Attachment_A_-_N2O_Analyzer_SOW_for_CTTF_HTF_Final2.pdf

Statement of Work

N2O Analyzer for EPA NVFEL Cold Temperature Test Facility & Hot Test Facility

January 21st 2015

U. S. Environmental Protection Agency Testing and Advanced Technology Division 2565 Plymouth Road Ann Arbor, Michigan 48105

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Attachment A

Table of Contents

1.0 General Requirements

1.1 Overview

1.2 General System Requirements

1.2.1 System

1.2.2 Identification

1.2.3 Documentation

1.3 References

1.4 Safety, Health and Environmental Provisions

1.5 Electrical Requirements and Utilities

2.0 Design & Functional Requirements

2.1 Overview

2.2 Analyzer Requirements

2.3 Electromagnetic Isolation and Interference

3.0 Installation

4.0 Acceptance

5.0 Training

6.0 Warranty

7.0 Optional Items

7.1 Option for Additional Analyzers

7.2 Option for Extended Warranty

1.0 GENERAL REQUIREMENTS

1.1 Overview

The United States Environmental Protection Agency (EPA) is mandated to measure nitrous oxide (N2O) emissions from motor vehicles and engines. Work to date on measurement of N2O has indicated that N2O concentrations in dilute exhaust gas will range from 310 ppb to 2000 ppb, requiring a highly accurate analyzer.

Investigation of broadband infrared source type analyzers including Non-Dispersive

Infrared (NDIR), -, and the Photoacoustic Spectrometer (PAS) has indicated that these technologies suffer from interference in the N2O absorption band from CO, CO2, and H2O. Although these technologies make attempts to correct for the interference, the concentrations of these gases in motor vehicle exhaust are too great in some cases to provide adequate correction at sub-1000 ppb N2O levels.

Gas chromatography has some analytical advantages compared to infrared instruments, but existing instruments are not well suited to the integrated real time process measurement functions associated with vehicle and engine gaseous emissions testing.

Recently, in response to new N2O emission regulations, instrument manufacturers have developed laser based infrared spectrometers in which the source emits infrared radiation in a narrow band width. This, in turn, eliminates the opportunity for interference as the infrared wavelength emitted by the source is focused on the region where N2O absorbs.

The EPA seeks to purchase two laser based N2O analyzers. This document describes the minimum design, functionality, and performance requirements of these N2O analyzers to be used in (1) light-duty chassis Hot Test Facility (HTF - Room 524) and (2) light-duty chassis Cold Temperature Test Facility (CTTF – Room 536) at the EPA National Vehicle and Fuel Emissions Laboratory in Ann Arbor, MI. These facilities are equipped with AVL AMA i60 emissions gas analyzers, AVL CVS i60 sampling systems and AVL iGEM Vehicle test cell host computer systems.

Your offer shall describe in detail how you intend to integrate your analyzer into both

CTTF and HTF test sites. Only offers that demonstrate this capability will be considered for this solicitation. Describe a minimum of three (3) examples of previous experience on analyzer integration projects of similar complexity for use in vehicle emissions testing facilities. These projects must be completed or in progress, within the previous five (5) years, and of similar scope, magnitude, and complexity to that covered under this Statement of Work (SOW).

1.2 General System Requirements

1.2.1 System

For the equipment specified, the contractor shall have total system responsibility, which shall include comprehensive integration with existing AVL test equipment,, quality

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assurance, delivery to EPA-NVFEL, installation, calibration, commissioning, acceptance testing, documentation and training of EPA staff, if required. The contractor shall be responsible for documenting measurement traceability and system acceptance.

1.2.2 Identification

The serial number, the date of production and the safety designation shall be conveniently displayed on the exterior of the analyzer. Any component of the device which must be periodically calibrated or verified shall have a serial number or other unique identifier.

