SOO for Tunnel 9 Hydraulics Upgrade.pdf

16 June 2026

Distribution A.

Approved for Public Release. Distribution is unlimited.

Per AEDC-IRA-26-1719

STATEMENT OF OBJECTIVE

FOR

TUNNEL 9 HYDRAULIC SYSTEM UPGRADE

ARNOLD ENGINEERING DEVELOPMENT COMPLEX

ARNOLD AIR FORCE BASE, TN 37389-9998

Table of Contents-1 Distribution A.

Table of Contents

1. BACKGROUND

1.1. Background

1.2. Statement of Need

1.3. Justification

2. SCOPE OF WORK

3. APPLICABLE DOCUMENTS

2.1 Government Documents

2.2 Non-Government Documents

4. REQUIREMENTS

4.1. General

4.2. Engineering/Design

4.3. Part Procurement

4.4. Demolition/Installation/Verification

Appendix A – Submittal Procedure Appendix B – Scope Split Table

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1. Background

1.1. NOTICE TO OFFERERS

This Statement of Objectives (SOO) is a high-level summary of a project that seeks to find contractors capable and willing to complete this project. Once a contractor that meets these requirements, along with the ability to access CUI, submits their capabilities for this project, a more detailed Controlled Unclassified Information (CUI) Statement of Work will be shared prior to bidding on the contract.

1.2. Background

Tunnel 9, a geographically separated unit of AEDC located in Silver Spring, MD, provides the Department of Defense with unique hypersonic ground test capabilities. A core feature of this facility is a high-speed, single-axis positioning system that allows for the collection of vital performance data under demanding conditions. This capability is powered by a complex hydraulic system that actuates several critical functions, including the primary high-speed motion of the test apparatus. Motion control is managed through a custom control architecture that sends command signals to a specialized three-stage servo-proportional valve, which is the centerpiece of the motion control and the primary focus of this upgrade initiative.

2. OBJECTIVE

2.1. The objective of this project is for the Contractor to perform a comprehensive modernization of a high-performance hydraulic motion system. The scope includes the design, procurement, installation, and commissioning of core system components, including the primary control valve, main actuating cylinder, and the Hydraulic Power Unit (HPU). All associated accumulators, intermediate valves, regulators, and piping necessary for the new system shall also be replaced.

Furthermore, the upgrade shall introduce two key enhancements: a dedicated filtration and cooling circuit to maintain hydraulic fluid health and additional instrumentation for improved system monitoring. The newly installed system must be designed for full mechanical and functional compatibility with existing, interconnected facility systems that are out of the scope of this replacement.

2.2. This Contract shall be broken up into 3 separate phases that will be quoted and executed separately to ensure flexibility for AEDC Tunnel 9 on scheduling/period of performance. Phase 1 includes engineering/design efforts. Phase 2 shall include component procurement and any pre-demolition assembly, testing, and verification. And phase 3 shall cover demolition of the current system and post-demolition assembly/installation, and testing/verification to complete delivery.

These 3 phases will be described in further detail in the subsequent sections and the requirements section.

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2.2.1. Phase 1 Engineering Design: The Contractor shall develop and deliver a comprehensive engineering design package. This includes all component sizing calculations, system simulations, schematics, a detailed bill of materials, and 2D/3D models. The design must be approved by AEDC before proceeding to Phase 2. Procurement of long-lead items may be initiated prior to phase 2 only with approval from AEDC. Phase is expected to begin upon award of contract.

2.2.2. Phase 2 Part Procurement: Following design approval, the Contractor shall procure all components. This phase also includes any off-site fabrication, pre-assembly of subsystems, and associated testing and verification required to prepare for on-site installation. Phase is expected to begin Fall 2026.

2.2.3. Phase 3 Demolition/Installation/Commissioning: The Contractor shall execute the on-site work at Tunnel 9, beginning with the demolition and disposal of the existing legacy system. The new system components and assemblies shall then be installed, integrated, and fully commissioned.

Final acceptance testing and verification will be performed to complete the project delivery. Phase is expected to begin Summer or Fall of 2027.

