Revised_Attachment_002_Technical_Factor_Elements_19_Mar_2014.xlsx
XLSX spreadsheet 20 KB Posted
- Attached to
- Update to the Lube Unit, Power Operated (LUPO) with a modernized diesel Powered Air Compressor (DPAC)
- Solicitation number
- M67854-14-R-5018
- Issued by
-
United States Marine Corps
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Revised Attachment 002 Technical Factor Elements
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Technical Factor Elements
| REVISED ATTACHMENT 002 | |||||||||||
| Technical Factor Elements | |||||||||||
| Paragraph number | Paragraph Title | Paragraph Contents | Written Response | Drawings / figures | Technical literature | Catalog description | Additonal relevant information | ||||
| Required? | Response: | Required? | Response: | Required? | Response: | Required? | Response: | Response: | |||
| 3.2.4.1. | Compressed air interface | The compressed air output shall exit the enclosure at the rear. The connection shall be a male 3/4 inch NPT thread connection. Neither the size nor the location of the connection is allowed to change, to ensure that the base unit is interchangeable with the current base units installed in the LUPO. For shipping and transport purposes, a cap shall be installed on the connection, to prohibit any water infiltration or any other potentially damaging contamination. The cap shall be removed and discarded before operation. | X | X | |||||||
| 3.2.4.2. | Remote panel mounting | The remote panel shall exhibit mounting locations identical to the mounting locations on the current Diesel Powered Air Compressor’s remote panel, in order to allow exchange without modification to the LUPO. Wire entry and exit points shall be identical to the current remote panel. No additional wire length shall be required in the remote panel, to ensure that no additional wire is required to connect the remote panel. | X | ||||||||
| 3.2.4.3. | Power interface | The power output shall be routed to the remote panel. Routing beyond the breakers provided in the remote panel is not required. Routing the power beyond the remote panel’s breakers will be accomplished by those who integrate the Diesel Powered Air Compressor into the LUPO. An exception to this is the power for lighting. The power for lighting shall be routed to the switch on the remote panel. Routing power beyond the switch for the lights shall be completed in the integration into the LUPO. | X | ||||||||
| 3.2.4.3.1. | Power output interface | Routing power beyond the remote panel is not required. Connections to the remote panel’s outputs will be made when the Diesel Powered Air Compressor is integrated into the LUPO. Access to the breaker’s output is required. Acceptable paths for routing wire to this access shall be described in the operational manual. | X | ||||||||
| 3.4.1. | Air compressor | The air compressor shall be a single stage, oil injected air compression unit that can maintain continual air use without an air tank. The air compressor shall exhibit either rotary screw or rotary vane compression methods. The Diesel Powered Air Compressor shall be capable of delivering at least 35 standard cubic feet per minute (scfm) at a pressure of 150 pounds per square inch, gage (psig). For reference only, the current Diesel Powered Air Compressor utilizes Rotorcomp/Verdichter’s NK-40 rotary screw compressor. | X | X | |||||||
| 3.4.1.2. | Air filtration | The Diesel Powered Air Compressor shall exhibit a two stage, dry type air filter. | X | X | |||||||
| 3.4.2. | Power delivery | The Diesel Powered Air Compressor shall be capable of delivering at least 3.3 kilowatts (kW) of power at 120 Volts AC at 60 Hertz. For reference only, the current Diesel Powered Air Compressor utilizes Mecc Alte’s S16W-90/C generator. | X | X | |||||||
| 3.4.4. | Diesel engine | The Diesel Powered Air Compressor shall operate using a diesel engine. This engine shall be liquid-cooled and shall operate to full capacity on both JP-8 and diesel fuel. For reference only, the current Diesel Powered Air Compressor utilizes Kubota’s D902 E3B engine. | X | X | |||||||
| 3.4.4.1.1. | System battery | The Diesel Powered Air Compressor shall be activated using a 12V battery. The salient characteristics of the battery are that it shall consist of a wound cell Absorption Glass Mat type battery that is available through the DoD supply system with a NSN and that it shall be suitable for starting the system in all required conditions. For reference only, the current Diesel Powered Air Compressor utilizes Optima’s YellowTop D34 battery NSN 6140-01-0457-5392. | X | X | |||||||
| 3.4.4.2. | Liquid cooled | In order to reduce the level of noise generated by the diesel engine, the engine shall be liquid cooled. The liquid used to cool the engine shall be heavy-duty ethylene glycol conforming to A-A-52624. | X | X | |||||||
