Containerized_Vacuum_Pump_System_Procurement_SOW_Tunnel_D_FBO_Edit.docx

28 JUNE, 2019

NOT SENSITIVE

AEDC IRA-XXXX

STATEMENT OF WORK

FOR

PROCUREMENT OF A CONTAINERIZED VACUUM PUMP SYSTEM

FOR AFRL/VKF WIND TUNNEL D

ARNOLD ENGINEERING DEVELOPMENT COMPLEX

ARNOLD AIR FORCE BASE, TN 37389-9998

1.

Table of Contents

1. SCOPE

2. APPLICABLE DOCUMENTS

2.1 Government Documents

2.2 Non-Government Documents

3. REQUIREMENTS

3.1 General System Requirements

3.2 General Installation Requirements

3.3 Verification

3.4 Acceptance

3.5 Submittals

Appendix A – Concept Drawings / Containerized Vacuum Pump Site Layout

4.

Table of Contents-1

1. SCOPE

1.1. The Contractor shall design, construct, and deliver a Containerized Vacuum Pump System that will be used to reduce the pressure in a 200,000 ft3 vacuum sphere from atmospheric or sub-atmospheric pressure to 2 mmHg or less. Process medium is air, originally sourced from a high-pressure compressor system. As a result of this and upstream processes, trace amounts of rust, oil, or nanoparticulate (< 250 nm) tracers may be present. Dew point is nominally -40°F at atmospheric pressure.

1.2. The Containerized Vacuum Pump System furnished by the Contractor shall be able to operate continuously from initially atmospheric pressure (approximately 740 mmHg). The Containerized Vacuum Pump System furnished by the Contractor may also be roughed in to some partial sub-atmospheric pressure by the existing Arnold Engineering Development Complex (AEDC) Tunnel D Vacuum System and shall be able to operate from initially sub-atmospheric pressures.

1.3. The Contractor shall provide delivery of the Containerized Vacuum Pump System to AEDC/AFRL VKF Tunnel D facility. The new Containerized Vacuum Pump System will be located on a concrete pad adjacent to the Tunnel D Vacuum Sphere immediately southeast of AEDC Building 607.

1.4. The Contractor shall provide on-site initial commissioning support for the Containerized Vacuum Pump System once utility hookups have been made by AEDC personnel subsequent to delivery.

2. APPLICABLE DOCUMENTS

2.1. Government Documents:

2.1.1 GSA Facilities Standards PBS P100/2018 Edition

2.2. Non-Government Documents:

2.2.1. ASME/ANSI B16.5

2.2.2. NEMA

2.2.3. NFPA 70

2.2.4. UL

3. REQUIREMENTS

3.1. General System Requirements:

3.1.1. The Contractor shall provide a vacuum pump system capable of bringing a volume of 200,000 ft3 with a leak rate of 500 CFM-mmHg from atmospheric pressure (approximately 740 mmHg) to 5 mmHg or less, in no more than 3.0 hrs.

3.1.2. The Containerized Vacuum Pump System provided by the Contractor shall be capable of bringing a volume of 200,000 ft3 with a leak rate of 1,000 CFM-mmHg from 250 mmHg to 5 mmHg or less in no more than 120 min.

3.1.3. The Containerized Vacuum Pump System provided by the Contractor shall be capable of bringing a volume of 200,000 ft3 with a leak rate of 1,000 CFM-mmHg from 100 mmHg to 5 mmHg or less in no more than 90 min.

3.1.4. The Containerized Vacuum Pump System provided by the Contractor shall be capable of bringing a volume of 200,000 ft3 with a leak rate of 1,000 CFM-mmHg to a minimum pressure of 1 mmHg or less.

3.1.5. The Contractor shall procure and deliver Containerized Vacuum Pump System in a period not to exceed 20 weeks from date of award.

3.1.6. The Containerized Vacuum Pump System shall permit partial reduction of operating capacity during maintenance of individual pumps or pump-booster systems, but overall capacity should not be reduced by more than 33% in such a scenario (i.e. no fewer than 3 separable systems). For maintainability, total number of pumps or discrete pump-booster systems shall not exceed 9.

3.1.7. The Contractor shall select a pump design intrinsically-suited to facilitated operation by minimal crew. That is, frequent oil replenishment, oil changes, or pump reconfigurations should be avoided by design. Dry-screw pumps or dry rotary vane pumps, for example, are seen to be advantageous in this regard.

3.1.8. The vacuum pump system shall be housed in a weatherproof shipping container or similar portable structure (hereafter the Container).