2.3. AEDC will be responsible for specific portions of the system design and integration. To ensure clarity, these responsibilities are outlined in a "Scope Split Table." Further details are provided in the Requirements within Section 4. w/ support from Contractor. A “supporting role” means that the party will answer questions and provide assistance but is not responsible for completing the task.

If a support request exceeds the scope of this definition, the parties involved will discuss a formal change.

No. Description AEDC Contractor

1 Project schedule coordination. Hold Required SE reviews with AEDC. Support Responsible

2 CAD model/measurements of structures interfacing with Hydraulic Equipment. Responsible Support

Design and Layout of Hydraulic Equipment & associated instrumentation (Proportional Valve, Cylinder, HPU, Manifolds, Accumulator, intermediate piping/components, pressure transducers, LDT).

Responsible

4 Design of brackets, mounts, enclosures for Hydraulic equipment. Support Responsible

Fabrication/Procurement of hydraulic equipment & associated instrumentation, and acceptance testing of Equipment prior to installation.

Responsible

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Provide Hydraulic System Simulation Results and predicted tuning parameters (gains, natural frequency, dampening factor etc.)

Responsible

7 Shipping of Hydraulic Equipment to AEDC Tunnel 9. Responsible

8 Preparation of demolition/installation area and access to area. Responsible

9 Demolition of previous hydraulic equipment required for installation (Proportional Valve, Cylinder, HPU, Piping etc.). Responsible

10 Disposal of removed hydraulic equipment (Proportional Valve, Cylinder, HPU, Piping etc.). Responsible

11 Assembly/Installation of new Hydraulic Equipment, including associated Piping/Tubing/Hoses/Connectors. Responsible

12 Integration of auxiliary functions to new HPU (model support positioner, axial translation, latching cylinders, etc.). Responsible

13 Control system design & supply of Motion Controller/PLC hardware. Responsible

14 Wire pumps, valves and instrumentation to Electrical Breakers, Motion Controller and PLCs. Responsible Support

15 Integration of valves and instrumentation into Tunnel 9’s control system. Responsible

16 Supply of working fluids (Hydraulic Fluid, Gaseous Nitrogen Cooling Water, Compressed Air if applicable) Responsible

Documentation and Manuals for the Hydraulic Equipment.

Orientation for AEDC Personnel on maintenance frequency and tasks. Provide instructions for common repair parts such as O- Rings, Packing, etc.

Responsible

18 Pre-Commissioning of Hydraulic Equipment (Besides Software Validation) Responsible

19 Demonstration of key software features during Pre-Commission Responsible Support

20 Commissioning Hydraulic System (Besides Tuning, Performance Verification) Support Responsible

21 System Tuning and validation of overall System Performance Requirements during Commissioning Responsible Support

22 Update applicable System Hazard Analyses & Work Instructions Responsible Support

Table 1: Scope Split Table

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3. APPLICABLE DOCUMENTS

Government Documents:

3.1. AEDC T1/T2 Standards (Piping and Pressure Vessels)

Non-Government Documents:

3.2. ASME B31.1 Power Piping

3.3. ASME BPVC VIII Pressure Vessels

3.4. ISO 4406 Cleanliness

3.5. OSHA 29 CFR 1926.302(b)(7)

3.6. MSHA 30 CFR 56/57.13021 High Pressure Hose Connections

4. REQUIREMENTS

4.1. General:

4.1.1. The Contractor shall design, fabricate, assemble, test and supply the hydraulic system to Tunnel 9, the Government, in accordance with all documents listed in Section 3 Applicable Documents and the details of Section 4 Requirements.

4.1.2. Contractor shall be able to access and view CUI information throughout the duration of the project.

4.2. CLIN 1: Engineering Design

4.2.1. General

i. The Contractor shall design, fabricate, test, and supply a complete hydraulic system in accordance with the objectives outlined in this document and all applicable government and industry standards

ii. Contractor shall adhere to a structured Systems Engineering (SE) process, including regular progress check-ins with the responsible AEDC Systems Engineer. This process shall incorporate formal design reviews at key project milestones, including, but not limited to, a Preliminary Design Review (PDR) and a Critical Design Review (CDR) prior to the start of fabrication.

iii. All new hardware must mechanically integrate with the existing motion apparatus and supporting structures. The components must be designed to