| 3.4.4.3. | Muffler | In order to further reduce the noise of the diesel engine, it shall be equipped with a muffler. The muffler shall exhibit sizing sufficient for the flow of the exhaust and to reduce engine noise to an acceptable level. See 3.7 for more requirements surrounding the noise of the Diesel Powered Air Compressor. | X | X | |||||||
| 3.4.4.4. | Enclosure insulation | Sound-dampening insulation shall be included on the interior of the enclosure. The insulation shall be attached to the enclosure permanently, and shall not be degraded by the anticipated operating environments. Because the enclosure is not anticipated to be watertight and the Diesel Powered Air Compressor is required to operate in all weather conditions, water infiltration shall not cause damage to or degradation of performance of the insulation. See 3.7 for more requirements surrounding the noise of the Diesel Powered Air Compressor. | X | ||||||||
| 3.4.5. | Operating temperature | The Diesel Powered Air Compressor shall be capable of operation in temperatures ranging from 0°F to 120°F in accordance with the test methods in MIL-STD-810’s Method 501.5 for high temperature and Method 502.5 for low temperature. | X | ||||||||
| 3.4.6. | Size | The envelope allowable for the base system, excluding any exhaust points, air outlets and pressure relief safety valves, shall not exceed the current envelope dimensions of a height of 32.3 inches, a length of 41.3 inches, and a width of 31.3 inches. The placement and size of the exhaust points, lifting hooks, air outlets, and pressure relief safety valves shall not impede the storage, removal, or operation of the Diesel Powered Air Compressor when installed on the LUPO. Note that the base system unit dimensions do not include the dimensions of the slide. | X | X | |||||||
| 3.4.6.1. | Mounting | To attach to the LUPO, the Diesel Powered Air Compressor is bolted to the base. The Diesel Powered Air Compressor shall exhibit mounting provisions that mate to the current holes of the base of the LUPO identically to the current Diesel Powered Air Compressor. | X | X | |||||||
| 3.4.6.2. | Vibration dampening | The mounting between the Diesel Powered Air Compressor and the mounting areas shall exhibit provisions to dampen the vibration that the unit would experience during transport. The base plate of the unit shall be isolated from the mounting brackets by the addition of rubber vibration dampeners. Other methods of reducing vibration will be considered on a case-by-case basis. | X | X | |||||||
| 3.4.7. | Weight | The base system shall not weigh more than 870 pounds when fully filled with fluids and ready for operation. When placed in long-term storage mode, the Diesel Powered Air Compressor shall weigh less than in operational mode. Note that this is the base system weight, and that the weight of the remote panel and the wiring harness are not required to be included in this weight. | X | ||||||||
| 3.4.7.1. | Operation time | The Diesel Powered Air Compressor shall operate for no less than 8 hours at full load without refueling. | X | X | |||||||
| 3.4.7.2. | Refueling | The Diesel Powered Air Compressor shall refuel through a cap located on the side of the compressor. This cap shall be able to be removed and replaced without moving any plates or panels. When the compressor is fueled, the level of fuel shall be readily evident on the remote panel, allowing the user to reduce the amount of overfill when fueling. | X | X | |||||||
| 3.4.8. | Exhaust output | The exhaust from the Diesel Powered Air Compressor shall be routed to a 1.75 inch stainless steel pipe located at the top of the enclosure. Due to the exterior mounting of the LUPO, the exhaust shall exhibit a rain guard that prohibits rain from entering the exhaust system when the Diesel Powered Air Compressor is not activated. | X | X | |||||||
| 3.4.10. | Wire connections | The Diesel Powered Air Compressor shall exhibit automotive-style connections between interior wires that are sealed and weather tight. The connectors shall be suitable for use in an off-road location with vibration characteristics. The connectors shall utilize a pin and socket system that conforms to SAE AS39029. The material for the connectors shall pass the testing in UL 94 HB. For reference only, a source of internal electrical connectors is Tyco Electronics’ AMPSEAL 16 series. | X | X | |||||||
| 3.4.12. | Lifting interface | The base system shall exhibit 4 lifting points on the top of the unit. These points shall allow the unit to be sling lifted and shall exhibit an even load between the points. | X | X | |||||||
