Cooling Turbine Test Cell SOW 06-25-2024.docx

COOLING TURBINE TEST CELL BLDG. 137, FRCE

1. SCOPE

This specification defines the minimum requirements for the turn key upgrade of the Cooling Turbine Test Cell (CTTC) located in Building 137 at Fleet Readiness Center (FRC) East, MCAS Cherry Point NC. The test cell upgrade shall consist of the removal of the existing system, design, acquisition, installation, integration, and testing tasks necessary to successfully complete the performance requirements of this specification. The new system shall be a supervisory data acquisition system to control, measure, display, and record all physical parameters required for testing of the subject cooling turbines in accordance with established overhaul procedures. Requirements for technical manuals, drawings, and personnel training for the operation and maintenance of the system are included in this specification.

2. APPLICABLE DOCUMENTS

2.1. GENERAL

While every effort has been made to ensure completeness of the list, users are cautioned that they must meet all of the specified requirements cited in this specification, whether or not they are listed in this section.

2.2. GOVERNMENT DOCUMENTS

This paragraph will identify Government documents to which the Contractor must comply. Unless otherwise specified, the version of these documents are those cited in the solicitation or contract or the current revision at the time of solicitation. See Table 1.

Table 1 - Government Documents

CP15-88-ZZ-1710 Rev A

2.3. NON-GOVERNMENT DOCUMENTS

This paragraph will identify Non-Government documents to which the Contractor must comply. Unless otherwise specified, the version of these documents are those cited in the solicitation or contract or the current revision at the time of solicitation. See Table 2 Table 2 - Non-Government Documents

https://www.assp.org/

https://www.assp.org/

2.4. COOLING TURBINE (CT)/AIR CYCLE MACHINE (ACM) OVERHAUL MANUALS

Table 3 – UUT Overhaul Manuals

204770-1-1/-2-1

204315-1-1 572430-1-1

2.5. ORDER OF PRECEDENCE

In the event of a conflict between the text of this document and the references cited herein, the text of this document takes precedence. However, nothing in this document supersedes applicable laws and regulations unless a specific exemption, in writing, has been obtained.

2.6. REVISION

The revision of any/all referenced documents that is the most current at the time of contract award shall govern.

3. REQUIREMENTS

3.1. GENERAL INFORMATION AND COVERAGE

The CTTC upgrade shall be of the contractor's design except as otherwise specified herein and shall be new, unused, and capable of performing its intended function in accordance with the operation and performance requirements specified herein.

3.1.1. Existing Capability

The Contractor shall maintain all current capabilities of the existing test stand.

3.1.2. Turnkey Delivery

The contractor shall deliver a turnkey upgraded test cell capable of successfully testing all aircraft components per applicable overhaul manual listed in Table 3.

3.1.3. Documentation of the Existing System

Documentation, drawings, and source code for the current system are not available and cannot be provided. The Contractor shall be responsible for reverse engineering the wiring/software/capabilities/methods of operation for the existing system as required.

3.1.4. Downtime

Total test cell downtime shall be limited to 90 Days. The Contractor’s Plan of Action and Milestones (POA&M) shall include the projected downtime of the test cell. Downtime is defined as the first day the existing test cell is not capable of testing 100% of its current capabilities until the completion of Final Acceptance Testing (FAT). Note that the test system must be calibrated per a NAVAIR Metcal approved calibration procedure and stickered prior to the start of FAT. Contractor’s Site Preparation and Installation Plan shall include detailed information, including risk mitigation, on how Contractor plans to meet the 90-day downtime requirement.

3.2. DEFINITION

The Cooling Turbine (CT)/Air Cycle Machine (ACM) test system shall be capable of automatically, semi-automatically, and manually testing the performance characteristics of multiple types of military CTs/ACMs in accordance with the applicable overhaul manuals listed in this specification. The test system shall simulate engine bleed air for each CT/ACM and perform data acquisition, processing, and control necessary to complete the required tests. The CT/ACM test system shall be designed so that all Unit Under Test (UUT) can be mounted on the test cart by one operator while maintaining standard work practices and ergonomic principles with minimal change in the test set-up between different UUTs.

3.2.1. Modes of Operation

The developed test system shall be capable of testing in automatic, semi-automatic, and manual modes. The operator shall be able to select the mode of operation.

