PWS-Pressurization System Upgrade to Test Cell 3.docx

Performance Work Statement For Pressurization System Upgrade for Tube Fatigue Laboratory

1.0 Background:

The U.S. Army Armament Research, Development and Engineering Center’s Benét Laboratories requires upgrades for one high pressure testing cell. This test cell conducts high pressure fatigue testing on Cannons and Artillery to establish safe service lives for the armaments used in the field and have been in operation since the early 1990's.

2.0 Scope/Objective:

2.1 The vendor shall develop a control system to operate the Instron control System in Test Cell #3. Test Cell #3 currently has capability to achieve 125 ksi with the 18” servo. The hardware, transducers and controls within the test cell needs to be able to operate up to 150 ksi.

2.1.1 Generate technical data for maintenance and supportability of the upgraded system including:

2.1.1.1 Hydraulic schematics

2.1.1.2 Technical drawings

2.1.1.3 Software code

2.1.1.4 COTS replacement part numbers

2.1.1.5 Electrical Schematics

3.0 Requirements:

3.1 The vendor shall provide a control panel upgrade that meets the following requirements:

3.1.1 A programmable controller based logic system to replace the existing electronics, relay logic and manual controls. The programmable controller will provide the system control functions.

3.1.2 A new electronic touch panel or portable controller operator interface terminal to function as the operator interface, replacing the conventional switches and indicators on the existing panels.

3.1.3 Additional sensors, controls and displays to permit remote and automatic operation of the testing sequence with feedback to the operator.

3.1.3.1 The system shall possess warning and alarm indicator(s) with audible signal device(s) to alert operator to changes in the system status. The term “audible” means that the operator must be able to detect the signal in the presence of noise from the work environment.

3.1.4 New 18” Servo will be supplied as a direct replacement to the existing 18” servo that was previously designed and supplier my Miller Fluid Power but is now obsolete. New servo will utilize the same bolt pattern existing on the upper platen, as well as support the same “Moog” brand operational servo valves on the upper manifold. This will ensure that a spare servo can be switched into position for continued operation.

3.1.5 The testing process, sequencing the equipment and collecting operating data during the test cycle.

3.1.5.1 Programming is provided to operate the hydraulic power unit and servo. Selection of test sequence including test pressure, overpressure release, dwell time, cycle rate, etc. are entered via the operator interface terminal.

3.1.5.2 Logic is added for overpressure shutdown and Overpressure Release operation.

3.1.5.3 Cycle counts are accumulated and recorded as defined by the governing documents listed, ITOP 3-2-829, and STANAG 4110.

3.1.5.4 Pressure versus time for test supply pressure is logged to the operator interface memory and is displayable in a trend chart. Stored data can be archived for record or data manipulation remotely.

3.1.5.5 Programming features shall prevent single point human failures through strong confirmations for options that could pose safety hazards.

3.1.5.6 Programming features shall prevent the omission of data from required fields and shall prevent the entry of data that exceed the field limit as well as inform the operator with an error message regarding the reason(s) for prevention of the errant data entry.

3.1.6 A manual Emergency Stop push button is provided to initiate shutdown, stopping all pump motors and relieving supply pressures.

3.1.7 A Test Cell Access Door Closed Interlock Switch is added to the system. The switch provides door closed indication and a remote operated electric lock. Release of the test cell door closed switch while the test is in progress will also initiate a system shutdown.

3.1.8 A watchdog timer is added to the system to monitor the controller and stop the process if the controller does not update within a time limit.

3.1.9 Vendor shall remove the existing gage board and other items to be replaced and install the new material, excluding ultra-high pressure piping and connections. Disposal of removed material is by others.

3.1.10 Vendor shall commission the revised system, functional testing and training.

3.1.15 The user interface shall provide continuous feedback to the operator regarding the system’s operational status.

3.2 Performance Metrics:

3.2.1 Cycle Rates:

3.2.1.1 System shall sustain a cycle rate of at least 15 cycles/minutes for pressures under 10,000 psi with low to moderate volume (Mortars).

3.2.1.2 System shall sustain a cycle rate of at least 3 cycles/minutes for pressures over 100,000 psi with large volumes (Cannons).

3.2.1.3 Cycle rates shall have an indefinite operation mode since fatigue performance is not always known up front for total cycles to failure.

3.2.2 Cyclic Performance:

3.2.2.1 Target pressure (+/- 2%) and lower threshold (15% of Target Pressure) shall be displayed during operation as the most recent high and most recent low during operation.