| 3.4.12.1 | Lifting points | The Diesel Powered Air Compressor shall exhibit no fewer than four lifting points located on the top of the base unit. These lifting points shall be recessed and spring loaded. Recessing the lifting points shall allow the points to fall completely within the envelope of the Diesel Powered Air Compressor when the unit is not being lifted. Spring-loading the lifting points shall cause the points to return to the resting position when not in use. The strength of each point shall be rated in accordance with MIL-STD-209. For a photograph of the top of the current Diesel Powered Air Compressor, see Figure 6. For reference only, the current Diesel Powered Air Compressor utilizes Eberhard Manufacturing Company’s part number 3-172. | X | X | |||||||
| 3.5.1. | Size | The remote control panel shall be no greater than 12.5 inches wide, 14.5 inches high and 6.25 inches deep. Note that these dimensions do not include the 12 V DC Crane switch. | X | X | |||||||
| 3.5.2. | Control panel enclosure | The remote control panel shall be contained in a NEMA type 13 enclosure. | X | ||||||||
| 3.5.3. | Starting provision | The remote control panel shall include provisions for the ability to start and stop the Diesel Powered Air Compressor. | X | ||||||||
| 3.5.4. | Safety reset switch | The remote control panel shall include a safety reset switch. When the compressor gages in 3.4.12 send a signal of temperature or pressure exceeding the set limit, the safety reset switch shall activate and shut down the system. When the compressor temperature and pressure return to acceptable levels, this switch shall allow a manual reset that permits the engine to be re-started. | X | X | |||||||
| 3.5.5. | Electrical breakers | The power output from the generator shall be routed to no fewer than 2 20-Amp GFCI electrical breakers. The breakers shall be push-reset type, to allow for easier operation on the remote panel. See 3.2.4.3 for more information on routing the power output from the generator. | X | X | |||||||
| 3.5.6. | Warning provisions | The remote control panel shall include warning lights to provide information about the engine coolant temperature and the engine oil pressure. These lights shall activate if the coolant temperature or oil pressure exceed safety margins defined by the engine manufacturer. | X | ||||||||
| 3.5.7. | Switches | Two switches are required on the remote panel. The first switch shall activate the red flood lights. The second switch shall activate the white flood lights. Each position of each switch shall be clearly labeled with the function of the position. | X | ||||||||
| 3.5.8. | Gages | The remote control panel shall include gages detailing the number of hours that the system has been operational, the fuel level of the system, and the A-C voltage of the system. For an example of the control and gage remote panel from the current LUPO, see Figure 7. | X | ||||||||
| 3.5.9. | Compressor gages | In addition to the gages required in 3.5.8, to ensure safe operation of the air compressor, the remote panel shall have two additional gages. These gages shall indicate compressor discharge oil temperature and compressor line pressure. These gages shall also contain a switch which activates at pre-set levels and sends a signal to the safety reset switch to cause operation to cease. The safety reset switch shall be located on the remote panel as stated in 3.5.4. The pre-set levels shall preclude damage to the unit from problems that increase oil temperature or compressor line pressure. | X | X | |||||||
| 3.6 | Wiring harness connection | The remote control panel shall be connected to the base system by a wiring harness. The wiring harness shall have a plug at one end to connect to the base system and be integrally connected to the remote panel at the other end. The connection to the remote panel shall be on the rear of the panel, directly below the outlet. | X | ||||||||
| 3.6.1 | Wiring harness plug | The plug that connects the base system to the wiring harness shall exhibit an arrangement of pins in the plug that disallows the insertion of the plug in any manner other than its intended orientation. The plug shall be adequately sized for the anticipated amperage loads. The plug shall exhibit an environmentally sealed, multi-pin circular connector. For reference only, the current Diesel Powered Air Compressor utilizes a Deutsch HD30 series 16 pin connector. | X | X | |||||||
| 3.6.2. | Wiring harness properties | The wires that compose the wiring harness shall be wrapped to inhibit separation. If all wires within the harness are correctly sealed and individually weather-tight, the wrapping is not required to seal the wires; however, the wiring harness shall be watertight and able to be immersed in water without damage or any loss of functionality. This requirement only applies to the harness, not to the ends, the base unit, or the remote panel. | X | ||||||||