3.2.1.1. Automatic Testing

The system shall be capable of automatic testing of all the CT/ACM’s listed in this specification. The contractor shall develop and implement a Data Acquisition and Control System (DACS) that shall fully control CT/ACM testing. The automatic test, for each UUT, shall have a test run time (including all tests in the applicable UUT Overhaul Manual) of less than the same UUT tested on the existing system. This includes data collection and test stand operation to automatically, and without user intervention, achieve:

· All test points as defined in the applicable Overhaul Manual

· Safe and controllable ramp rates

· Continuous UUT and test system parameter monitoring and recording

· Alarming and safe automatic shutdown

3.2.1.1.1. Automatic Testing Initiation

Automatic Testing shall be initiated by the test stand operator via touch screen or mouse/cursor manipulation of a "sequence start" selection on the DACS.

3.2.1.1.2. Bumpless Mode Change

Transfers from automatic mode to manual mode shall be seamless and bumpless.

3.2.1.1.3. Force Advance

The Operator shall have the ability to “force” any test step to advance to the next step. Force advance shall not override any automatic shutdown due to operating limits being exceeded.

3.2.1.1.4. Automatic Testing Recording

Each successful execution of an automated test sequence shall be recorded and stored in memory as a file. This file shall include all run data and stand parameters for the entire duration of the test, as well as include a time/date stamp that indicates start/finish time in hours/minutes/seconds as well as day, month, and year. Recorded data share be searchable.

3.2.1.2. Manual Testing

Operation of the test stand in manual mode shall be possible. The manual mode shall allow full control of all test stand functions with complete monitoring of all critical parameters to provide automatic shutdown due to operating limits being exceeded. At any time during automatic testing the operator shall have the ability to interrupt the automatic test sequence and switch to the manual mode. Software shall have both text field (for inputting a specific valve position, etc.) and increase/decrease set point buttons. Step size of increase/decrease button shall be configurable by the operator (i.e. 0.1/1/5/10 % valve position increments). All alarm functions and shutdowns routines shall operate in the manual mode.

3.2.1.3. Semi-Automatic Mode

Test system shall have the capability to run semi-automatically (i.e. the operators shall have the ability to manually control individual air valves while the software controls the rest of the system). All alarm functions and shutdown routines shall operate in the semi-automatic mode.

3.3. TYPICAL OPERATING CHARACTERISTICS

Typical UUT operating characteristics include speeds up to approximately 120,000 rpm, inlet pressures ranging from 0 psi to 300 psi, temperatures ranging from -60 °F to 500 °F, flow ranges up to 90 lb. per min. It is the responsibility of the contractor to obtain actual inlet conditions and required ranges and accuracy of test stand instrumentation from the technical manuals listed in this specification. The Contractor shall be responsible for providing instrumentation capable of supplying and measuring airflow, pressure, dew point, speed, vibration, shaft displacement, temperatures, etc. as require per the technical overhaul manuals listed in this specification.

3.4. CONFIGURATION AND DESIGN

The CT/ACM test system shall be configured and designed for installation in the 94402 test room of Building 137 at FRC EAST, MCAS, Cherry point, NC, for reference see attachment 17. Final arrangement shall be determined by the successful offeror to best suit the area of application and the requirements of this specification. The system as installed by the Contractor cannot be allowed any space outside the designated area without prior Government approval in writing. Available test cell floor space is approximately 270 sq. ft. (12 x 24 ft.). Available control room floor space is approximately 160 sq. ft. (9 x 18 ft.). Test cell ceiling height is approximately 20 ft. The test stand shall provide means for performing CT/ACM test procedures in accordance with the technical manuals listed in this specification. The test stand shall be designed for continuous operation (at least 10 hours a day).

3.5. PERMITS

The Contractor shall obtain all permits required for the scope of contractor supplied services. This includes, but is not limited to, building permits, hot work permits, and environmental permits. The Government will supply to the contractor Points of Contact (POCs) that may be responsible for, or provide assistance in, obtaining the required permits.

3.6. REMOVAL OF EXISTING SYSTEMS

The contractor shall remove the existing CT/ACM Test System. The contractor shall be responsible for the safe and proper removal, disposal, and site restoration. The contractor shall remove instrumentation and valves non-destructively. Construction debris shall be properly disposed.