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iv. System design shall prioritize long-term reliability at consistent performance. Components shall be selected for extended service life and zero-leak performance under all operating conditions.

v. System design shall facilitate rapid fault diagnosis through clear, permanent labeling of all components and conductors, and the inclusion of diagnostic test points at critical system locations.

vi. System shall prioritize serviceability. Components requiring periodic service or replacement, such as proportional valve(s), cylinder wear components, filters and transducers, shall be located to allow for unobstructed access for removal and installation without the need to dismantle unrelated major assemblies.

vii. Pump Motors and all other components receiving electrical input shall be supported by Tunnel 9's existing electrical supply system.

viii. All instrumentation, including the primary position transducers, shall provide signals that are fully compatible with AEDC’s motion controller (for high sample rate) or control system PLC (for low sample rate). While standard 0-10V or 4-20mA signals are preferred for general sensors, specialized interfaces (i.e. SSI, EtherCAT) for position feedback are acceptable.

ix. All components (except the HPU and Kidney Loop), shall be rated to operate reliably in a near-vacuum environment for up to three hours. If components are not inherently vacuum-rated, a suitable environmental enclosure or alternative solution shall be provided.

x. All wetted components shall be compatible with DTE-26 Ultra or alternative compatible selected hydraulic oil.

xi. All valves, piping, tubing, hoses, connectors, and other wetted components shall be rated to meet or exceed the full main system pressure, unless installed in a pressure-reduced circuit. If installed in a reduced-pressure circuit, they may have a pressure rating appropriate for that circuit's maximum operating pressure, provided the entire circuit is protected by a secondary pressure relief valve. The set pressure of this relief valve must not exceed the maximum allowable working pressure of the lowest-rated component within that circuit.

xii. System design must maintain current or equivalent safety features (interlocks, design elements, snubber controls, automated shutdown, health monitoring, valve double block and bleed, whip restraints, etc.) that maintain system safety for operation and maintenance, mitigating equipment/personnel hazards outlined in 215-T9-TCN-BHA-01, 215-T9- HYD-BHA-01, and 215-TCN-C.S.ENT.-01/02/03.

xiii. Must meet applicable AEDC Security standards which includes use of hard-wired connectors (No wireless/Bluetooth communications) and approved software/operating systems.

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xiv. New hardware shall meet applicable ASME B31.1 (Power Piping), ASME BPVC (Pressure Vessels) and AEDC T1/T2 Standards (Piping and Pressure Vessels).

xv. The hydraulic system's lowest natural frequency shall be minimally 4 times that of the predicted nominal maximum frequency of acceleration to avoid resonance from any operational command or motion profile, ensuring stable and predictable performance.

xvi. Motion apparatus shall be capable of free motion when the system is de-energized and isolation valves are open.

xvii. Contractor shall design all field piping, hydraulic hoses, nitrogen tubing to/from accumulators, instrumentation lines, and any supporting hardware (i.e. vacuum balancing line for the manifold.

xviii. A complete set of system- and component-level drawings shall be provided.

This also includes a full hydraulic schematic with Bill of Materials (BOM).

The drawings must be reviewed by responsible AEDC Systems Engineer prior to start of fabrication of the Hydraulic System.

xix. A design calculation package shall be provided that proves key metrics are met with the proposed design. This includes but is not limited to: pressure drop, flow rates, system natural frequency/frequency of acceleration, structural analysis on actuator and relevant mounting hardware, linear actuator speed/acceleration. Design package must be reviewed by responsible AEDC Systems Engineer prior to start of fabrication of the Hydraulic System.

xx. Contractor shall provide specification/data sheets for all commercially available items selected.

4.2.2. Cylinder Design:

i. Cylinder shall be a double-acting single rod hydraulic cylinder.

ii. Cylinder shall have a working stroke of 120.5” (~3060.7 mm) to replicate the current of motion.

iii. Cylinder & Rod Assembly shall be capable of achieving linear speed of 13 ft/s (3.96 m/s). Fluid velocity at ports shall not exceed 55 ft/s.

iv. Cylinder bore and rod size shall be selected to provide the required force and acceleration capabilities while maintaining adequate structural integrity.

v. The actuator shall be installed in a horizontal orientation on the moving portion of the test apparatus, where it will interface with the existing mechanical drive linkage.

vi. Cylinder shall include ports for mounting pressure transducers at both the rod and cap sides/ports to monitor the pressure within the cylinder chambers. Transducer signal shall be compatible with the selected motion controller. The pressure range is 0-5000 psig and shall be accurate to +/- 25 psi at 1000 samples/sec.

