20180628-MEC-SOW.pdf

NAVAIR 4.4.6.2 Electrical Test Operations and Maintenance Branch

Procurement of Moveable Temperature, Altitude, and Humidity Environmental Test Chambers

The Naval Air Warfare Center – Aircraft Division (NAWCAD) has developed a requirement for two (2) Moveable Environmental Chambers (MEC) to perform unique mission based environmental evaluations.

DESCRIPTION/SPECIFICATION/STATEMENT OF WORK

1 Background

The Naval Air Warfare Center Aircraft Division (NAWCAD) has a requirement to procure two moveable environmental chambers (MECs) for use in the Electrical Test Operations & Maintenance (ETO&M)

Branch Laboratory. The ETO&M Branch Laboratory is a testing facility which consists of numerous test areas that are designed to evaluate electrical power generation, battery and power conversion systems, electrical power distribution systems, electrical power quality, electrical starting and emergency electrical power and avionics systems under simulated flight conditions.

The MECs will be utilized to provide controlled environments during testing of Naval aircraft, shipboard, and ground-based electrical, avionic or mechanical components and systems. The predominant test methods will come from MIL-STD-810, MIL-HDBK-781, MIL-G-21480, and MDC A4241 for combined temperature, altitude, and humidity. The results of the testing will be used for Naval reliability, qualification, safety of flight, flight worthiness, and evaluation programs. With the use of the ETO&M branch electrical bus-ways along with the MECs, full aircraft simulations can be used to assess thermal, mechanical, and electrical synergetic stresses on both legacy and new technologies.

2 Scope The contractor shall provide for design, manufacturing, delivery, installation, start-up, documentation, and warranty of two (2) Moveable Environmental Chambers and all ancillary equipment required as detailed in this statement of work.

3 CLIN 0001 – MEC – QUANTITY 2

3.1 MEC Technical Requirements

3.1.1 Controlled Chamber Parameters

The chamber shall simultaneously control the temperature, pressure altitude, and humidity.

3.1.2 Temperature

The chamber temperature range shall be -73 °C to +177 °C with a control tolerance of ±1.0 °C as measured at the control sensor after stabilization.

3.1.3 Heating and Cooling

The chamber, with mechanical cooling, will perform the following temperature transitions:

+85 °C to -65 °C in 15 minutes or less (10 °C per minute average rate of change)

-65 °C to +85 °C in 15 minutes or less (10 °C per minute average rate of change)

The chamber shall have LN2 boost capability for high ramp rate applications.

Notes:

Static Load Used for Calculations: 200 lb. of aluminum, billets

Live Load Used for Calculations: Ability to hold 5,500 watts at -65°C (need actual load)

3.1.4 Humidity

The humidity range shall be 20% to 95% RH as limited by a 5°C dew point and a maximum dry bulb temperature of 85°C with a control tolerance of ±3% as measured at the control sensor

3.1.5 Altitude

The altitude range shall be site level to 80,000 feet (clean and dry chamber) with the following transition rates.

1. Site level to 20,000 feet in 1 minute or less, clean and dry chamber

2. 20,000 to 50,000 feet in 4 minutes or less, clean and dry chamber

3. 50,000 to 80,000 feet in 15 minutes or less, clean and dry chamber

The system shall allow altitude profiles to be programmed as ramp steps for controlling climb and dive rates at any desired rate less than the maximum chamber capacity rating. The system shall control altitude to within 500 feet of the set point at altitudes below 50,000 feet and within 2% of the set point at altitudes above 50,000 feet. The chamber shall maintain pressure parameters within tolerance in the presence of a 0.2 lbm/minute leak at wire penetration interfaces.

3.1.6 Combined Environment

MEC system shall provide both cycling and steady-state altitude and temperature capability between

+150 °C and -60 °C at any altitude between site level and 65,000 feet. The system shall provide temperature and humidity environments between 20% - 95% RH as limited by a 4 °C dew point and a maximum dry bulb temperature of 85°C, at site level pressure only.

3.2 Environmental Chamber

The moveable environmental chamber will be primarily used to provide specific environments for rotating equipment (e.g. generators) installed on an electric drive stand. The conditioned space portion of the chamber will be positioned in a manner as to surround the test article and place it in the specific environment. The chamber may also be used for typical applications not requiring adaptation to a drive stand (i.e. a door as described in 3.2.8) will cover the conditioned environment). The environmental chamber will be used in a crowded machinery room and must be maneuvered along a concrete floor to facilitate use on multiple drive stands.

3.2.1 Interface

The chamber shall have a means for sealing the environmentally conditioned space around the test article while mounted to the drive stand.

3.2.2 Chamber Interior Dimensions

The chamber vessel interior shall have a clear usable workspace of at least 42 inches width, depth, and height.

3.2.3 Chamber Envelope Dimensions

The entire chamber (or individual modules) must not exceed 120 inches long x 84 inches deep x 100 inches high (see Figure 1).

Figure 1: Notional chamber illustration with major dimensions

3.2.4 Transport

The chamber system shall have an electric drive system that allows movement of the chamber / chamber modules within this space by no more than two operators. The rolling elements used to support the chamber during transport shall not damage flooring during transport. The unit shall be capable of being maneuvered along pathways approximately 84 inches wide. Upon final location the chamber shall have a means for locking the chamber system in place.

3.2.5 Positioning

The system shall have a motorized system for fine adjustment of the chamber vessel position to allow precise vertical and lateral alignment and placement of the chamber vessel around the test article.