1.2.3 Documentation

An electronic version and at least two hard copies of the N2O analyzer documentation shall be provided to the Project Officer upon delivery of the system. All documentation shall be in English and shall include at least the following:

a) Operational manuals

b) Electrical and pneumatic diagrams

b) Recommended on-hand spare parts

c) Maintenance instructions

The operation manual shall include complete information on the analyzer functions and capabilities.

1.3 References

All references shall be the most currently available as of the date of this contract being awarded.

1.4 Safety, Health and Environmental Provisions

1.4.1 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 any relevant building and safety codes specified by NEC, OSHA, and NFPA wherever they might apply, to create a safe system and work environment.

1.4.2 Significant risk factors such as noise, ventilation of toxic gases, heated surfaces, electrical shock, and safety interlocks to prevent accidental errors shall be evaluated by the Contractor, and control measures to ensure the safety of operations and maintenance personnel shall be implemented by the Contractor wherever feasible.

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

1.4.4 Sound dampening/suppression devices and/or materials shall be installed as needed to limit noise levels to 60db at 10 feet from any devices delivered and installed under this contract.

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1.4.5 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.

1.4.6 The Contractor shall strive for the minimization of the generation and release of harmful materials to the environment in all component selection, system design, and operational strategies and installation requirements of this contract.

1.5 Electrical Requirements and Utilities

1.5.1 EPA will provide the following types of electrical power, as required, within 10 feet of the point of use:

120 VAC Clean Uninterrupted

120 VAC

The supply voltages are regulated to ±10%, and the frequency is 60 Hz ±0.5Hz.

1.5.2 All equipment shall be installed in accordance with the most recent edition of NFPA 70, National Electrical Code and required local codes.

1.5.3 Equipment design and installation shall permit operation in compliance with

Occupational Safety & Health Administration (OSHA) Standards Part Number 1910.

Electrical equipment shall comply with Part 1910 Subpart S.

1.5.4 Equipment design and installation shall be in compliance with the most recent edition of

NFPA 70E, Standard for Electrical Safety Requirements for Employee Workplaces.

1.5.5 Equipment design and installation shall provide energy-isolating devices required for equipment operators to follow the OSHA rule on the Control of Hazardous Energy (Lockout/Tag out) of Title 29 of the Code of Federal Regulations (29 CFR) Part 1910.147.

1.5.6 All power receptacles and plugs shall be heavy duty, industrial grade.

1.5.7 Any clean/uninterruptible power outlets shall be clearly marked and in a color selected by the Project Officer.

1.5.8 Any clean/uninterruptible power outlets shall be isolated from utility grade power systems and installed in accordance with the principles of IEEE Std. 1100.

1.5.9 Control and signal cables shall be isolated from power cables. All signal cabling shall not be adversely affected due to capacitive or inductive interference.

1.5.10 All Control and signal cables/wires shall be permanently labeled with to/from and

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signal/function name information that corresponds with the provided electrical schematic.

1.5.11 Digital I/O communications channels shall conform to recognized industry standards such as IEEE 802, RS232, RS485, IEEE 488, IEEE 1394, or USB.

2.0 Design & Functional Requirements

2.1 The CTTF N2O analyzer shall be installed the control room (Room 538) adjacent to the

CTTF test cell (Room 536) at the NVFEL. The HTF N2O analyzer will be installed in the control room (Room526) adjacent to the HTF test cell (Room 524) at the NVFEL.

Due to space constraints preference will be given to those systems that can be installed in the existing analytical cabinets or are rack-mountable.

The N2O analyzers shall provide full functionality for both continuous dilute analysis when sampled directly from CVS exhaust stream, and batch analysis from Kynar CVS sample bags.

2.2.1 The analyzers shall at a minimum be integrated into the existing AVL CVS i60 system as well as the existing AVL iGEM Vehicle test cell automation system and data processors for both CTTF and HTF. CTTF and HTF also have an AMA i60 analytical system.

While we do not require that the proposed analyzer integrate directly to this system it cannot interfere with the functionality or performance of the existing AMA i60 analytical bench.