3.2.2.2 Target Pressure shall be able to be set from 250 to 150,000 psi for cyclic operation.

3.2.2.3 The following parameters shall be able to be setup for each test and adjustable during operation:

3.2.2.3.1 Low Cycle Dwell Time

3.2.2.3.2 High Cycle Dwell Time

3.2.2.3.3 Ramp Rate rising (psi/sec)

3.2.2.3.4 Ramp Rate falling (psi/sec)

3.2.2.3.5 Target Pressures low

3.2.2.3.6 Target Pressure high

3.2.2.3.7 Overpressure Release

3.2.3 Static Pressure Hold:

3.2.3.1 System shall require to maintain a target pressure within +/- 2% and held at pressure upwards of 150,000 psi with large volumes (Cannons).

3.2.3.2 Target Pressure shall be able to be set from 250 to 150,000 psi for static operation.

3.2.3.3 System shall require to ramp pressure up to target pressure in steps as defined by operator, and to be able to hold pressure at those steps at user defined time intervals.

3.2.3.4 The following parameters shall be able to be setup for each test and adjustable during operation:

3.2.3.4.1 Pressure Dwell Time

3.2.3.4.2 Ramp Rate rising (psi/sec)

3.2.3.4.3 Ramp Rate falling (psi/sec)

3.2.3.4.4 Target Pressure

3.2.3.4.5 Overpressure Release

3.2.4 Limits of operation:

3.2.4.1 Actuating the upper limit of intensifier movement shall gradually return the system to a state of “zero” or “home” gradually to allow the system to start back up.

3.2.4.2 The user interface shall provide feedback to the operator regarding the system’s operational status and the impending state change after the operator actuates the upper limit of intensifier movement.

3.2.5 Overpressure:

3.2.5.1 Overpressure Release protection in place to prevent spiking the test specimen and pressure is set by operator.

3.2.5.2 Overpressure Release releases test specimen pressure and shuts the system down from cyclic operation and gradually returns the system to a state of “zero” or “home”.

3.2.5.3 The user interface shall provide feedback to the operator regarding the system’s operational status and the impending state change after the operator actuates the upper limit of intensifier movement.

3.2.6 System Performance:

3.2.6.1 Strain Cells and Pressure Transducers for high pressure testing shall be durable enough to withstand an average of 500,000 cycles per year at the stated pressure ranges.

3.3 Control Panel Software:

3.3.1 Software shall be capable of displaying the following:

3.3.1.1 Last peak pressure

3.3.1.2 Last minimum pressure

3.3.1.3 Cycle count evaluated against ITOP 3-2-829 for allowable deviation from target pressure and minimum pressure values.

3.3.2 Software shall be capable of processing the following:

3.3.2.1 Outputting the data into other raw formats other than proprietary format.

3.3.2.2 Processing data live as well as post processing collected data.

3.3.2.3 Display certain outputs in color or another means to differentiate from a “normal” or an “outlier”.

3.3.2.4 Customizing the user interface to allow the raw data trace to be displayed along with the active feedback listed above.

4.0 Installation Requirements:

4.1 The vendor shall remove old controller.

4.2 The vendor shall remove existing servo valve.

4.3 The vendor shall install new controller and servo.

4.4 The vendor shall extend hydraulic tubing for relocated gauges and hydraulic controls if necessary.

4.5 The vendor shall install new pressure sensors and cabling.

4.6 The vendor shall install new test cell door limit switch.

4.7 The vendor shall re-connect existing motor control, valve and sensor wiring.

5.0 Inspections, Tests, and Demonstration:

5.1 One week of on-site support to commission and test each upgraded system and provide training schedule dependent on workload.

5.2 The vendor shall perform all inspections and tests required and as specified by the drawings, specifications, and/or standards cited in the manufacturers technical documentation to insure total compliance with manufacturers machine installation procedures. At a minimum, the contractor shall perform, demonstrate, and document inspections, examination(S) and or test(s) on this equipment. Final inspection and acceptance of the equipment at destination shall be predicated upon the supplier’s successful completion of all tests required as stated above.

5.3 Vendor shall run a sample piece to obtain the testing parameters on the graphical unit interface as well as final test results requested in the requirements section of this scope of work. Final inspection and acceptance of the equipment shall be predicated upon the supplier’s successful completion of all tests required as stated above.

5.4 The government and awardee vendor shall mutually agree on a reasonable schedule for demonstration within the limitations of the delivery schedule stated in the contract.

5.5 Operator and Maintainer Demonstration:

5.5.1 The vendor shall conduct a demonstration to confirm that target audience system operators and system maintainers are able to perform operational and maintenance tasks correctly and within the time limits in accordance with the technical documentation.

7.0 Written Deliverables/Reporting Requirements:

7.1 The vendor shall design, develop and document the replacement controls and associated equipment. Engineering drawings, bills of material and product literature, will be provided for review, prior to fabrication.

7.2 A system description of operation is appended for review and comment. The system operating requirements will need to be confirmed and approved as listed in the Performance Metrics by the Government, prior to the programming of controls and the operator interface unit.