3.1.9. The maximum footprint of the Container shall not exceed 8 ft × 40 ft.

3.1.10. The internal layout of the Containerized Vacuum Pump System should be such that necessary routine maintenance access to each pump is facilitated, and that removal of a pump from the enclosure is possible without forklift access (e.g. skids with wheels and sufficient access to roll to an exit). The Container shall have suitably large, lockable exterior doors or access panels to allow this.

3.1.11. A personnel door shall be also installed for routine operator access to the Container.

3.1.12. Access to the container shall be secured with keyed locks and/or padlocks.

3.1.13. The Containerized Vacuum Pump System shall have a single standard ASME/ANSI B16.5 flange for air inlet, 14” to 24” in size as appropriate for vacuum performance. The AEDC-provided inlet header to the sphere will be a single straight length approximately 25 ft long as shown in the attachment, and will adapt up to a 32” diameter before entering the vacuum sphere.

3.1.14. Each of the pump(s) installed used in the Containerized Vacuum Pump System shall have a vacuum rated pneumatically actuated control valve at its inlet for isolation from the vacuum chamber. Valve(s) shall fail closed.

3.1.15. The Contractor shall provide on the main inlet header (14” - 24” per 3.1.13) a vacuum rated pneumatically-actuated control valve in-line, either internal or external to the container, for isolating the sphere from the container as a whole. This valve shall be oriented to seal primarily with the sphere at vacuum and the container as the pressure side, but shall be safely operated in the opposite direction.

3.1.16. Power to the system shall be three-phase 480VAC 60 Hz and terminated in a lockable and fusible disconnect on the outside wall of the container. Any accessory/control power of lower voltages must be derived from this 480 volt source with fusing on both primary and secondary side of the control transformer(s). Any control transformer(s) must be sized to at least 125% of the expected load.

3.1.17. The total current demand of the enclosure (pumps and any accessory power) of the system when operating at full capacity shall not exceed 400 amps at 480 VAC 3-phase.

3.1.18. Pump(s) and ancillary systems shall have lockable service disconnects.

3.1.19. All electrical cabinets and materials shall be NEMA 4 enclosure rated and UL approved.

3.1.20. System shall be prewired and factory-tested.

3.1.21. The Containerized Vacuum Pump System shall be as self-contained as possible. Oil, cooling, filtration, controls, and other ancillary systems shall be contained in the container with as few external connections as possible.

3.1.22. Water may be employed for equipment cooling in an open-loop fashion. AEDC may provide ‘raw’-water cooling at 60-110 psig in a 1-1/2” NPS pipe up to 150 LPM. Water temperatures may approach or even slightly exceed 85 degrees Fahrenheit during summer months and reach to a low temperature of 50 degrees Fahrenheit during winter months– a chiller system or other mitigation, as well as a heater system for winter months should be provided if deemed necessary to enable uninterrupted vacuum ops year-round, for all system pressures. Contractor shall furnish any necessary flow conditioning (filters, etc.) and flow indicators / flow switches for equipment protection. Filters shall be of a dual-basket design allowing online switchover and maintenance.

3.1.23. Compressed air (shop-grade) may be provided to the Containerized Vacuum Pump System, if necessary, at 90-100 psig in a 1/2” NPS pipe up to 300 SLPM. Contractor shall provide necessary conditioning (filters, driers, etc.).

3.1.24. The container shall be complete with ventilation, heating, lighting, and insulation to allow year-round operator/maintenance occupancy and equipment operation in Middle Tennessee climate.

3.1.25. Discharge of air shall be through the roof outside of the container and have a standard ANSI flange for ducting to optionally be attached. Exhaust air shall be free of visible oil mist, whether by selection of a dry pump design or by a mist eliminator system external to the container. If the latter, trapped oil should be reclaimed and plumbed in as appropriate to reduce consumption and maintenance demand.

3.1.26. System shall have PLC control, HMI to display pump and system status, hour meters, maintenance meters, and pump faults.

A. The controls shall be a PLC-based system capable of standard Ethernet-based industrial communications protocols (Modbus TCP, Profinet, EtherCAT, etc.) for tie-ins to customer’s existing GE RX3i PLCs. Via this protocol, the following capabilities shall be possible from the existing customer PLC: remote pump run status, temperature, pressure, cooling flow indications as recommended by Contractor (read-only), remote control of isolation valves (write), indications of valve limit switch positions (read-only), and remote single-pump shut-down / E-stop (write).

B. A table of registers/tags, descriptions, and units/value mappings for the parameters listed in 3.1.20.A shall be provided as a programming reference for customer integration.

C. The Contractor shall provide a soft copy of the PLC code. The PLC source code shall be provided or accessible via Ethernet.

