Attachment_A_-_SOW.docx

Attachment A

Handheld Engine Dynamometer and Test Stand At the National Vehicle and Fuel Emissions Laboratory

Statement of Work

U. S. Environmental Protection Agency National Vehicle and Fuels Emissions Laboratory 2565 Plymouth Road Ann Arbor, Michigan 48105

1. BACKGROUND:

The U.S. EPA’s Testing and Technology Division (TATD) has a need to add handheld small engine testing capability to an existing test site. The purpose of this Statement of Work is to procure a dynamometer (or combination of multiple dynamometers), controller and engine test stand(s) suited to testing small, handheld, spark ignited engines. The system shall be capable of simulating the handheld engine cycle for engines with maximum power output ranging from 0.5 kW to 7.45 kW and capable of operation in horizontal orientation.

1.1. General Description of Test Site

1.1.1. The test stand and related equipment will be installed in rooms 513 within the NVFEL, which is an existing test cell. This test cell is also known as NRSI or Small Engine test site. The test cell has an adjoining control room (Room 320). A structural mezzanine is above the test cell which is available for installing large and bulky items that do not need to be installed on the first floor. The test systems shall be designed to fit within the existing space.

1.1.2. The EPA will be removing all old instrumentation from this area, and preparing any facility infrastructure upgrades that may be necessary. These areas will be available for inspection during the solicitation site visit.

1.2. Safety, Health and Environmental Provisions

1.2.1. Providing for a safe working environment is the highest priority in all EPA equipment purchases and installation activity. The contractor shall abide and comply with all building and safety codes specified by OSHA, BOCA, and NFPA wherever they might apply, to create an inherently safe system and work environment.

1.2.2. Significant risk factors exist such as noise, toxic gases, heated surfaces, electrical shock. Safety systems shall be considered, including safety interlocks to prevent accidental errors, and control measures to ensure the safety of operations and maintenance personnel shall be implemented wherever feasible.

1.2.3. As required by OSHA, all equipment shall be designed to provide for straightforward lockout protection in accordance with OSHA regulations. Written lockout instructions, in hard copy and electronic formats, shall be provided as part of the “as installed” documentation package.

1.2.4. Noise or vibration from equipment installed as part of this contract shall not penetrate the building or cause adverse effects on other equipment in the facility. Sound dampening/suppression devices and/or materials shall be installed as needed to limit noise levels to 60db at 10 feet from any devices to be located outside of the test cell (excluding the mezzanine), 75db at 10 feet for devices located in the test cell (room 513). Devices to be located in the control room (room 320) must meet the 60db requirement.

1.2.5. The contractor shall consider energy efficiency in all component selection, system design and operational strategies. Energy efficient equipment, such as those with The “Energy Star” designation shall be utilized when possible.

1.2.6. The contractor shall minimize, to the extent possible, the generation and release of harmful materials to the environment in all component selection, system design, operational strategies and installation requirements.

1.2.7. The contractor shall be responsible for ensuring that its employees and subcontractors attend a mandatory NVFEL safety briefing and follow all NVFEL safety requirements presented, as well as all applicable OSHA/MIOSHA regulations, while working at NVFEL.

1.2.8. The contractor shall provide the NVFEL Project Officer with a complete list of chemicals to be utilized during installation and commissioning operations at NVFEL, and their associated Material Safety Data Sheets (MSDS) prior to equipment delivery.

1.2.9. All specifications in Section 1.2 shall apply to all items delivered under this contract, including both required items and options.

1.2.10. As mandated by Executive Order 13514, Federal Leadership in Environmental, Energy, and Economic Performance and U.S. Federal Acquisition Regulation Subpart 23.705, federal agencies are required to satisfy at least 95% of their annual acquisition requirements for electronic devices with EPEAT-registered products. EPEAT criteria addresses the full product life cycle (e.g., energy conservation, reduced use of toxic materials, product longevity, and end-of-life management). ENERGY STAR is not EPEAT. As stated at Section 1.2.5, Energy Star is desirable, EPEAT is mandatory. In those instances where the contractor cannot meet this requirement, provide explanation as to why this criteria cannot be met. Currently, EPEAT covers Computer Desktops, Notebooks, Monitors, Tablets, Printers, copiers, multi-function devices or All-in-One devices, scanners, and fax machines. Visit www.epeat.net for more information.

1.3. Testing Application Description:

This test system will be employed to perform certification emissions testing in accordance with 40CFR§1065 and 40CFR§1054 on Class III, IV and V handheld engines typically used in lawn or yard maintenance applications such as string trimmers, chainsaws and leaf blowers. The test procedure is a two mode test and is outlined in 40CFR§1054 Appendix II (see table below).