7.3 Engineering documentation including drawings, program listings, operator interface unit configurations and vendor literature will be supplied as Operation and Maintenance records.

7.4 The vendor shall provide a written Certificate of Compliance that the Control Panel System Upgrade & software meets the quoted specifications per contract. (DI-MISC-81356A).

8.0 Applicable Documents:

8.1 International Testing and Operations Procedures (ITOP 3-2-829) – Cannon Safety Test.

8.2 North Atlantic Treaty Organization Standardization Agreements (STANAG’s) – STANAG 4110.

9.0 Training:

10.0 Period of Performance:

10.1 The Delivery for the controller and servo for test cell #3 shall be 12 months at most from funding execution to installation and training of staff. This includes installation of new hardware, software and three weeks of trial and tests to correct any system issues on Test Cell #3.

11.0 Warranty:

11.1 The vendor shall offer a standard commercial warranty on labor, parts, and materials for a minimum period of one (1) year from the date of installation.

12.0 Security Requirements:

12.1 Access and General Protection/Security Policy and Procedures. Contractor and all associated sub-contractor employees shall provide all information required for background checks to meet installation access requirements to be accomplished by Installation Provost Marshal Office, Director of Emergency Services or Security Office. Contractor workforce must comply with all personal identity verification requirements (FAR clause 52.204-9, Personal Identity Verification of Contractor Personnel) as directed by DOD, HQDA and/or local policy. In addition to the changes otherwise authorized by the changes clause of this contract, should the Force Protection Condition (FPCON) at any individual facility or installation change, the Government may require changes in contractor security matters or processes.

12.2 For Contractors Not Requiring a CAC, but Require Access to a DOD Facility or Installation. Contractor and all associated sub-contractor employees shall comply with adjudication standards and procedures using the National Crime Information Center Interstate Identification Index (NCIC-III) and Terrorist Screening Database (TSDB) (Army Directive 2014-05/AR190-13), applicable installation, facility and area commander installation/facility access and local security policies and procedures (provided by government representative), or, at OCONUS locations, in accordance with status of forces agreements and other theater regulations.

13.0 USG Point(s) of Contact:

1 Buffington Street, Bldg. 115 Watervliet, NY 12189 lucas.b.smith.civ@army.mil Phone: 518-266-4192

USG Contracting Officer: Mrs. Melissa Ryder 1 Buffington Street, Bldg.40

Watervliet, NY 12189 melissa.a.ryder4.civ@army.mil

518-266-4829

14.0 Environmental Requirements:

14.1 Compliance with Environmental Laws and Regulations: Contractor shall comply with all applicable federal, state, and local environmental laws, statutes, regulations, executive orders, permits, Army regulations (with supplements), as well as Major Subordinate Command (MSC) and installation regulation, policy, Host Tenant Agreement, Interagency Service Support Agreement, or Status-of-Forces Agreement. Contractor shall immediately report any conflicts between applicable federal, state, local environmental laws, statutes, executive orders, and provisions of Army Regulation 200-1, and any specifications within this contract to the Contracting Officer Representative (COR).

14.2 Compliance with Green Procurement Requirements: Contractor shall follow Federal EPA Comprehensive Procurement guidelines (www.epa.gov/cpg) and Army Contracting Command Quick Guide (https://acc.aep.army.mil/accapps/ACCMAP/Documents/Quick-Guide-for-Sustainable-Procurement.docx) for acquisition of building materials and products and select materials that have a long life cycle; the least toxic materials; recyclable materials; materials that are resource-efficient; materials with the maximum recycled content; materials harvested on a sustained yield basis; and products causing the least pollution during their manufacture, use, and reuse.

14.3 Compliance with License and Certification Requirements: Contractor shall obtain all license and certification required by Federal, State, and Local environmental laws and regulations necessary to adhere to the specifications of this contract. The Contractor shall submit all plans, notifications, reports, submittal documents, and fees required by Federal, State, and Local environmental laws and regulations to the appropriate Federal, State, and Local authority and/or agency as necessary to adhere to the specification of this contract. All required licenses and certifications required by Federal, State, and Local environmental laws and/or regulations shall be considered a contract deliverable upon award

14.4 Notification of Federal and State Regulators: Contractor shall immediately notify the Designated Government Representative (DGR) and COR of the arrival on site of any Federal, State, and/or DoD environmental regulator or enforcement agent and/or the receipt of any correspondence from a Federal or State environmental agency.