The following hardware shall be turned over to the Government upon removal. The Government reserves the right to keep any items removed at time of demolition

· Any/All Flowserve/Valtek valves

· Any/All National Instruments data acquisition hardware

· Any/All Allen Bradley PLC hardware

· Any/All pressure transducers

· Any/All Endevco vibration measurement equipment

· Any/All Agilent 35670A and associated amplifier

3.7. COOLING TURBINE/ACM FACILITY CHARACTERISTICS

3.7.1. Government Furnished Compressed Air

The Government furnished compressed air is divided into four segments: 1) Shop Air (SA), 2) Compressed Air (CA), 3) 300H (Hot), 4) 300C (Cold). The Government will furnish hot and cold compressed air sources. Due to multiple pneumatic component cells operating from the same government furnished supply system, typical hot and cold header pressures are available at 300 +10/-50 psig, temperatures at approximately 850 + 150 ºF (hot) 85 + 10 ºF (cold), and airflow up to 275 pounds per minute (ppm) with typical airflow of less than 100 ppm. Dew point typically ranges from 0°F to -40°F. Contractor equipment shall be designed to withstand fully (100%) saturated air in the event of air dryer failure. Contractor shall provide an additional means to provide dry air if required for provided equipment. Typical pressure fluctuations vary from 1 psi/sec up to approximately 4 psi/sec. Hot and cold header pressures vary independently of each other. The contractor is also responsible for maintaining clean dry air (20 micron filtration or better, oil-free) to all pneumatically controlled instrumentation and UUT devices.

3.7.1.1. Compressed Air Shutdowns

If a compressed air system shutdown is required the Contractor shall submit the shutdown request in writing to the Technical Point of Contact (TPOC) at least 30 days prior to the requested shutdown, The Government has the ultimate authority on approving and scheduling shutdowns. Work performed during a shutdown may need to occur during non-working hours to avoid conflicts with production. Contractor shall lock-out/tag-out compressed air system while work requiring a shutdown is being performed.

3.7.2. Air Flow Measurement System

The existing air flow measurement system on each channel (A, B, and C) shall be upgraded/replaced as part of this contract

3.7.2.1. Design Pressure and Temperatures

Air flow measurement system shall be designed to withstand a maximum pressure of the compressed air system; 300 psig and a temperature of 1000 °F. Air flow measurement system shall meet all accuracy requirements of the UUT overhaul manuals and ASME MFC-3M-2004

3.7.2.2. Compliance with ASME MFC-3M-2004

All applicable requirements of ASME MFC-3M-2004 shall be complied with. Any requested deviations require, in writing, the Government’s approval.

3.7.2.3. Flow Conditioner

Contractor shall determine if a flow conditioner is required to meet the requirements of the UUT overhaul manuals, this contract, and ASME MFC-3M-2004. If it is determined that a flow conditioner is required it shall be a Zanker style flow conditioning plate. Required ASME class shall be determined by the contractor. ASME class at a minimum shall be 300

3.7.2.4. Pipe Interconnects

All Piping interconnects shall be either:

· Grayloc

· ASME Flange

The contractor shall determine required ASME class. ASME class at a minimum shall be 300.

3.7.2.5. Orifice Plate Fitting

Existing orifice plate fitting/flange shall be re-used. Contractor shall re-condition orifice plate fitting as required and/or replace as needed.

3.7.2.6. Orifice Plates

Two (2) different sized, unidirectional orifice plates shall be provided for each channel (six (6) in total). The orifice plates must be compatible with the orifice plate fitting. For reference the existing nominal orifice sizes are 1.1200” for Channel A and B and 0.4260” for Channel C. Existing orifice plate dimensions are provided for reference only. Contractor is responsible for the proper sizing of office plates to ensure all requirements of the UUT Overhaul Manuals and ASME MFC-3M-2004 are met. The plates shall be compliant with Section 2-4 of ASME MFC-3M-2004. The orifice plate material shall be Inconel 625. A suitable storage container shall be provided to help ensure the plates maintain a condition compliant with Section 2-4 of ASME MFC-3M-2004.

3.7.2.7. Temperature Measurement

A Resistance Temperature Detector (RTD) shall be used to measure air temperature at the orifice. RTD shall meet or exceed the accuracy requirements of ASME MFC-3M-2004, the UUT overhaul manuals, and the existing calibration procedure (LCP-CPB-MX-1288, Attachment 4)

3.7.2.8. Orifice Differential Pressure Transducer

3.7.2.8.1. Accuracy

To meet flow measurement range and accuracy requirements the existing system uses a low and high range orifice pressure transducer (one (1) pair low and high per air channel). The new test system shall use one (1) orifice differential pressure transducer per channel. Accuracy shall meet or exceed the accuracy requirements of ASME MFC-3M-2004, the UUT overhaul manuals, and the existing calibration procedure (LCP-CPB-MX-1288, Attachment 4) for both the high and low range transducers.