3.2.6 Internal Liner

The chamber liner shall be constructed of corrosion resistant materials and shall insure a hermetic seal preventing moisture migration into the chamber during low-temperature operation. All liner seams and corners shall be designed to allow for thermal expansion during temperature cycling operation. All interior parts exposed to the chamber environments shall fabricated of corrosion-resistant materials. The floor shall be sloped in a manner to direct all condensates toward a drain located under the rear wall conditioning plenum. The chamber vessel insulation shall be isolated from the working space.

3.2.7 Chamber Exterior

The exterior of the chamber is manufactured of heavy duty steel framework with sheet metal panels.

Panels covering serviceable components shall be equipped with quick release fasteners for ease of access.

Removable panels shall be equipped with gasket seals to prevent ambient air and moisture migration into the insulation space during low temperature operation to prevent frost build-up and subsequent saturation of the insulation. The chamber exterior shall be finished with a coating resistant to typical corrosive agents present in an industrial application per best commercial practices.

3.2.8 Door and Hardware

The chamber shall include a recessed side access panel with a viewing window. The panel shall allow full access to the chamber workspace. The panel shall maintain an airtight and moisture-proof seal under all chamber operating conditions.

3.2.9 Conditioning System

Cooling, heating, and other related conditioning components shall not protrude into the work space. The air circulation system shall assure proper air distribution and prevent air stratification throughout the chamber.

3.2.10 Refrigeration System

The refrigeration system shall use non-explosive and ozone-friendly refrigerants. Only ASME approved refrigerant vessels, over pressure limit cut-out switches, pressure relief valves shall be used in the refrigerant systems (R-507 /R-508).

3.2.11 Electrical System

Motor starters, heater contactors, relays and other electrical components shall be packaged enclosed in a power distribution panel and shall include thermal and electrical overload protection. The chambers shall be operating on standard 480 volt 3-phase power. All electrical components and wiring shall conform to

National Electrical Manufacturers Association Standards. All wiring shall be clearly labeled and identified with wires and terminals labeled to correspond to the electrical schematic.

3.2.12 Instruments and Controls

The system shall provide the following instruments and controls for both local and remote monitoring and control of the system including temperature, pressure, humidity, and user-defined data logging / text export of all control and indicator parameters. Instruments shall be mounted and housed in a control panel enclosure allowing easy user access during chamber operation. The system shall provide user–defined alarm notification and automatic system shutdown capabilities. The system shall allow remote operation via Ethernet through a National Instruments© LabVIEW interface. (CDRL A001)

3.2.13 Software

All system software shall comply with requirements specified within Department of Defense Instruction

8500.01, Cybersecurity and be compatible with Microsoft Windows 10 Professional. (CDRL A002)

3.2.14 Electrical Overload Protection

The system shall provide electrical and thermal overload protection for individual circuits and components.

3.2.15 Fan Openings

All fans with openings larger than 3/8 of an inch shall have guard screens.

3.2.16 Over-Temperature Safety Limit

The system shall have adjustable protection measures to protect the chamber from exceeding design limits.

3.2.17 Pressure Relief

The system shall have a means for pressure relief to prevent excessive pressure build-up in the system.

3.2.18 Accessibility

All system hardware shall be easily accessible for maintenance and removal.

4 CLIN – 0002 Documentation

4.1 Operation Instruction Manual (CDRL A003)

Operator instruction manuals shall be provided. The manuals shall include wiring and plumbing schematics.

4.2 Maintenance Instruction Manual (CDRL A004)

Maintenance instruction manuals shall be provided. The manuals shall include wiring and plumbing schematics.

4.3 Spare Parts List (CDRL A005)

The contractor shall provide a complete parts list for all systems and their sources.

4.4 Illustrated Parts Breakdown (CDRL A006)

The contractor shall provide a complete illustrated parts breakdown for all systems.

4.5 Engineering Drawings (CDRL A007)

The contractor shall provide a complete set of as-built engineering drawings including schematics of all systems. In addition, the contractor shall provide a complete set of assembly drawings. All drawing packages shall have sufficient detail to fully describe each system they represent.

4.6 Installation Drawings (CDRL A008)

Installation interconnection drawings shall be furnished at the earliest possible time to assist in facilities and installation planning. The contractor shall provide procedures and system calibration requirements.

4.7 Calibration Manual (CDRL A009)

The contractor shall provide

4.8 Warranty (CDRL A010)

The Contractor shall include a one (1) year warranty effective Full Operational Capability (FOC).

4.9 System Specification (CDRL A011)

The Contractor shall include a system specification which completely describes all system operational capabilities.

4.10 Engineering Drawings/Schematics (CDRL A005)

The Contractor shall provide the following at FOC

1. 100% dimensional drawings including Bill of Materials (BOM)

2. Electrical wiring schematics including BOM

3. Mechanical drawings/schematics including BOM

4.11 Specifications (CDRL A006)

The Contractor shall provide specifications for chamber and subsystems.

5 CLIN 0003 DELIVERY

5.1 Packaging

All shipments required for the MEC hardware shall arrive in palletized packaging for ease of unloading at the Building 1461 loading area.

5.2 Heavy Shipment

Any shipment exceeding four-thousand (4,000) pounds shall be defined as a Heavy Shipment.

Each Heavy Shipment shall adhere to the following:

1. Contractor shall notify the Government not less than one (1) week in advance of shipment.

2. Selected shipper shall schedule the specific date and time of delivery.

3. Shipper shall notify the Government immediately upon any deviation to the delivery schedule.

6 TECHNICAL POINT OF CONTACT

R. Greg Nepini ronald.nepini@navy.mil

301-342-0872

7 Shipping Address

ATTN: Michael Goodnow

Commander Naval Air Systems Command

48298 Shaw Road, Bld. 1461

Patuxent River, MD 20670

301-342-0814

FOB: Destination mailto:ronald.nepini@navy.mil