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vii. Cylinder shall be compatible with a new LDT/MLDT (Linear Displacement Transducer / Magnetostrictive Linear Displacement Transducer) solution for improved position and velocity accuracy. The LDT/MLDT shall have a resolution of 0.5 microns or less and a linearity deviation of 50 microns or less. Sensor shall also be hardwired to the primary motion controller and sample at 1000 samples/sec.

viii. Cylinder shall utilize wear resistant materials or coatings to maximize service life/reduce risk of corrosion.

ix. Cylinder design shall allow for ability to replace wear components (bushings, seals etc.)

x. Cylinder ports shall use high-integrity, leak-free fittings. Preferred serviceable connections include SAE J1453 O-ring face seal (ORFS) or dual-ferrule compression fittings (e.g., Swagelok®).

4.2.3. Control Valve Design:

i. The replacement Control Valve shall be a high-performance, two or three-stage proportional valve designed for closed-loop control of the hydraulic actuator.

ii. Valve shall have a 4-way, 3 position (4W3P) with P-A B-T, P-B A-T and all ports blocked in the center. In a de-energized or powered-off state (zero current), ports A and B shall drain to the tank (T).

iii. Valve shall have a rated flow capacity at a specified pressure drop to achieve the required actuator maximum speed of ~13 ft/s.

iv. Valve shall exhibit a step response time of 55 ms or less for a 0-100% command change to ensure rapid and accurate positioning.

v. Valve shall include an integrated Linear Variable Differential Transformer (LVDT) for main spool position feedback. The feedback signal shall be compatible with the selected motion controller and sample at 1000 samples/sec.

vi. Valve’s electrical connection type must interface with the motion controller if that be Ethercat, or standard signal types like +/- 10V, or 4-20mA.

vii. Valve or its mounting manifold shall include ports for pressure transducers to monitor the mainstage supply (P), A, and B port pressures and the pilot supply pressure. Transducer signal shall be compatible with the selected motion controller. The transducers shall have a range of 0 to 5000 psig and shall be accurate to +/-25 psig at 1000 samples/sec.

viii. The valve assembly and its associated manifold shall be securely mounted to the primary equipment structure. The layout must be optimized to minimize the length of hydraulic connections to the actuator while also providing sufficient access for maintenance tasks.

ix. Valve Assembly shall incorporate features to facilitate system flushing, such as dedicated flushing ports or a bypass plate.

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x. Valve Assembly shall provide a dither function, either generated internally by its onboard electronics or accepted from an external control signal.

xi. A and B Ports of Proportional Valve shall be isolated from the cylinder when not actively being controlled via solenoid actuated (or equivalent actuation medium) blocking valves that are controlled from a touch panel and computer via hardwire to the existing PLC hardware. The valves are only permitted to open when interlock is satisfied that pressure differential results in a balanced net force on the rod and cap ends of the cylinder.

xii. Proportional Valve and/or manifold ports shall use high-integrity, leak-free fittings where necessary. Preferred serviceable connections include SAE J1453 O-ring face seal (ORFS) or dual-ferrule compression fittings (e.g., Swagelok®). The use of tapered pipe threads (NPT) is prohibited on connections larger than 1/2", any use of NPT must be specially approved by Tunnel 9 System Engineering.

4.2.4. Design of Piping/Tubing/Hoses/Connections:

i. Hard Connections shall be used between the accumulators and actuator, and total pipe connection length shall be optimized for controllability and performance.

ii. Piping/Tubing/Hoses/Connections shall be selected and sized to support the transient and continuous flow rates required to reach maximum actuator speed of 13 ft/s and system pressure required to reach the maximum acceleration of 130 ft/s^2. Fluid velocity shall not exceed 55 ft/s at any point in the system. Exceptions for components (i.e. Proportional Valve) shall be reviewed and approved by AEDC System Engineer.

iii. All Piping must be ASTM A106 Grade B Seamless Steel Pipe or equivalent and tubing seamless ASTM A269 316/316L, 304/304L stainless steel, or equivalent.

iv. Piping/Tubing shall be securely supported and clamped at regular intervals to prevent vibration and stress on the fittings as specified by manufacturer.