3.7.2.8.2. Burst Rating

Orifice differential pressure transducer shall have a burst pressure limit of 1,000 psi or better

3.7.2.8.3. Hart Communication

Transducers shall be configurable via Highway Addressable Remote Transducer (HART). HART software shall be installed on the test system computer. Contractor shall provide the necessary hardware and wiring to allow transducer configuration from the test system computer.

3.7.2.9. Flow Computations

The CT/ACM air flow calculations must conform to the following requirements.

3.7.2.9.1. Air Mass Flow

Air flowrate (given in lb./minute) shall be calculated using Eq. 2-1 of ASME MFC-3M-2004.

3.7.2.9.2. Discharge Coefficient

Orifice Plate Discharge Coefficient shall be calculated using Eq. 2-4 of ASME MFC-3M-2004.

3.7.2.9.3. Expansibility Factor

Expansibility Factor shall be calculated using Eq. 2-6 of ASME MFC-3M-2004.

3.7.2.9.4. Air Density

Air density shall be calculated using the real gas equation of state. Refer to Eq. 8-5.10 of ASME PTC 19.5-2004 for example. A lookup function is required to obtain the compressibility factors for a given temperature and pressure. It is not necessary to factor in humidity during calculations.

3.7.2.9.5. Air Velocity

For calculation purposes, air viscosity shall be assumed to be dependent on temperature only. A lookup function is required to retrieve viscosity at a given temperature.

3.7.2.9.6. Reynolds Number

Pipe Reynolds number shall be calculated using Eq. 1-4 of ASME MFC-3M-2004.

3.7.2.9.7. Effects of Thermal Expansions

The effect of thermal expansion on inner pipe diameter and orifice diameter must be accounted for in all applicable calculations. Temperature shall be sourced from the nearest thermocouple downstream of the orifice plate. Refer to section 2-4 of ASME PTC 19.5-2004.

3.7.2.9.8. Calculation Constants

The isentropic exponent of air, and atmospheric pressure shall be programmed as constants. These programmed constants must be user adjustable.

3.7.3. Dew Point Sensor

The contractor shall provide a new dew point sensor. Sensor shall be capable of reading dew point as well as relative humidity of air provided to UUT. Sensor shall meet or exceed the accuracy of the existing sensor/tolerances of LCP-CPB-MX-1288 (Attachment 4)/Requirements of the CT/ACM Overhaul Manuals Sensor shall be capable of interfacing with Johnson Control Metasys. Contractor is responsible for identifying Metasys interface requirements. Dew point and Humidity shall be visible on the Operator’s control screen.

3.7.4. Pressure Transducers

Contractors shall replace all existing pressure transducers with new pressure transducers of equal or better accuracy. Transducer accuracy shall meet all requirements of the CT/ACM Overhaul Manuals as well as LCP-CPB-MX-1288 (Attachment 4). Contractor shall provide any additional transducers as required to meet the applicable CT/ACM Overhauls Manuals. Transducers shall be configurable via Highway Addressable Remote Transducer (HART). HART software shall be installed on the test system computer. Contractor shall provide the necessary hardware and wiring to allow transducer configuration from the test system computer. The Contractor shall provide a thermally stabilized cabinet for the pressure transducers. The cabinet shall have an external viewable meter to read internal cabinet temperature. All transducer shall be labeled as to their corresponding Data Acquisition (DAQ) channel number. Labels shall be permanently affixed and oil, water, and temp resistant. Pressure transducers shall have NPT ports adapted to ¼” 37° JIC flares. Each pressure transducer shall have an isolation valve and ¼” 37° JIC input port to be used for transducer calibration. All pressure lines shall be fitted with a bleed port for evacuation of trapped air. All pressure transducer lines/connections shall be stainless steel tubing terminate via ¼” 37° JIC flares. The use of push to connect hose in not allowed.

3.7.5. New Operator’s Station

The contractor shall provide a new operator’s station (desk) to support the required monitors, video screens, and other required hardware. Operator’s view out of the test cell window may only be minimally obstructed.