The general test cycle begins with a warm-up period using full load at rated speed. Following thermal stabilization, a full load @ rated speed data-log is recorded, followed by no load @ idle speed data-log. The following are expected characteristics of the engines subject to this test procedure:

1.3.1. Idle Speed: The expected idle speed range is approximately 2000 to 4000 RPM.

1.3.2. Rated Speed: The expected rated speed range is approximately 6500 to 12000 RPM.

1.3.3. Maximum Speed: The expected maximum speed is approximately 12000 RPM.

1.3.4. Rated Torque: The expected rated torque range is 0.75 to 9.5 Nm.

1.3.5. Rated Power: The expected power output range at rated speed is 0.5 to 7.45 kW.

1.4. System Integration:

The existing test site is equipped with a National Instruments LabViewTM based custom test cell controller. The dynamometer will initially be manually operated independently from the host test cell controller. At a later date, EPA expects to integrate the dynamometer test stand with the test cell controller, but not as part of this contract. For this reason, bidders shall propose a method for integrating the system with the LabViewTM based test cell controller. The proposal must allow for the communication of torque and RPM set-points, current values and dynamometer control states at 10 Hz minimum. The system shall integrate a safety string or fault system.

2. SPECIFICATIONS:

The contractor shall deliver a dynamometer and test stand package, suitable for testing handheld two and four cycle engines. The minimum required components shall include:

2.1. An engine test stand, suitable for easily mounting engines to simulate their normal operation in a horizontal shaft orientation.

2.2. One, or a combination of ranges of, Eddy Current dynamometer(s) that satisfy the Testing Application Description listed above.

2.3. A dynamometer controller (capable of digital communication with the Host of torque and rpm set-points, current values and dynamometer control states at 10 Hz minimum).

2.3.1. An external static power amplifier or dynamometer drive if applicable.

2.3.2. An isolation transformer if applicable.

2.4. A torque measurement system for sensing applied load with minimum range of 0.00-9.50 Nm

2.5. A zero speed directional encoder, or similar sensor, for dynamometer speed detection

2.6. Calibration equipment.

2.6.1. Calibration arms suitable for clockwise and anticlockwise load calibration.

2.6.2. Weights for calibration across the full range of dynamometer torque.

2.7. Any additional equipment or hardware required to integrate with existing test cell Host Automation hardware. This shall include communication or interface modules where applicable.

2.8. The equipment shall meet all of the requirements listed in Section 3.

3. COMPONENT REQUIREMENTS:

3.1. Engine Test Stand Requirements

3.1.1. The test stand shall operate in the horizontal orientation.

3.1.2. The rotating centerline of the dynamometer shall be no less than 30 and no more than 40 inches above floor level.

3.1.3. Dynamometer shall have an external cooling system.

3.1.4. The test stand shall be equipped with provisions to bolt to the existing bedplate (bedplate has 1-1/8” wide T-slots, spaced 12” on center).

3.1.5. The test stand shall have leveling feet or other suitable equipment installed.

3.1.6. The test stand shall be equipped with a T-slot integrated bedplate for purposes of engine test fixture attachment. The T-slots shall be oriented parallel to the dynamometer shaft.

3.2. Dynamometer Requirements

3.2.1. Shall be a Dry Gap Eddy Current style absorber.

3.2.2. Shall be externally cooled by a primary/secondary glycol system or by forced air.

3.2.3. The dynamometer shall be capable of simulating the G3 test cycle defined by 40CFR§1054 Appendix II. See Testing Application Description (Section 1.1).

3.2.4. The contractor shall supply an appropriate dynamometer drive and isolation transformer if applicable. Single phase up to 240VAC electrical supply is available at the existing site for this application. Alternate power requirements must be specified by vendor application.

3.2.5. The dynamometer shall be capable of at least 12000 RPM.

3.2.6. The dynamometer shall operate in horizontal orientation.

3.2.7. The dynamometer shall be capable of absorbing a minimum of 7.45 kW of power from 6000-12000 rpm continuously for a minimum of 30 minutes.

3.2.8. A combination of multiple dynamometer sizes is acceptable if required to fulfill the above requirements. Offers including multiple dynamometer sizes shall include separate engine test stands (see 3.1) for each dynamometer.

3.2.9. Rotational inertia shall be less than 6*10-3 kg*m2. Offers including a combination of absorbers to accommodate the required power range shall detail the rotational inertia of each unit.

3.2.10. Dyno lubrication system, where applicable (shall integrate with a safety string)

3.2.10.1. Lubrication system shall include all necessary pumps, heat exchangers, piping, valves and fittings necessary.

3.2.10.2. System shall be installed to Engine Test Stand, and integrated with the dynamometer absorber.

3.3. Dynamometer Controller Requirements

3.3.1. The controller shall provide at minimum, the ability to zero and span torque (load) feedback.

3.3.2. The controller shall provide the ability to control the dynamometer states locally and remotely by a Host system.

3.3.3. The contractor shall supply an external static power amplifier or dynamometer drive if required for the application

3.3.4. The contractor shall supply an isolation transformer if required for the application

3.4. Torque Measurement Requirements

3.4.1. The torque measurement system shall be linear in accordance with 40CFR§1065.307 Table 1:

3.4.2. The load sensor shall measure dynamometer housing loads (case torque).

3.4.3. 40CFR§1065.205, Table 1: Engine torque transducer performance specifications

3.4.4. Torque measurement shall be available in both directions of rotation.

3.4.5. Torque unit of measurement shall be Newton-Meter

3.5. Speed Measurement Requirements

3.5.1. The speed measurement system(s) shall be linear in accordance with 40CFR§1065.307 Table 1.

3.5.2. The speed measurement system shall comply with 40CFR§1065.210(b)(1): minimum of 60 pulses per rev with a frequency counter that rejects common-mode noise.

