCV4

P4

M4

PCV3

P3

PG3

V7

V3

V4

V9

V8

PG4 RV4

(3550 psi)

RV3

(3550 psi)

CV3

CV4

CV7

CV8

PCV2

P2

M2

PCV1

P1

PG1

V5

V1

V2 V6

PG2 RV2

(3550 psi)

RV1

(3550 psi)

CV1

CV2

CV5

CV6

F2

F7

V15

RV5

(300 psi)

V17

HE2

V14 V16

HE1

V18 V19

TS2

RES2 RES3 RES4

QD4

QD19

QD20

QD34

BAY 201*

V25 V21

CASE DRAIN

RETURN

3500 psi SUPPLY

* Hydraulic System interfaces repeat internally in BAY 202 (QDs on west wall), BAY 203, and the HIGH BAY.

CV14

SG1

SG2

P5

V12

F3

PG5

F4

PG6

PG7V13

V27

FILL

PASSIVE FILTERING

SYSTEM

V11V10

Raw WaterDrain

QD3

East Wall

PWT MIB Ind H2O

EXISTING MIB HYDRAULIC SYSTEM SCHEMATIC

NOT SENSITIVE

EXISTING MIB HYDRAULIC SYSTEM RESERVOIRS

BAY 201

NOT SENSITIVE

EXISTING MIB HYDRAULIC SYSTEM PUMP/MOTOR ARRANGEMENT WITH CONTROL

STATION

BAY 201

1.4.3 SYSTEM INTERFACES

The MIB hydraulic system interfaces the following systems as shown in the block diagram in Section 1.4.4 and the table in Section 1.4.5:

• Building electrical power up to 480VAC,

• Building raw water,

• Building industrial water (downstream of backflow valve to potable water),

• Building storm drain system,

• Building service air piping (Shop Air),

• Bays 201, 202, 203, and 204, The MIB hydraulic system is located inside the PWT MIB in Bay 201 (northwest corner of the building). The electric motors are powered with 480 VAC power, while the control stations and other components are powered with 240VAC or 120VAC power. The heat exchangers are primarily cooled with raw water, but during raw water outages, building industrial water is used. The water leaving the heat exchangers drains to the storm drain. Building service air piping supplies shop air to the air operated actuator for the hydraulic system bypass valve. The MIB hydraulic system supplies hydraulic fluid under pressure to each of the MIB Bays.

1.4.4 INTERFACE BLOCK DIAGRAM

MIB hydraulic system Interface Block Diagram

Model Installation Building hydraulic system

Building Service

Air Piping

Building Raw

Water

Building Industrial

Water

Building Electrical

Power

Bay 201

Environmental Safety

MIB Buildup Schedule

Government Regulations

Water/Power Outages

Building Storm Drain

Bay 202 Bay 203 Bay 204

NOT SENSITIVE

1.4.5 INTERFACE LOCATION AND REFERENCE DRAWINGS

TYPE BOUNDING SYSTEM INTERFACE LOCATION DRAWING NUMBER

Piping Building Service Air Piping Shop Air Lines in Building Bay 201 N/A

Piping Building Raw Water Tee in Building Bay 201 South Wall 512-M2, 512-M3, 512- M4

Piping Building Industrial Water Tee by Hose Reels in Building on Southwest corner of Bay 202

512-M2, 512-M3, 512- M4

Piping Building Storm Drains Tee into Storm Drain Line Building Southwest corner of Bay 201

512-M2, 512-M3, 512- M4

Electrical 480VAC and 120 VAC Disconnect Boxes Feeders into Bay 201 PMTR9735

System MIB hydraulic system Existing System Diagram, Bay 201 PT010768

Electrical Proposed Building Electrical Distribution Unit Substation and Bay 201 PT533145-Page_1

Controls Proposed Controls Routing and Interfaces Bays 201, 202, 203, 204 PT533145-Page_2

Hydraulic Proposed Piping Basic Installation Bays 201, 202, 203, 204 PT632929.01

Containment Curb and Pad

Proposed Basic Installation Plan Bay 201 PT632929.07

Piping Potable and Raw Water, Storm Drain, and Shop Air Bay 201 PT632929.09

MIB hydraulic system Interface Location and Reference Drawing Table

1.5 OPERATIONAL CONCEPT

Test articles are installed and checked for pretest operation in the MIB Bays. This work is conducted so as to minimize time to install the test cart into the tunnel circuit and start the testing process. Remote start/stop locations shall be located in each of the MIB Bays.