| 3.7 | Noise | The Diesel Powered Air Compressor shall comply with the steady-state noise limit in MIL-STD-1474 Requirement 3 when measured as a mobile generator set. Under full load, the Diesel Powered Air Compressor shall produce less than 70 decibels (dB) of noise when measured at a distance of 7 meters. Components like the insulation and the muffler shall be designed using state-of-the-art technology to reduce the noise output of the system to this level. Measurements at 7 meters shall be taken at no fewer than 8 locations: once offset from each of the front, rear, roadside, and curbside, and once offset from each corner. All other measurement criteria shall be in accordance with SAE J1074 for layout and testing. The Diesel Powered Air Compressor shall be tested as a unit with full draw of both electrical power and compressed air. | X | X | |||||||
| 3.7.2 | Maximum noise | No sound measurements of the Diesel Powered Air Compressor shall require a caution label in accordance with MIL-STD-1474. Therefore, all measured sound levels shall be less than 100 dB. | X | ||||||||
| 3.10.1. | Powder coat | The exterior of the Diesel Powered Air Compressor shall be finished with a powder coat paint that is durable and scratch resistant. In order to ease cleaning and maintenance requirements, panels on the interior of the Diesel Powered Air Compressor shall be powder coated wherever possible. Note that many areas are not feasible to powder-coat on the interior, and these areas are not required to be powder coated. | X | ||||||||
| 3.11.3.2 | Corrosion resistance | The Diesel Powered Air Compressor shall exhibit a conformal coating that protects all electronic components from corrosion due to environmental conditions. The conformal coating shall allow all electronics to operate in all environments without degradation. The Diesel Powered Air Compressor will be deployed in locations adjacent to salt water and will operate in salt spray environments. In order to better withstand the corrosive environments expected when deployed, all electrical connections, circuit cards and other electronic components within the unit that may be susceptible to corrosion shall be coated with a corrosion resistant layer. Note that this requirement includes all circuit boards, electrical connection areas, and gage connections, as well as other areas within the unit that could be prone to damage by corrosion. This requirement covers the base system, the remote panel, and the wiring harness. For reference only, a conformal coating that protects electronics from this type of corrosion is Parylene. | X | X | |||||||
| 3.11.3.3. | Operating altitude | The Diesel Powered Air Compressor shall include an analysis of the effects of the altitude of operation on the output of the Diesel Powered Air Compressor. This analysis shall show the compressed air output at 150 psi from operation with both diesel and JP-8 from sea level to 15,000 feet at increments of no less than 500 feet. This information shall be plotted on a graph that shows the flow output on the vertical axis and the elevation on the horizontal axis. Inclusion of the altitude report will constitute passing this requirement. | X |
Example
| Example Response | |||||||
| Paragraph number | Paragraph Title | Paragraph Contents | Written Response | Drawings / figures | Technical literature | Catalog description | Additonal relevant information |
| 3.4.13.1 | Lifting interface | The Diesel Powered Air Compressor shall exhibit no fewer than four lifting points located on the top of the base unit. These lifting points shall be recessed and spring loaded. Recessing the lifting points shall allow the points to fall completely within the envelope of the Diesel Powered Air Compressor when the unit is not being lifted. Spring-loading the lifting points shall cause the points to return to the resting position when not in use. The strength of each point shall be rated in accordance with MIL-STD-209. For a photograph of the top of the current Diesel Powered Air Compressor, see Figure 6. For reference only, the current Diesel Powered Air Compressor utilizes Eberhard Manufacturing Company’s part number 3-172. | The base system can be lifted from 4 lifting points on the top of the unit. The Eberhard 3-172 are spring-loaded to return within the enclosure dimensions. Each point is rated to 2,000 pounds. | Attachment 2 contains figures. Figure 16 shows the lifting points. Note that the points are contained within the envelope of the base unit. | See attachment 2 Figure 17 for a finite element analysis that shows the anticipated forces for lifting the base unit by the lifting points. | Attachment 4, page 8 contains the catalog discription of the Eberhard lifting points. | Attachment 5, page 3 contains an analysis comparing the attachment point rating to the frame strength and the requirements of MIL-STD-209, showing that the requirement is met. |
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