SATPC0035168 Tab 04 4 SOW Rev.pdf

D-Site – Facility Fire Barrier and Energy Containment Analysis for Battery Test Cell

Statement of Work

Background:

The D-site test facility at NASA’s Armstrong Test Facility (ATF) in Sandusky, OH, is being renovated and re-purposed to support the development and testing of novel battery designs. A battery test cell has been designed to support ongoing research and will be used for performance testing of prototype battery designs. The battery test cell at D-site consists of three separate rooms within the facility:

Battery Test Chamber, Control Room, and Equipment Room.

Design Requirements of the Battery Test Cell:

1) Battery test chamber must fully contain, within the confines of the chamber, all potential fire and explosion hazards associated with battery testing to include a thermal runaway event.

a) Test chamber shall comply with NFPA 855 section 4.7.13 and be separated from other areas of the building by fire barriers with a minimum 2-hour fire resistance rating and horizontal assemblies with a minimum 2-hour fire resistance rating and constructed in accordance with the local building code, unless otherwise stated or defined by federal, state, local regulations.

b) Test chamber shall be evaluated for blast-resistance, deflagration ventilation, and pressure-relief capabilities to define an Energy Containment Rating to support battery testing activities to include battery abuse testing. The test chamber shall not be operated in way to exceed the Energy Containment Rating of the test chamber design as to cause damage to facility or equipment and/or death or serious injury to personnel.

2) Battery Test chamber will be designed to meet NASA safety requirements and applicable regulations or building codes and will be designed and operated in a way to meet or exceed the minimum level of safety required.

3) Test cell must be designed to reduce any inherent risks during normal operation that would impact the following hazards:

a) Life safety – hazards that could potentially cause death or serious injury to personnel.

b) Mission continuity – failures which could have serious impact on mission capability and/or operability.

c) Facilities protection – failures that could cause serious damage to facilities or equipment resulting in significant financial loss.

d) Environmental impact – hazards that could have serious impact to the adjacent facilities or operations or to the surrounding community.

Scope of work:

NASA is seeking a third-party assessment and design review of the D-Site Battery Test Cell to verify that the test chamber is designed to meet a minimum fire barrier protection and energy containment rating.

The awardee shall give an overall assessment that the facility meets minimum structural requirements and is able to perform as intended to meet the research goals of the project. The awardee will be given ATF facility access to perform a site survey and will be provided with facility drawings and other required relevant documentation as it relates to the work performed.

Work Certification/Qualification Requirements:

Work shall be performed and/or reviewed for acceptance and compliance by a professionally accredited/state-certified Professional Engineer (PE) or Fire Protection Engineer (FPE).

Work to be performed:

1. Inspection and evaluation of test cell design and analysis of building design and construction for the purpose of establishing a Fire Protection Rating (hour-rating) for the Battery Test Chamber.

Fire barriers (walls, floor, ceiling/roof) of test cell to include all adjoining walls/structural members, doors, vents, wall penetrations, and feedthroughs adjacent to control room shall be evaluated to ensure that test cell meets a minimum of 2-hour fire resistance rating as defined by industry standards. Any noted design deficiencies must be identified, and recommendations made to meet minimum requirements based on regulations, industry standards, and best practices or other recommend methods of compliance.

2. Analysis of Battery Test Chamber design shall be performed for the purpose of establishing an Energy Containment Rating (defined in Watt-hours or Amp-hours) to define the upper testing limits of the Battery Test Chamber. Inspection and evaluation will be performed on structural members (walls, floor, ceiling/roof) of test chamber and any adjoining walls/structural members, doors, ventilation systems, wall penetrations, and feedthroughs to ensure that adequate pressure relief, deflagration venting, or other control measures are in place to prevent damage to facility and/or equipment and/or death or serious injury to personnel, in the event of a battery thermal runaway or battery explosion. Well established and widely used methods of modeling and simulation can be used to support analysis but method must be identified. Any noted deficiencies of the test chamber design must be identified, and recommendations made to meet minimum requirements based on regulations, industry standards, and best practices or other recommend methods of compliance.

Deliverables:

1. For the Firing Protection Rating Analysis, awardee shall provide NASA with a report that contains, at a minimum, the following information:

a. Names of inspectors/reviewers and any relevant professional qualifications and/or certifications held by the individuals involved with D-Site Battery Test Cell design analysis and review.

b. Summary of work performed.

c. Detailed analysis to include findings and recommendations to meet minimum level of requirements and/or compliance with regulations and standards.

i. Minimum level of design requirements of the battery test cell:

1. “Test chamber shall comply with NFPA 855 section 4.7.13 and be separated from other areas of the building by fire barriers with a minimum 2-hour fire resistance rating and horizontal assemblies with a minimum 2-hour fire resistance rating and constructed in accordance with the local building code, unless otherwise stated or defined by federal, state, local regulations.

2. Compliance with any other applicable regulations and standards

d. Assessed ratings derived through evaluation, inspection, and analysis performed:

i. Fire-resistance rating of test chamber (in hours) and list of any recommended design changes required to meet 2-hour fire resistance rating for any fire barriers that separate the battery test chamber from other areas of the building.

e. List of regulations and standards referenced.

2. For the Energy Containment Rating awardee shall provide NASA with one separate report that contains, at a minimum, the following information:

a. Names of inspectors/reviewers and any relevant professional qualifications and/or certifications held by the individuals involved with D-Site Battery Test Cell design analysis and review.

b. Summary of work performed.

c. Detailed analysis to include findings and recommendations to meet the following:

i. Minimum level of design requirements of the battery test cell:

1. “Test chamber shall be evaluated for blast-resistance, deflagration ventilation, and pressure-relief capabilities to define an Energy Containment Rating to support battery testing activities to include battery abuse testing.”

ii. Compliance with any other applicable regulations and standards

d. Assessed ratings derived through evaluation, inspection, and analysis performed:

i. Defined Energy Containment Rating (in Watt-hours or amp-hours) for test chamber.

e. List of regulations and standards referenced.

Deliverable Lead Time:

All deliverables are due NLT 5 weeks from the date of award.

Facility Layout:

Figure 1. D-Site Facility Layout, NASA Armstrong Test Facility

Figure 2. D-Site Facility - Exterior 3D Model

Battery Test Chamber Description

Test Chamber (Room 108) Construction:

• 169 sq. ft. room (approx.. 13’x13’)

• 13’ high, 26” thick reinforced concrete walls

• 60” thick floor slab.

• 18’ high slanted, sheet metal shed roof with sheet metal sidewalls above the concrete wall section.

• North facing wall (above concrete portion of wall) has inlet and exhaust for 3000 cfm ventilation system. 40” x 40” deflagration vent will be installed between ventilation inlet and exhaust.

Figure 3. Test Chamber - Rough Dimensions