3.7.5.1. Operator’s Chair’s

The Contractors shall provide two (2) new chairs to be used at the Operator’s station. Chair shall at a minimum have adjustment for

· Seat height

· Seat depth

· Arm height

· Tilt tension

· Tilt lock

3.7.6. Cabinets, Consoles, and Enclosures

The Contractor shall provide all new cabinets, consoles, and enclosure. Accessibility to chassis, assemblies, or parts contained within cabinets, consoles or other enclosures shall be provided from outside the basic equipment through the use of access doors, by mounting such items on withdrawal slides, swinging doors, through cable extenders and cable retractors, provisions for circuit card extenders which will allow part or module operation in the open position, or other arrangements to permit adequate access for properly servicing the equipment automatic or manually operated locks shall be provided to lock the chassis in the servicing position. When withdrawal slides are used, they shall be of guided sectional assembly with tracks and rollers. Complete removal and access for servicing of electronic equipment contained within cabinets, consoles or other enclosures shall be provided from either the front or rear of the equipment. Guide pins or locating pins, or the equivalent, shall be provided for mechanical alignment during mounting. All cabinets, consoles, and enclosure shall contain interior lighting to aide in maintenance.

3.7.6.1. Vortex Cooling

If vortex coolers are utilized the Contractor shall confirm existing utilities and the excess capability of the air system. Contractor shall provide additional compressed air supply if required. If vortex coolers are to be used:

· A hand valve is required in close proximity to each cooler to allow for easy shutdown for enclosure maintenance.

· Vortex air supply must have self-draining moisture traps or air dryers to ensure air supply does not contain moisture.

· Coolers must have temperature control. Vortex coolers shall not run on a continuous basis.

3.7.7. Test Carts

The upgraded test system shall be fully backwards compatible with all existing test carts. Contractor shall refurbish/partially upgrade all CT/ACM test cart, excluding the F-18 and V-22 test carts (See Table 4). All equipment shall be new and commercially off the shelf (COTS). No custom equipment/hardware is allowed unless explicably approved in writing by the Government. Any custom hardware shall not be proprietary and include all information/detail/data required to manufacture/reproduce the item. Refurbished/upgraded test carts shall meet all requirements of the applicable CT/ACM Overhauls manually as well as all requirements of this specification. At a minimum, the following hardware shall be upgraded/replaced:

· All pneumatically and/or electrically controlled valves

· All flexible piping

· All electrical connections and wiring

· All speed sensors

· All thermocouple sensors

· All excursion/proximity probes

3.7.7.1. New F-18 Test Cart

The contractor shall provide a duplicate F-18 Test Cart identical in capability to the existing test cart. The existing test cart shall also be fully compatible with the upgraded test system. All equipment shall be new and commercially off the shelf (COTS). No custom equipment/hardware is allowed unless explicably approved in writing by the Government. Any custom hardware shall not be proprietary and include all information/detail/data required to manufacture/reproduce the item. Two (2) sets (four (4) total) of excursion/proximity probes shall be provided. Test cart shall fit through the existing test cell personnel door which is approximately 2’ 9” wide and 6’ 10” tall. New test cart shall meet all the requirements of this specification and applicable CT/ACM Overhaul manuals.

3.7.7.2. V-22 Test Cart

The V-22 cart shall not be upgraded and/or duplicated as part of this contract. The Contractor shall ensure the existing V-22 cart and all associated equipment/hardware is fully compatible with the upgraded test system and meets all requirements of the associated CT/ACM Overhaul manual.

3.7.7.3. Hardware Requirements

All new hardware provided shall be designed for the environment for which it will be used. For excursion/proximity probes, speed sensors, and other hardware that sensor inside the air duct/piping this means the ability to withstand temperature from -60°F to 400°F and a dew point of up to 50°F.

Table 4 – Test Carts Test Cart Plant Account

204315-1-1 572430-1-1 Contractor shall update test cart in accordance with section 3.7.7

204770-1-1/-2-1 Contractor shall update test cart in accordance with section 3.7.7

1671D000 Contractor shall update test cart in accordance with section 3.7.7

3.7.8. Agilent Integration

All existing capabilities of the Agilent 35670A Dynamic Signal Analyze shall be incorporated into the test system software. This includes but may not be limited to:

· Real-time Vibration Spectral Analysis

· Oscilloscope Functionality

· Vibration Scans

· Vibration Surveys using Displacement Probes

· Balance Polar Plots

· Operator Adjustable Signal Averaging

· Operator Adjustable Search Bands

Contractor is responsible for incorporating all Agilent capabilities required per the applicable CT/ACM Overhaul manual. Agilent shall be turned over to the Government.

3.7.9. Plumbing

The contractor shall install all necessary plumbing, filters, insulation, valves, sensors, and hardware required for testing all UUTs of this specification. All process piping, associated components, and hardware shall be new and unused.