Diagnostics will provide methods of maintaining and troubleshooting the equipment.

2.0 APPLICABLE DOCUMENTS AND STANDARDS

ASME B31.3 Process Piping AEDC ENGR STD-T-2 AEDC Standard Pressure Piping ISO 16889 Hydraulic Fluid Power Filters – Multi-Pass Method for Evaluating Filtration Performance of a Filter Element

NASA 15205 Cleaning Procedures for Process Piping Systems

3.0 FUNCTIONAL AND PERFORMANCE REQUIREMENTS

3.1.1 General

3.1.1.1 The normal operating conditions for this system shall be a one pump/motor operation capable of 3500 psi and 90 gpm at each connection in Bays 201, 202, 203, and 204. Provisions shall be made to operate both pumps simultaneously.

3.1.1.2 Piping and hydraulic components shall be sized for 5000 psi operating supply pressure and 180 gpm supply flow at each connection in Bays 201, 202, 203, and 204. The flow rate in the supply main distribution headers shall not exceed ten feet per second.

3.1.1.3 The hydraulic system piping shall be sized to carry the required flow up to 180 gpm for the return lines and 40 gpm for the case drain lines. The flow rate in the return main distribution headers and case drain main distribution headers shall not exceed five feet per second. The case drain lines shall not exceed 50 psi pressure from the test cart connections to the reservoir.

3.1.1.4 Two assemblies, each a single pump and motor set, shall be provided for redundancy or backup capability in the event of a single pump failure.

NOT SENSITIVE

3.1.2 Mechanical Requirements

3.1.2.1 The hydraulic pumps shall be Denison P16 Q2R1D-C1000 or approved equivalent.

3.1.2.2 All piping shall be stainless steel.

3.1.2.3 The piping level shall be positioned above the floor for ease of maintenance (filter clearance issues, trip hazards, etc.). The piping shall be sloped in such a way as to allow draining at low point drains. Low point drain connection shall be provided so that no run of piping could trap fluid in the system. High point bleeds shall also be provided.

3.1.2.4 The existing piping distribution system to Bays 201, 202, 203, and 204 shall be removed. New piping shall be installed.

3.1.2.5 The piping to these quick disconnects shall meet the pressure, flow, and fluid velocity requirements specified in 3.1.1. The new hydraulic piping should be aligned with the East wall of Bays 201, 202, 203, and 204.

3.1.2.6 Quick disconnects in Bays 201, 202, 203, and 204 shall be positioned in an ergonomic manner. The existing brand and model of quick disconnects shall be used to match existing connections on the test carts. The piping to these quick disconnects shall meet the pressure, flow, and fluid velocity requirements specified in 3.1.1.

3.1.2.7 A concrete curb shall be installed around the hydraulic system for oil spill containment and shall be sized to hold 110% of the reservoir capacity. Containment surfaces shall be coated to prevent oil from penetrating the concrete and also have a non-slip surface applied so as to reduce personnel slips/trips while working in area during spill clean up.

3.1.2.8 Hydraulic and mechanical noise suppression devices (surge suppressors and/or isolation devices) shall be installed to reduce noise levels and transmission of noise throughout the system and into the building structure so as to maintain noise below 85 dbA for 8 hour exposure.