Clamps shall be of a non-abrasive material to prevent damage to the pipes.

v. Connections shall fit selected components (proportional valve, cylinder, accumulators, pump isolation valves etc.) and fit within the current equipment housing without any modifications unless minor modifications (obvious non-impact to structural integrity) are absolutely necessary.

vi. Flexible Hoses may be used where necessary to accommodate movement between components. Hoses shall be selected using the guide for SAE Hydraulic Hose Specifications & rated for the system's maximum operating pressure and temperature.

vii. Flexible Hoses outside of shielded spaces must feature a whip restraint in accordance with “MSHA 30 CFR 56/57.13021 High Pressure Hose Connections”.

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viii. Connections on high-pressure lines shall be made using high-integrity, leak-free fittings. Preferred serviceable connections include SAE J1453 O-ring face seal (ORFS) or dual-ferrule compression fittings (e.g., Swagelok®). For permanent connections, socket-weld fittings and butt-welds are acceptable. The use of tapered pipe threads (NPT) is prohibited on connections larger than 1/2", any use of NPT must be specially approved by Tunnel 9 System Engineering.

4.2.5. Offline “Kidney” Filtration Loop Design:

i. Separate Cooling Filtration Loop shall feature a separate pump that is connected to the main hydraulic reservoir.

ii. Filtration Loop Pump Motor shall be able to be toggled on and off from the primary operator station and control panel via hard-wire to existing PLC’s.

iii. Filtration Loop Electric Motor shall be sized for the existing electrical disconnect in the facility utility area for LOTO purposes and not exceed the voltage current load rating when operating at the same time as the main pump. (480 V, 100 A Capacity, 3 Phase, 60HP).

iv. Filtration Loop System shall contain course and fine particle filtration (10 micron and 3 micron) as well as moisture filtration.

v. Filtration Loop System shall provide oil cooling via optimally sized shell and tube style heat exchanger, that can be connected to T9’s city/chiller water supply (~80 psi). Oil temperature shall not exceed 130°F over 6 hours of runtime.

vi. Filtration Loop System shall contain necessary safety features such as pressure relief before the filter stages.

vii. Filtration Loop System shall contain system monitoring devices such as a pump outlet pressure gauge, temperature gauges/transmitters on the water and oil inlet/outlet of heat exchanger and analog/digital flow meters on the oil and water lines.

viii. Filtration Loop Connections on high-pressure lines shall be made using high-integrity, leak-free fittings. Preferred serviceable connections include SAE J1453 O-ring face seal (ORFS) or dual-ferrule compression fittings (e.g., Swagelok®). For permanent connections, socket-weld fittings and butt-welds are acceptable. The use of tapered pipe threads (NPT) is prohibited on connections larger than 1/2", any use of NPT must be specially approved by Tunnel 9 System Engineering.

ix. Resulting fluid velocity from Filtration Loop Pump flow rate shall not exceed 20 ft/s at any point in the system.

4.2.6. Hydraulic Power Unit (HPU) Design:

i. HPU shall be redesigned/altered to support the Proportional Valve and Piston Flow Rate & Pressure requirements while maintaining same ability to supply other existing auxiliary hydraulic functions.

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ii. HPU configuration shall maintain uninterrupted hydraulic power and control to the primary translation assembly during all translational movements of the dynamic system structure. The HPU must be designed to accommodate this motion, either by being physically integrated with the dynamic structure, moving independently alongside it, or through appropriately managed flexible connections.

iii. HPU Pump shall be variable displacement & pressure compensated featuring a case drain.

iv. HPU Electric Motor shall be sized for the existing electrical disconnect in the basement for LOTO purposes and meet the voltage current load rating when operating with the kidney loop pump (480 V, 100 A Capacity, 3 Phase, 60HP).

v. HPU Motor shall be able to be toggled on and off from the primary operator station and control panel via hard-wire to existing PLC’s.

vi. HPU shall be equipped with a high-pressure filter placed directly downstream of the pump.

vii. The HPU design shall include a valve configured to automatically vent stored hydraulic energy (including energy stored in accumulators) whenever the system is de-energized.

viii. HPU shall include health monitoring features including but not limited to:

• Oil temperature sensor shall be located at the case drain; range 0°F to 200°F and shall be accurate to +/-5°F at 10 samples/sec.