D. Any protocol conversion hardware required to interface from the vendor PLC to the customer’s GE Ethernet Interface Module (IC695ETM001) is the responsibility of the vendor to procure, program and install within the vendor’s PLC system.

E. A connection from the customer’s hardwired E-STOP pushbutton to the vendor’s control panel shall be provided. The loss of this normally closed circuit shall initiate action within the vendor’s control system to safe the containerized vacuum system.

F. The Contractor shall provide a soft copy of the HMI code. The HMI source code shall be provided or accessible via Ethernet.

G. If the Contractor chooses a PLC/HMI platform other than GE, Contractor shall include a license and installation media for the necessary programming software.

H. Programming software installation and PLC/HMI implementation must not require the use of USB storage media or hardware authenticators.

3.1.27. All electrical components included in the pump assembly shall be NEMA 4 rated for weather protection. Any light bulbs for vendor controls shall be LED.

A. The control panel shall be a NEMA 4 rated indoor/outdoor enclosure with HMI and weather protection for robustness to basic cleaning/exposure, but may be located inside the container for additional protection and access control.

B. The panel shall have full size 30mm control components and indicators. The panel-mounted components shall include, but are not limited to, the following:

1. Emergency Stop Button with Red Operator.

2. Local/Remote Selector Switch with black operator, with Local (Amber) and Remote (White) lights.

3. Ready to Run Light(s) in Green.

4. Trouble Alarm light(s) in Red.

5. Run push button(s) with black operator.

3.1.28. Red running beacon shall be installed on the exterior top of the container.

3.1.29. Alarm horn shall be mounted on the outside of the container.

3.1.30. 120VAC convenience outlets shall be provided, but need not exceed (2) 15A circuits.

3.1.31. Vendor shall supply a recommendation electrical and mechanical spare parts for the unit (oil, filters, bearings, relays, fuses, control transformers, etc.).

3.2. General Delivery / Commissioning Requirements:

3.2.1 The Contractor will be responsible for off-loading the containerized vacuum pump from the delivery truck onto the storage pad(s) located at the southeast corner of AEDC Building 607 at Arnold AFB, TN. AEDC personnel will then be responsible for connecting the vacuum line extension to the Containerized Vacuum Pump System and will be responsible for running the 480V Power Supply, cooling water, and control cables to the NEMA rated enclosure located at the storage pad. When these connections are completed, the Contractor will send a technical representative to verify hookups and oversee initial commissioning and testing of the containerized vacuum system.

The Contractor/Contractor’s A/E shall make (a) site visit(s) and determine the level of effort necessary to complete the project in a timely and professional manner. The site survey shall take into consideration the building support systems, equipment operating environment, and any other requirement necessary to conform to this Statement of Work (SOW).

The following includes, but is not limited to, the work required to fulfill the objectives of this project as necessary for each technical discipline.

3.2.2 Architectural Requirements:

3.2.2.1 The Contractor/Contractor’s A/E shall work with AEDC to define requirements for the AEDC-provided supporting pad(s), vacuum line extension and electrical and control cable routing. These will be constructed by AEDC personnel prior to delivery of the Contractor system.

3.2.2.2 Container(s) required to meet the performance specifications in paragraphs 3.1.1, 3.1.2, 3.1.3, and 3.1.4 must fit inside the area adjacent to AEDC Building 607 as shown in “Appendix B – Concept Drawings / Containerized Vacuum Pump Site Layout.” The container(s) must be arranged such that there is 10 ft of space around each container to allow access to each side of the container for maintenance.

3.2.2.3 The Contractor/Contractor’s A/E shall design and construct a thrust block on the vacuum line extension if deemed necessary.

3.2.2.4 The Contractor/Contractor’s A/E shall place the inlet header flange for the vacuum line to the sphere to facilitate the interface with the existing vacuum port located on the northeast side of the vacuum sphere as shown in “Appendix B – Concept Drawings / Containerized Vacuum Pump System Site Layout.” Detailed drawings specifying the above-ground-level height of the center of this port, etc. are provided in the Appendix.

3.2.3 Civil & Geotechnical Requirements:

3.2.3.1 N/A

3.2.4 Electrical Requirements:

3.2.4.1 The Contractor/Contractor’s A/E shall provide conduit stubs/junction boxes as appropriate on the north end (Building 607 side) of the container for routing of electrical and control cables to breaker cabinets and junction boxes in the southeast corner of Building 607. 480 volt power, low voltage AC controls, Ethernet/24VDC cabling, and Safety Grounding shall be given separate conduits. Refer to the GSA Facilities Standards PBS P100/2018 Edition for additional information.