3.5.3. The speed measurement system shall comply with 40CFR§1065.205, Table 1: Engine speed transducer performance specifications

3.5.4. Rotation speed unit of measurement shall be Revolution Per Minute.

3.6. Calibration Equipment Requirements

3.6.1. The contractor shall supply dynamometer calibration arms for calibration.

3.6.1.1. The contractor shall provide a calibration certificate showing the arm length from dyno shaft centerline to weight position in metric units.

3.6.1.2. The calibration certificate shall indicate the length of the arm is traceable to a NIST standard within ± 0.5%.

3.6.2. The contractor shall supply calibration weights, hangers, and all other equipment required to perform load cell calibrations in both Clockwise and Anticlockwise direction.

3.6.2.1. A minimum of 6 equally spaced calibration weight combinations over the range of the load cell are required.

3.6.2.2. The contractor shall provide a calibration certificate for each weight showing the weight is traceable to a NIST standard within ± 0.5%.

3.6.3. The contractor shall supply documentation of traceability in accordance with 40CFR§1065.310(c)(1).

3.6.4. All calibration system components shall be constructed of 300 series stainless steel.

3.7. Integration Method

3.7.1. The contractor shall propose a method of integration to allow for the digital exchange of data and control states at a minimum of 10 Hz.

3.7.2. The proposed method of integration shall be compatible with a LabViewTM based test cell controller.

4. DELIVERABLES:

4.1. The test stand, dynamometer, and all other equipment included in this statement of work shall be delivered to:

USEPA National Vehicle and Fuel Emissions Laboratory Testing and Technology Division, Engine Testing Center 2565 Plymouth Road Ann Arbor, MI 48105

4.2. The contractor shall include the following deliverables:

4.2.1. System Documentation (minimum 2 hardcopy sets and a .pdf version) including:

4.2.2. System Schematics showing as installed state including controls, signal wiring as well as plumbing.

4.2.3. A list of all proprietary system warning and alarm messages, with full explanation as to their exact meaning, impact and action required.

4.2.4. Installation Instructions

4.2.5. Recommended maintenance procedures and interval

4.2.6. Recommended calibration procedures and interval

4.2.7. List of consumables and maintenance parts (with recommended supply sources)

4.2.8. MSDS sheets for applicable maintenance and consumables.

4.3. Specifications for each supplied component including:

4.3.1. Isolation Transformer and Dynamometer Drive, if applicable

4.3.2. Dynamometer

4.3.3. Dynamometer Controller

4.3.4. Torque Measurement System

4.3.5. Speed Measurement System(s)

4.3.6. Calibration arms and weights

4.4. Warranty:

4.4.1. Contractor shall warrant the performance and function of all products delivered under this contract for a minimum of one year after formal EPA system acceptance and approval.

4.4.2. This warranty shall provide for cost-free repair or replacement of covered hardware and software

4.4.3. The warranty requirements shall also apply to the options.

5. THE CONTRACTOR SHALL PROVIDE THE FOLLOWING OPTIONS LIST:

5.1. Dyno Cooling Package to consist of a sealed secondary glycol based loop and will interface with building chilled water loop. Package shall include all required pumps, heat exchangers, valves, control hardware, piping and fittings.

5.2. Additional identical specification eddy current absorber(s) with storage crate(s).

5.3. The contractor shall offer an option for an Extended Warranty, renewable every year for a period of four years beginning at the end of the initial one year warranty described above.

5.3.1. This Warranty shall cover parts, labor, and travel expenses if applicable, and shall include at least one preventative maintenance visit at no additional charge.

5.3.2. If an option is not exercised for the Extended Warranty in a certain period, that option shall not be available for exercise in future years. For example, if the Extended Warranty Option is not exercised during Option Period 2, that option is not available in Option Period 3.

6. SCHEDULE OF DELIVERABLES:

Dates shown are nominal completion deadlines relative to the contract award date or exercise option date. Where dates are not shown, the Contractor shall propose appropriate dates at the Project Kickoff Meeting. All days are calendar days. All Technical Interchange Meetings (TIMs) are to be held at EPA-NVFEL. Phone calls, E-mail, teleconferencing or video conferencing will be an acceptable alternative for some meetings. The Contractor or EPA, as needed, may schedule TIMs.

Attachment A

RFQ-OH-16-00038

Statement of Work