All process piping and associated components shall be designed, constructed, and installed per the applicable requirements of ASME B31.l based on the maximum temperature and pressure conditions to which they will be exposed. All process air piping, valves, and measuring devices shall be equipped with flanged connections. Contractor shall test all plumbing to ensure there are no leaks. All rigid pneumatic sensor lines shall be stainless steel construction with 37 Degree flare. No push to connect hose is allowed. Overhead mounting of plumbing is preferred, where possible. The CT/ACM test system design shall include system isolation valves and spare pressure ports at key locations for maintenance troubleshooting and potential future additions of measuring instruments.

3.7.10. Filters

Contractor shall replace the three (3) channel air filters after upgrade and prior to running any UUTs. In addition, contractor shall provide one complete set of spares for channel air filters (three (3) filters total). Filters shall be at 20 micron or better.

3.7.11. Insulation

Insulation shall be provided on all rigid piping exposed to above-ambient (mixed or hot) process air streams. The insulation shall possess a minimum continuous temperature rating of 1100 ºF. Sufficient thickness of insulation shall be provided to maintain surface temperature at or no more than 50 ºF change above ambient temperature. Metal over-wrap is preferred. To facilitate maintenance, insulation shall be of a type which can be quickly removed and re-installed for valve/component replacement.

3.7.12. Process Air Valves

The Contractor shall replace all process air valves on Channels A, B, and C. The new valves shall be a direct replacement of the existing air valves. New valves shall be Flowserve/Valtek or equivalent. Contractor shall utilize Flowserve/Valtek serial numbers to ensure correct direct replacement is procured. The Contractor shall also note any controller configuration settings prior to removal. The Contractor shall provide all hardware, software, wiring, etc. required for the capability to control the Exhaust/Vent valve from the test system software. The CT/ACM test system contains three (3) air channels (A, B, and C) used for supplying simulated engine bleed air to the UUT’s. These channels are located in the Channel Room of the CT/ACM test system, for reference see Attachment 16 -- Layout. All replacement valves shall have the ability to be automatically and manually controlled (open and closed) from the test system software. The valves that shall be replaced in the channel room shall at a minimum include:

· Channels A and B, Two (2), Mark 1 High Performance 2” Globe Valves

· Channels A and B, Two (2), Mark 1 High Performance 2” 3-way Mixing Globe Valves

· Channel C, One (1), Mark 1 High Performance 1” Globe Valve

· Channel C, One (1), Mark 1 High Performance 1”, 3-way Mixing Globe Valve

3.7.12.1. Pressure and Temperature Stability

Air supplied to the UUT shall not vary/oscillate more than +/- 1 PSI and +/- 5 °F from set point during test. Contractor shall provide additional pressure and temperature regulating valves and/or other hardware if required to meet this requirement.

3.7.12.2. Bleed Air Valves

The contractor shall replace the bleed air valves located on each channel in the test cell (three (3) valves total). New bleed air valves shall be a direct replacement of the existing valves. Bleed valves shall have the ability to be automatically and manually controlled (open and closed) from the test system software.

3.7.12.3. PID Control and Tuning

All process air valves shall be Proportional-Integral-Derivative (PID) Loop controlled. Contractor shall provide a means to tune the PID Loop Control via software from the operator’s console. The Software shall have the capability to use unique PID Tuning profiles with each UUT if required. PID tuning constants/profile shall be exportable and restorable.

3.7.13. Inlet Duct

The contractor shall provide a louver for the test cell inlet air. Louver shall be designed to prevent Foreign Object Debris (FOD) from entering the test cell. Louver shall be designed to not allow particles 20 micron in diameter into the test cell. Louver shall be controllable by the operator from the ground level.

3.7.14. Wiring and Hoses

The Contractor shall replace all existing data, communication, signal, vibration monitoring, and control wiring. The Contractor shall replace all hoses present in the test system with new hoses. The Contractors shall replace all terminal block, connectors, fittings, etc. used for termination and or connections of said wiring and hoses. The Contractor shall replace the existing boom/arm used to route wiring/hoses/etc. from the control room cabinets to the test cell. The replacement boom/swing arm shall be of similar style to the existing boom. Boom connection panel/plate shall be clearly labeled. Label shall be compatible with the test environment (for example: oil, temperatures, vibration) The boom harness shall incorporate 25% spare unused electrical contacts and pneumatic taps fully populated and terminated back to the electrical and pressure transducer cabinet in the control room. This shall include two BNC 50 Ohm coaxial cables wired from the electrical cabinet and terminated at the boom connection plate. All wire, plumbing, and hardware installed shall new unused.