• Pressure transducer located at the pump outlet; pressure range 0 to 5000 psi accurate to +/-25 psig at 10 samples/sec.

• High/Low oil level reservoir alarms [float switch(es)].

ix. HPU Connections on components shall be made using high-integrity, leak-free fittings. Preferred serviceable connections include SAE J1453 O-ring face seal (ORFS) or dual-ferrule compression fittings (e.g., Swagelok®).

For permanent connections, socket-weld fittings and butt-welds are acceptable. The use of tapered pipe threads (NPT) is prohibited on connections larger than 1/2", any use of NPT must be specially approved by Tunnel 9 System Engineering.

x. HPU Fluid Velocity shall not exceed 20 ft/s in the HPU supply to the accumulators and not exceed 30 ft/s in return to the reservoir from cylinder.

4.2.7. Accumulator Design:

i. Accumulators & associated piping (Gaseous Nitrogen & Hydraulic) shall be redesigned if one of the following can’t be met with the other changes to the hydraulic system:

a. Max allowable pressure (MAWP) is less than the new HPU/system operating pressure.

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b. Total effective fluid volume meets new servo/actuator required volume/flow rate.

ii. Accumulators shall be of the bladder type, chargeable with dry-nitrogen gas.

iii. Accumulators shall have sufficient effective volume to supply the peak flow demands of the actuator during a maximum velocity command through 90% of the stroke, without allowing the main system pressure to drop below 75% of the nominal operating pressure.

iv. Accumulators must fit the primary translation assembly and have ample clearance with all surrounding facility enclosure walls.

v. Accumulator Connections on components shall be made using high-integrity, leak-free fittings. Preferred serviceable connections include SAE J1453 O-ring face seal (ORFS) or dual-ferrule compression fittings (e.g., Swagelok®). For permanent connections, socket-weld fittings and butt-welds are acceptable. The use of tapered pipe threads (NPT) is prohibited on connections larger than 1/2", any use of NPT must be specially approved by Tunnel 9 System Engineering.

4.2.8. Simulation

i. Contractor shall demonstrate validation of system performance (system response time, actuator displacement/velocity/acceleration) via physics-based simulation model that serves as a digital prototype of the dynamic motion system. This model shall include relevant inputs used, in addition to the performance outputs. This shall be delivered in a written report format with figures that shall be approved by AEDC System Engineer.

ii. Contractor shall provide their simulation model or system parameters to AEDC to create their own similarly-performing simulation model via AEDC enterprise software.

iii. Contractor shall provide transfer function coefficients to model a 2nd order hydraulic system. These coefficients shall include: Damping factor, natural frequency, frequency of acceleration, Positive/Negative system gain, maximum compression, and maximum force of the system.

iv. Contractor shall supply predicted simulation gain constants to support the tuning and calibration of the motion controller with the new hardware.

4.3. CLIN 2: Part Procurement

4.3.1. General

i. The Contractor shall supply all components of the hydraulic system as specified in the engineering design section.

ii. The Contractor shall provide all manufacturing and factory acceptance testing of the hydraulic equipment.

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iii. Contractor shall coordinate with AEDC representatives to ship all hardware to AEDC White Oak, 10905 New Hampshire Ave, Silver Spring

MD, 20903.