14.5 Inspections of Work Sites: Contractor shall submit to potential Federal, State, Army and installation work site environmental regulatory inspections and/or investigations into noncompliance, and fully cooperate with such inspections/investigations by providing the appropriate records and documentation. Environmental regulatory agencies are authorized by law to inspect any work site for environmental compliance with regulatory requirements. If an inspection is conducted, it will not stop or disrupt ongoing contract activities. The inspection will only require the work site environmental officer, or supervisor/manager to answer questions and/or escort the inspector to specific work site areas with the potential to affect environmental quality.

14.6 Reporting Noncompliance: Contractor shall immediately report any nonconformance and/or noncompliance with applicable Federal, State or Local environmental laws, Army and installation environmental regulations or policies to the COR and DGR.

14.7 Conformance with Environmental Management System: Contractor shall take the necessary actions to identify, monitor, and control those contract operations and activities that pose risk of contamination, or can negatively impact the natural and/or human environment.

14.8 Use of Hazardous Materials: Contractor shall assign all hazardous materials management responsibilities to the appointed ECD. Contractor shall contact the DGR or COR to obtain technical assistance from Environmental Office for assisting the ECD with achieving and maintaining compliance with hazardous material storage, issue, use, and disposal requirements. Contractor shall submit to the COR and/or DGR a hazardous material inventory. The hazardous material inventory will be submitted 30 days prior to commencement of work for contracts that exceed 180 consecutive days. The inventory list will contain the hazardous material type and maximum quantities of materials anticipated to be stored on-site. The hazardous material shall be properly identified and include any applicable identification number, such as National Stock Number or Special Item Number. The Contractor shall maintain copies of Safety Data Sheets for all hazardous materials used and stored on-site during performance of the contract. Contractor shall not supply or deliver any hazardous materials or chemicals to an installation that are listed on EPA toxic chemical list without prior written approval from DGR and/or COR.

14.9 Prevention of Spills: Contractor shall adopt the installation's Spill Prevention Control and Countermeasures Plan (SPCC) if transporting, processing, storing, or in any way managing hazardous waste, hazardous material, petroleum-oils-lubricants, or other restricted items. In case of a spill, the person in control of the spill site or their designated representative shall take appropriate action to protect workers and bystanders; contain the spill (if it can be done safely); secure the spill site; restrict ignition sources; and immediately contact the installation Fire and Emergency Services (Fire Department).

14.10 Protection of Sensitive Areas: Contractor shall comply with all installation designated sensitive and/or off-limit area restrictions. Sensitive areas are generally demarked indicating what activities (e.g., driving, digging, foot traffic) are prohibited. The Contractor shall also adhere to the following installation sensitive areas requirements:

14.10.1. Cultural Resources Sites: Do not excavate, remove, damage, or otherwise deface any archeological resource located on public lands.

14.10.2 Endangered Species Habitats: Do not initiate any action that may disturb, endanger, or damage to any degree the habitat of a threaten and endangered species.

14.10.3 Wetlands: Do not excavate or take any action that could fill or damage any wetland unless working under a project specific Corps of Engineers 404 permit. Wetlands include streams, riparian areas, bogs, marshes, and swamps.

14.11 Corrective Action for Noncompliance: Contractor shall when given a verbal and/or written notice of environmental noncompliance or nonconformance by the COR, take immediate corrective action. Failure or refusal to comply promptly may be grounds for the Contracting Officer to invoke the appropriate contractual remedies. This may cause all or part of the work to be stopped immediately until satisfactory corrective action has been taken.

14.12 Noise: Make the maximum use of low-noise emission products, as certified by the EPA. Blasting or use of explosives will not be permitted without written permission from the Contracting Officer, and then only during the designated times. Pile-driving operations shall be coordinated through the DGR and COR.

14.13 Mercury Materials: Mercury is prohibited, unless specified otherwise, and with the exception of mercury vapor lamps and fluorescent lamps. Dumping of mercury-containing materials and devices such as mercury vapor lamps, fluorescent lamps, and mercury switches, in rubbish containers is prohibited. Remove without breaking, pack to prevent breakage, and transport out of the activity in an unbroken condition for disposal as directed. Immediately report to the DGR and COR instances of breakage or mercury spillage. Clean mercury spill area to the satisfaction of the Contracting Officer. Cleanup of a mercury spill shall not be recycled and shall be managed as a hazardous waste for disposal.

14.14 Universal Waste / e-Waste Management: Universal waste including but not limited to some mercury containing building products such florescent lamps, mercury vapor lamps, high pressure sodium lamps, CRTs, batteries, aerosol paint containers, electrical equipment containing PCBs, and consumed electronic devices, shall be managed in accordance with applicable environmental law and installation instructions.

14.15 Pollution Prevention / Hazardous Waste Minimization: Minimize the use of hazardous materials and the generation of hazardous waste. Consult with the Environmental Office for suggestions and to obtain a copy of the installation's pollution prevention/hazardous waste minimization plan for supporting waste minimization goals.