3.1.2.9 New reservoir shall meet the following minimum requirements:

• Stainless steel construction;

• Provide indication and alarms of critical oil levels;

• Heater to maintain sufficient oil temperature to prevent condensation problems and maintain oil viscosity to not compromise pump suction pressure;

• Passive filtration must be operational to activate heater;

• Temperature readout;

NOT SENSITIVE

• Baffles;

• Sloped bottom to low point drain;

• Desiccant breathers;

• Magnetic probe for ferrous metal particulate collection installed to allow inspection without draining reservoir;

• Return line terminates below minimum fluid level with diffuser on end of line;

• Oil level sight glass connected at both top and bottom to tank;

• Personnel Access for cleaning of reservoir;

• All sides and the bottom shall be constructed so they may be visually inspected;

• Additional ports shall be provided on top of the reservoir for non-intrusive inspections of the oil and interior of reservoir; and

• Sized to contain nominally 4 times the maximum flow rate as specified in 3.1.1.

3.1.2.10 Heat exchangers shall be installed in the system to prevent the oil from exceeding 180º Fahrenheit at any point in the system.

3.1.2.11 Each pressure sensor installed in a tee to the main line shall be installed with double block and bleed protection upstream of the sensor.

Each temperature sensor shall be installed with thermal well to allow removal and replacement without draining system.

3.1.2.12 Filtration shall be installed in the pump case drain line to the reservoirs to aid in the removal of particles and contamination that occurs when a pump fails. The filtration shall be sized so as to not create backpressure to the pump.

3.1.2.13 A multi-stage passive filtration system shall be provided to maintain the oil cleanliness within the ISO 16/14/12 range. The system shall have the following requirements:

• Differential pressure switches on the filters shall indicate on the control station when a filter needs to be replaced.

• Filtration shall be rated to β3(c) ≥ 200 (per ISO 16889) with a pressure drop across element not to exceed 10 psi during normal operation using Mobil DTE 24 hydraulic fluid.

• Flow rate shall be 4 times tank volume per hour.

• The pump inlet piping shall be designed with a tee in the line with the intent of using this line to fill the reservoirs with oil.

• The passive filtration system shall have provision to drain the oil from the reservoir to an external tank.

• System shall be equipped with Stauff Test Ports, model number

SMK20-1/4NPT-VD, for the collection of oil samples.

• Test Ports shall be installed in a manner that accommodates efficient maintenance.

NOT SENSITIVE

3.1.2.14 Supply line filtration shall meet ISO 16889 β10(c) ≥ 200. Return line filtration shall meet ISO 16889 β7(c) ≥ 1000. Passive filtration shall meet ISO 16889 β3(c) ≥ 200. All filtration shall be sized so as not to exceed a differential pressure of 15 psi during flow conditions.

3.1.2.15 Provision shall be made for oil sampling ports that are used across the base to standardize oil sampling equipment and methods.

3.1.2.16 Piping shall be cleaned after welding to reduce the contamination in the system per NASA 15205 Cleaning Procedures for Process Piping Systems or equivalent.

3.1.2.17 All piping shall be designed, fabricated, and tested in accordance with ASME B31.3 Process Piping and AEDC Engineering Standard T-2 AEDC Standard Pressure Piping.

3.1.2.18 Pump and motor shall be installed in accordance with Denison Publication LT2-00009-1-A.

3.1.3 Electrical and Control Requirements

3.1.3.1 The electric motors shall be 200 hp motor capacity, with frame size of 447TS and speed of 1780 rpm. Motor starting shall not produce undesirable electrical voltage fluctuations on the MIB building power system.

3.1.3.2 The motor protection shall be included in a starter and sized to protect 200 hp motors and prevent any equipment damage. The motor starter shall have capability to communicate to the master control station for event logging.

3.1.3.3 Each start/stop station (master and 3 remote) shall have an indication of switch/sensor outputs.

3.1.3.4 Each start/stop station shall have the pushbuttons to start and stop each pump and to open and close the bypass and loader valves.

3.1.3.5 The control logic on the start/stop stations shall be such that one pump may be started and then the second started without having to stop the first pump. The control logic shall be such that the pumps cannot be started with the bypass valve in the closed position.