The contractor shall provide, integrate and configure all necessary sampling hardware and control software with the existing AVL systems in order to fully control analyzer functions, and other functions for data collection, processing and reporting, in keeping with the current operation of both CTTF and HTF test cell control, sampling, analytical, and post test processing systems. N2O concentration and mass emission results shall be added to the existing test reports and existing, test validation reports. Integration shall not degrade current operation of the test cell in any manner.

The analyzers for both sites must be integrated such that they meet performance requirements to run emissions tests per 40 CFR Part 86 & 1066 (Light-Duty Chassis Test Procedures).

2.2.2 The N2O analyzers shall meet the requirements of 40 CFR Part 1065/1066 in terms of features, performance, usage requirements, and calibration/verification requirements.

2.2.3 The combined interference from the maximum concentrations of the interference gases (for example CO, CO2, and H2O) that are at least a high as that expected during testing shall not exceed ±5 % of the flow-weighted mean concentration of N2O expected at the light-duty chassis standard of 10 mg/mi.

2.2.4 The analyzer shall be able to sample and update N2O concentrations at a minimum frequency of 10 Hz for continuous measurement operation. The analyzer shall be able to communicate these results to the test cell automation system, AVL iGEM Vehicle running on AVL Puma Open platform.

2.2.5 Analyzer zero and span drift shall each be less than ± 1% FSD over 4 hours.

2.2.6 At a nominal concentration of 20% of each analyzer range, stability shall be less than 10ppb standard deviation on the low range of the instrument and less than 1ppm standard deviation on the high range over a 10 minute sampling period.

2.2.7 The N2O analyzers shall have performance that provides robust chemical measurement at low and sub-PPM levels. Analyzers shall utilize wide dynamic range technology and automatic range selection as required.

2.2.8 The linearization function and other diagnostic checks shall at a minimum be handled through the analyzer control interface software. The linearization function shall be designed to function according to the following parameters:

a) Selection of up to a fourth order curve with the ability to select curve order.

b) Option to allow the curve intercept to float or be forced to zero.

c) Allowance to modify fit tolerance; default values shall be set at the minimum of 2.0% of point or 1.0% of full scale. Full scale in this sense shall be considered to be the highest concentration utilized in the linearization function.

d) Verification of linearity according to 40 CFR part 1065.307.

e) Secondary confirmation of curve fit and accuracy by utilizing an independent gas standard that is at an intermediate concentration; acceptable tolerance shall be modifiable in the same manner as curve fit tolerance above. Default limit shall be ± 2.0% of point.

f) Candidate curves shall not be made active automatically.

Reporting of linearization and any diagnostic check results shall be readily available in keeping with the current operation of both CTTF and HTF test cell control, sampling, analytical and post test processing systems.

The HTF and CTTF sites currently use an AVL gas divider for linearization and other diagnostic checks. If necessary, additional ports shall be included to connect directly to the gas divider. The proposed instrument must be able to communicate with this gas divider to perform the aforementioned tasks or provide a gas divider of equivalent performance meeting requirements of CFR 1065.248. The proposed solution shall allow the user to perform linearity verifications per CFR 1066.135 and other necessary diagnostic checks.

2.2.9 The contractor shall provide and install all necessary system plumbing, including heated sample lines, filters, heated and unheated sample probes and overflow calibration devices, and all required transfer tubing, fittings and valves. As installed there must be no

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contamination in sample plumbing that would be detectable on any range of the analyzer.

2.2.10 The contractor shall provide plumbing for connection of analytical gases, and required utility gases, from an EPA-provided valve rack within approximately 20 feet, or less, of the instrument. Gases will be supplied at nominal pressures specified by the contractor, regulated at the gas source. Valve rack fittings will be for ¼ inch outside diameter tubing. The contractor shall provide and install permanently-mounted stainless steel lines to connect to the valve rack and any additional gas shutoff valves, or regulators required by the contractor’s system. The ends of each line end shall be labeled with line number, gas type and nominal concentration

2.2.11 Plumbing for the transfer of zero and span gases, as well as the dilute exhaust samples, shall be of 316 stainless steel tubing passivated and electro-polished (Ra<10). Short lengths of Teflon® tubing may be used to facilitate final connection to analyzers. All solenoid valves shall have stainless steel bases and plungers constructed of a durable material which does not out-gas or otherwise change the composition of the gas flowing past them.