3.7.14.1. Wiring

All electrical connections between the boom and the test carts shall be made using military specification D38999 circular connectors. All wiring shall be clearly labeled on both ends identify signal and connection points. Cables and labeling shall be compatible with the test environment (for example: oil, temperatures, vibration) and properly protected and strain-relieved. Cables shall be provided with permanently mounted protective caps. UUT cables shall not interfere with artisan’s UUT removal/installation procedures.

3.7.14.2. Hoses

All hoses shall be of a type that are not service life limited, defined per NAVAIR 01-1A-20 (T.O. 42E1-1-1) – Aviation Hose and Tube Manual. Hoses shall be clearly labeled on both ends to identify pressure and connection point. All hoses shall be provided with permanently mounted protective caps or other means to prevent ingress of foreign object debris (FOD). UUT hoses shall not interfere with artisan’s UUT removal/installation procedures. Hoses and labeling shall be compatible with the test environment (for example: oil, temperatures, vibration) and properly protected and strain-relieved.

3.7.14.3. Mechanical Fasteners

All wiring and hose runs on the test system shall be mechanically fastened. No adhesive tape shall be used to fasten wire or hoses.

3.7.14.4. Label Marker

The Contractor shall provide a metal tube laser cutter and engraver with live preview to be used for proper labeling. Laser shall be at least 38W. Cutter/engraver shall have a built-in chiller and air compressor. Cutter/engraver shall be capable of speeds of at least 1200mm/s with an accuracy of 0.001mm or better. Contractor shall include Lightburn to be used for label design.

3.7.15. Vibration Monitoring

The Contractors shall replace the existing Endevco 6634 vibration monitoring system including the chassis, vibration amplifier, and all associated wiring. New system shall maintain all existing capabilities. Vibration monitoring system shall be capable of monitoring four (4) separate vibration signals concurrently.

3.7.15.1. Accelerometers

The Contractor shall provide new accelerometers.

· Two (2) each Meggitt/Endevco 2273AM20 or equivalent

· Two (2) each Meggitt/Endevco 2271A or equivalent

3.7.16. Calibration

All instrumentation/systems used for quantitative measurement are required to be calibrated by methods traceable to the National Institute of Science and Technology (NIST). The contractor shall provide all special cables, hoses, adapters, connections, fixtures, torque arms, and tools necessary for in-house calibration of the system. Contractor shall provide the necessary fixture/s for calibration of excursion probes. Fixture shall be dimensionally verified by the Government prior to use for test stand calibration. The contractor shall provide all peculiar calibration equipment. Peculiar calibration equipment includes custom fixtures, specialized electronics, etc., not in the FRC East calibration inventory of standards. The Contractor shall perform the initial scaling/calibration of all calibrated channels. The Contractor is responsible for providing all necessary standards/signal sources required to perform initial scaling. FRC East personnel will perform an official calibration, including stickering of the test stand for production use, prior to Final Acceptance Testing.

3.7.17. Test Cell Emergency Stops (E-Stops)

The contractor shall provide an emergency stop system in accordance with ISO 13850 - Safety of Machinery- Emergency Stop – Principles for Design. The emergency stop system shall be capable of being:

· Operated and monitored by system software and

· Manually in the form of a prominent lighted red mushroom button(s) located such that the operator can quickly activate it.

3.7.17.1. Locations

The contractor shall provide an emergency stop at the following locations (at a minimum):

· At the exit of each door in the test cell

· On the control console

· E-Stops shall be located and provided such that there is an emergency stop always within a reasonable reach, during normal operations.

· E-Stops shall not be located such that the activation of an emergency stop will require personnel to travel to a more hazardous position to activate it.

3.7.17.2. Operation

The emergency stop shall bring the system to a safe state as fast as possible.

3.7.17.3. Life Safety Rated Relays

Relays and relevant hardware used in the E-Stop circuits shall be suitably rated for life safety applications.

3.7.17.4. Responsibility for Inspection

The contractor shall be responsible for the performance of all inspection and testing of the E-Stop prior to running any UUTs. The Government reserves the right to perform any of the inspections set forth where such inspections are deemed necessary to ensure supplies and services conform to prescribed requirements.

3.8. COMPUTER SYSTEM

The Contractor shall provide a new server/workstation class computer designed for high reliability and availability.