3.1.3.6 The master start/stop station in Bay 201 shall be located such that the pump/motor arrangements are visible from the station. It shall contain the PLC based control system. All sensors, buttons, and lamps shall be connected to the PLC I/O, analog and digital. All PLC components shall be GE devices for commonality of spares. Communication between PLC and I/O devices shall be “Genius” GE communication protocol. The master start/stop station in bay 201 will contain discrete devices to allow pump operation if PLC communication is lost.

3.1.3.7 Supply, return, and case drain lines at each test cart connection shall have pressure, temperature, flow, etc. instruments to provide local readings as well as at the master control station.

3.1.3.8 The master control station shall have data storage capability. A snapshot of all parameters shall be stored every 5 minutes. Logged data shall be stored in digital format and easily transferred into an Excel spreadsheet.

3.1.3.9 If high oil level is indicated in the reservoir an audible alarm (70 dbA) shall sound in Bays 201, 202, 203, and 204 so as to provide warning of potential spills.

3.1.3.10 High oil temperature of 180º Fahrenheit in the reservoir shall cause the pumps to stop operation and turn off the oil reservoir heaters.

Indication of high oil temperature shall be provided on the control stations in Bays 201, 202, 203, and 204.

3.1.3.11 Temperature sensors shall be installed at the inlet and outlet of the heat exchangers for both oil and water. This data will not be provided at the remote control stations.

3.1.3.12 Temperature, pressure, and flow sensors shall be installed to measure pump inlet, pump outlet, and case drain conditions at each pump to provide local readings and to connect to the master control station for data recording to provide improved predictive maintenance tools and troubleshooting capability. Pressure sensors shall be installed at any pre-charge loop or between stages of the pumps.

3.1.3.13 A pressure switch with dual set points shall be installed in the supply line, return line, and case drain line. High oil pressure shall be indicated with indications on the control stations and low oil pressure on the supply line shall cause the hydraulic pumps to stop. High pressure on the return and case drain lines shall stop the pumps.

3.1.3.14 Flow meters shall be installed at the inlet and outlet of the heat exchangers for both oil and water.

NOT SENSITIVE

3.1.3.15 Flow meters shall be installed in the hydraulic pump case drain line to give visual indication and ability to record data. Flow switch shall be installed in the hydraulic pump case drain line so as to stop the hydraulic pumps when excessive pump case drain flow of 10 gpm is seen. An indication of this condition shall be put on the control stations.

3.1.3.16 Filters shall include monitoring for operational conditions. The monitoring shall provide an indication at control station in Bays 201, 202, 203, and 204.

3.1.3.17 Heaters shall be installed so as to maintain an oil temperature in the reservoir of 80º F with no pumps in operation.

3.1.3.18 Indications of each individual pump/motor hours of service shall be provided at the master control station.

3.1.3.19 Lighting and receptacles shall be provided in the location of the hydraulic system installation at equipment level for operation and maintenance.

3.1.3.20 In addition to being PLC controlled, the safety critical indicators shall be hard-wired to provide backup.

3.2 PHYSICAL CHARACTERISTICS

The upgraded hydraulic system shall be generally located in the same area as the existing hydraulic system. Mobil DTE 24 shall be the hydraulic fluid to be used in this system.

3.3 LIFE CYCLE/DUTY CYCLE

The upgraded hydraulic system shall be designed to have a lifespan of 20 years. The system shall be designed for a yearly service of 2000 hours.

3.4 RELIABILITY, AVAILABILITY, MAINTAINABILITY

3.4.1 The mean time to repair to replace a pump shall be no more than four hours using three craftsmen assuming functional spare pumps are available for installation.

3.4.2 The time to repair for a pump shall be no more than forty man-hours.

3.4.3 The mean time between failure of a pump shall be no less than two thousand hours of service.

NOT SENSITIVE

3.5 SPARE PARTS

Sufficient spares shall be identified to ensure that the reliability, maintainability, and availability requirements are met.

3.6 ENVIRONMENTAL CONDITIONS

No adverse environmental operating conditions apply. The hydraulic system will be installed within an existing building structure. Extremely cold conditions may still be experienced due to aging heaters in this location.