3.2.4.2 The Contractor/Contractor’s A/E shall design and construct all line voltage conductors to be made of copper and be of adequate size to meet the full load requirements of selected equipment as recommended by the manufacturer.

3.2.4.3 The Contractor/Contractor’s A/E shall design and construct all electrical wall penetrations to be sealed in accordance with NFPA and NEC requirements.

3.2.4.4 The Contractor/Contractor’s A/E shall design and construct all wiring to comply with all applicable NEC codes and authorities having jurisdiction.

3.2.4.5 The Contractor/Contractor’s A/E shall design and construct all electrical conductors including control conductors in mechanical rooms to be installed in rigid conduit and appropriate fittings used.

3.2.4.6 The Contractor/Contractor’s A/E shall design and construct standard terminal block layout per code compliance. All cable terminations to be NEC compliant for supplied Control and Power Cabling.

3.2.4.7 The Contractor/Contractor’s A/E shall terminate all cabling at a terminal block per code compliance. Final power hook up shall be the responsibility of AEDC personnel.

3.2.5 Structural Requirements:

3.2.5.1 The Contractor/Contractor’s A/E shall consult/cooperate with AEDC personnel during design and construction of the storage pad to include footing systems and slab systems, as well as the vacuum line extension, such that the combined work is compatible at delivery.

3.2.5.2 Contractor/Contractor’s A/E shall provide corrosion control on any exposed vacuum piping / flanges / valve.

3.3. Verification:

3.3.1. The Contractor/Contractor’s A/E shall verify vacuum header assembly is leak-free prior to delivery and shall provide a report documenting test results.

3.3.2. The Contractor/Contractor’s A/E shall support AEDC during commissioning efforts to include leak check, electrical check and controls check of fully integrated Containerized Vacuum Pump System.

3.4. Acceptance: The Government will accept the Containerized Vacuum Pump System and all related components and equipment upon satisfactory operation after installation and commissioning at AEDC.

3.4.1. Engineering Analysis and Calculations for Containerized Vacuum Pump System:

A. Vacuum Pump Performance Curve showing vacuum pump capacity (ACFM) as a function of sphere pressure (Torr or psia).

B. Time to pump down a volume of 200,000 ft3 with a leak rate of 1,000 CFM-mmHg to 5 mmHg from the following pressures for the Containerized Vacuum Pump System :

1. 740 mmHg (3.1.2)

2. 250 mmHg (3.1.3)

3. 100 mmHg (3.1.4)

C. Time to pump down a volume of 200,000 ft3 with a leak rate of 1,000 CFM-mmHg to an ultimate pressure < 1 mmHg (3.1.5)

D. Maximum amperage of the Containerized Vacuum Pump System.

E. Calculation of System Ultimate Pressure and time to reach it from atmosphere

F. Weight and center of gravity of the container/vacuum pump assembly.

3.4.2. Drawings for the Containerized Vacuum Pump System furnished:

A. Final assembly drawings for the vacuum pump/container assembly.

B. Bills of Material, details, and assembly information for the end user to replace parts or repair the Containerized Vacuum Pump System.

C. Vacuum Line and Electrical/Control cable drawings

3.4.3. Controls Source Code and Required Software Licenses

A. PLC source code

B. HMI source code

C. Programming software install media (if other than GE Proficy/Cimplicity). No USB storage media.

D. Programming software license (if other than GE Proficy/Cimplicity). No USB hardware authentication.

3.4.4. Operation and Maintenance Manuals for Containerized Vacuum Pump System furnished. Include:

A. Schematic diagrams (wiring diagrams for electric motor actuator and motor starter).

B. Operating and maintenance instructions including lubrication, cleaning, and calibration instructions.

C. Manufacturer’s bulletins, cut sheets, and descriptive data for each piece of equipment.

D. Parts list and recommended spare parts. The list shall give the manufacturer’s name, part number, and a vendor for each item.

3.4.5. Warranty: The Contractor shall provide a one year warranty for the Containerized Vacuum Pump System stating that it is free from any manufacturer defects. The warranty period shall begin after acceptance at AEDC.

3.4.6. Submittal Table:

Table I. Required Submittal List - Completed

APPENDIX A

CONCEPT DRAWINGS / CONTAINERIZED VACUUM PUMP SITE LAYOUT

Figure A-1. Vacuum System Container Site Layout Concept

Figure A-2. Elevation of Container System Inlet Header vs Approx. Ground Level

Figure A-3 Site Photograph 1

Figure A-4 Site Photograph 2

Figure A-5 Site Photograph 3

Figure A-6 Site Photograph 4

Appendix B-5 image1.png image2.png image3.png image4.png image5.png image6.png