3.8.1. Computer Minimum Specifications

The new computer shall be running the latest version of Window 10 PRO and have the following minimum specifications.

Minimum Computer Specifications

w/ Lockable, Externally Removable SSD Sled

Test Cell monitor shall be mounted on a wall adjustable arm/stand.

3.8.2. Maximum Allowable CPU Usage

The overall average CPU usage, as displayed/reported by the Windows Task Manager, shall not exceed 35%, with the test application active, while testing a UUT. In addition, no individual processing core shall exceed an average of 50% with the test application active, while testing a UUT. Verification of performance shall be tested during acceptance and will be described in the Acceptance Test Plan.

3.8.3. Maximum Allowable RAM Usage

The system shall keep at least 50% of its physical memory available with the test application active, while testing a UUT, as defined by the Windows Task Manager. Verification of performance shall be tested during acceptance and will be described in the Acceptance Test Plan.

3.8.4. Maximum Allowable Storage Usage

The system shall employ dual hard drives. The hard drives shall have a minimum of 70% free disk space after all applications, software, and data required for operation of the test system is installed. The use of RAID is not allowed. One disk shall serve as the primary drive for the OS and core applications while the second drive will be used for data and record storage as well as for backups. An additional 1TB external SSD shall be provided to use for image backups. Contractor shall take an image backup on the system at the completion of Final Acceptance Testing.

3.8.5. Computer Warranty

The computer system shall come with an extended warranty of at least five years, after completion of acceptance testing, next business day, on-site, covering all hardware systems. The contractor shall provide a placard detailing the computer warranty details and expiration date. The contractor shall affix the placard to computer.

3.8.6. LabVIEW

The National Instruments LabVIEW version shall be the latest stable version of LabVIEW available at the time of contract award. LabVIEW full development license shall be installed on the test system computer.

3.9. CALIBRATION AND SOFTWARE DEVELOPMENT LAPTOPS

The Contractor shall provide TWO (2) new ruggedized laptops. One to be used during system calibration and one for software maintenance and development.

3.9.1. Laptop Minimum Specifications

The new laptops shall be running the latest version of Window 10 PRO and have the following minimum specifications. RAM and Storage shall be user serviceable.

Minimum Computer Specifications

3.9.2. Maximum Allowable CPU Usage

The overall average CPU usage, as displayed/reported by the Windows Task Manager, shall not exceed 35%, with the development and/or calibration software active.

3.9.3. Maximum Allowable RAM Usage

The system shall keep at least 50% of its physical memory available with the development and/or calibration software active, as defined by the Windows Task Manager.

3.9.4. Maximum Allowable Storage Usage

The hard drives shall have a minimum of 70% free disk space after all applications, software, and data is installed.

3.9.5. Calibration Software

The calibration laptop shall contain all the software required to perform a complete system calibration from the calibration laptop. This includes the ability to verify and scale all calibrated channels from within the test cell. Calibration laptop shall not be required for calibration but should act as a tool to aid in calibration of items that require the calibration artisan to be away from the primary desktop. Calibration artisan shall have the ability to freely switch between the desktop and laptop during calibration.

3.9.6. Development Software

The development laptop shall include all software required to update, modify, build, compile, diagnose, etc. all delivered software and hardware to include LabVEIW, PLC, and other configurable and or software diagnosable hardware.

3.10. SOFTWARE

3.10.1. Model Configuration Graphical User Interface (GUI)

A model configuration GUI shall exist for the creation of new UUTs as well as the modification of test parameters for all existing UUTs. When creating a new UUT the capability shall exist to “copy” an existing UUT profile to use as a baseline. All parameter requiring configuration for UUT testing shall be configurable within the GUI. This includes all set points, operating limits, warnings, and alarms. Only parameters/channels pertinent to the UUT being configured shall be displayed and configurable. Configuration utility shall include ability to create generic configurations, for example a configuration that would set an inlet air flow/temp/pressure and display/record a pressure drop across a heat exchanger to check for cleanliness. This includes at a minimum.

· Compressor Inlet Pressure

· Compressor Inlet Temperature

· Compressor Outlet Pressure

· Compressor Outlet Temperature

· Turbine Inlet Pressure

· Turbine Inlet Temperature

· Turbine Outlet Pressure

· Turbine Outlet Temperature

· Orifice Pressure

· Orifice Temperature

· Orifice Differential Pressure

· Dry Air Rated Turbine Outlet Temperature

· Pressure Differential, Compressor Out and Turbine In

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