2.2.12 Each analyzer shall have a minimum of two ranges (Low & High). Typical concentrations require a 5ppm range for low and 200ppm range for high. Each analyzer shall have one span gas and one mid-span gas inlet per active range. Span gases may be shared between analyzers and ranges, where concentrations permit. Span concentrations shall be between 85% and 95% of the nominal upper range concentration. Mid-span gases shall be between 10% and 60% of the nominal upper range concentration.

2.3 Electromagnetic Isolation and Interference

The analyzer electrical components shall be sufficiently shielded to minimize interference and inaccuracies due to electromagnetic fields created by laboratory equipment.

3.0 INSTALLATION

The contractor shall provide on-site supervision of all installation, commissioning and acceptance activities. All contractor personnel shall receive 1-hour briefing by EPA personnel on specific safety and security issues. All contractor personnel and subcontractor personnel must comply with EPA/NVFEL safety and security measures while working at NVFEL. Typically, work may be undertaken at NVFEL between the hours of 7:00 AM to 5:00 PM Monday through Friday, with the exception of Federal holidays. The contractor shall be responsible for the timely removal and disposal of all packaging and materials left from the shipment and installation of the instruments.

4.0 ACCEPTANCE

Confirmation shall include, but not be limited to:

a) Compliance with all referenced portions of the CFR.

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b) Successful performance of CFR system verifications.

c) Verification of compliance with analyzer accuracy, stability, repeatability, response time and drift requirements.

d) Verification of complete integration with the test system including functionality and data collection, processing, and test reporting and quality control validation as necessary to run all light-duty test procedures per 40 CFR Part 86 and Part 1066

e) Successful completion of EPA regulatory chassis test demonstrating full analyzer compliance with the Code of Federal Regulations.

f) Successful performance of other automated functions outlined in this Statement of Work including proper function of quality control monitoring and safety monitoring as applicable.

g) Evidence that all other requirements of this Statement of Work have been fulfilled.

h) System documentation as detailed above.

The contractor shall summarize the results of acceptance testing in a written report cross referenced to SOW and CFR requirements. The report shall be suitably comprehensive to provide evidence of SOW and CFR compliance to a third party reviewer.

5.0 TRAINING

Training shall be provided by the device manufacturer and shall include full descriptions of all functions of the system, including hardware, software, operation and maintenance.

The training shall accommodate up to eight (8) persons.

6.0 WARRANTY

6.1 The cost of the two N2O analyzers shall include a standard commercial one-year warranty covering all parts and labor. Warranty period should commence after acceptance. The contractor shall provide instructions describing the procedures needed to repair, replace, or adjust components which are not covered by the warranty. The contractor shall provide information necessary to properly select replacement parts not covered. All repairs performed by the contractor, either under warranty or not, shall be guaranteed for the period of the warranty.

7.0 OPTIONAL ITEMS

7.1 Option for Additional Analyzer

The contractor shall provide an option for the purchase up to two additional N2O analyzers that meet all SOW requirements described above. This option shall remain in place for up to two years after receipt of contract award (ARO).

7.2 Extended Warranty

The contractor shall offer an option for an Extended Maintenance and Service Warranty, renewable every year for a period of four years beginning at the end of the initial one year

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warranty described above. This Warranty must cover parts, labor and travel expenses, if applicable, and shall include at least one preventive maintenance visit at no additional charge.

If an option is not exercised for Extended Maintenance and Service in a certain period, then that option is no longer available for exercise in future years. For example, if the Preventative Maintenance Option is not exercised in Option Period 2, then that Option is NOT AVAILABLE in Option Period 3.

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