4.3.2. Pitch Cylinder

i. Contractor shall conduct a hydrostatic pressure test of the Cylinder’s design pressure at a minimum. Contractor shall provide AEDC with a certificate including the maximum pressure and hold time at a minimum.

ii. If welding is required, Cylinder shall be welded by an individual qualified via internationally recognized standard (ASME, AWS, ISO, etc.). Contractor shall provide AEDC with a weld inspection certification.

iii. Contractor shall provide a Material Certification and Certification of Conformance (CoC) that verifies the materials used, and dimensions specified from the approved cylinder fabrication drawing.

iv. Contractor shall demonstrate the cylinder’s ability to achieve the desired speed and acceleration in the retract and extend direction using a test setup at their own facility. This test must be either witnessed live by AEDC or documented and certified.

v. Contractor shall provide a specification sheet for the selected position transducer & pressure transducers and calibration documentation (Calibration to be completed by the contractor or OEM)

4.3.3. Proportional Valve

i. Contractor shall provide specification sheet for the selected proportional valve that includes the model configuration information.

ii. Contractor shall provide calibration/performance documentation for the selected valve. This includes but may not limited to: Pressure vs Flow curve data, Step/Frequency Response Data, LVDT Output Signal (Null, Ends of Stroke etc.)/Linearity, & fail safe function.

iii. Contractor shall demonstrate the ability to produce the required flow rate/pressure calculated from the design phase, using a test setup at their facility. This test must be either witnessed live by AEDC or documented and certified.

iv. Contractor shall provide a Material Certification and Certification of Conformance (CoC) that verifies the materials used, and dimensions specified from the approved manifold fabrication drawing.

v. Contractor shall provide a specification sheet for the selected transducers and calibration documentation (Calibration to be completed by the contractor or OEM)

4.3.4. Piping/Tubing/Hoses/Connections

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i. For any hydraulic/pneumatic hoses supplied, the Contractor shall conduct a hydrostatic pressure test to the hose’s design pressure at a minimum.

Contractor shall provide AEDC with a certificate including the maximum pressure and hold time at a minimum.

ii. Contractor shall provide a Material Certification and Certification of Conformance (CoC) that verifies the materials used for the Piping and Tubing, and dimensions specified from the approved fabrication drawing (run length, schedule/thickness, bend radius etc.).

iii. Any offsite welding of sections shall be welded by a qualified individual in accordance with ASME 31.1 Section 127 or other international recognized standard (AWS, ISO, DIN etc.). Welds shall be visually inspected per ASME

31.1 Section 136.4.2 by NDE Personnel (qualified in accordance with ASME

31.1 Section 136.3.2). Contractor shall provide AEDC with a weld inspection certification verifying all tubing/piping welds have been inspected.

iv. Contractor shall provide certification of cleanliness (ISO 4406 16/14/11) of any sub-assemblies of piping/tubing.

4.3.5. Offline Filtration (Kidney) Loop

i. Contractor shall complete a functional test of the Kidney Loop. Contractor shall demonstrate the unit can supply the specified maximum system operating pressure and flow rate for a prolonged period of time. This test must be either witnessed live by AEDC or documented and certified by a qualified individual.

ii. Associated instrumentation shall be calibrated and demonstrated to be functioning/accurate. This test must be either witnessed live by AEDC or documented and certified by a qualified individual.

4.3.6. Power Unit (HPU)

i. Contractor shall complete a functional test of the HPU. Contractor shall demonstrate the unit can supply the specified maximum system operating pressure and flow rate for a prolonged period of time. This test must be either witnessed live by AEDC or documented and certified by a qualified individual.

ii. Associated instrumentation shall be calibrated and demonstrated to be functioning/accurate. This test must be either witnessed live by AEDC or documented and certified by a qualified individual.

iii. Contractor shall provide a certificate of conformance (CoC) for the assembly verifying the package dimensions of the unit.

iv. Contractor shall provide certification of cleanliness (ISO 4406 16/14/11) for the HPU assembly.

4.3.7. Accumulators

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i. Accumulators shall be designed, fabricated, and certified in accordance with ASME BPVC Section VIII, Division 1, and shall bear the U-Stamp symbol.

ii. Contractor shall conduct a hydrostatic pressure test in accordance with ASMC BPVC VIII. Contractor shall provide AEDC with a certificate including the maximum pressure and hold time at a minimum.

iii. Accumulators shall be welded by a qualified individual in accordance with ASME BPVC IX or other international recognized standard (AWS, ISO, DIN etc.) in accordance with VIII. Welds shall be visually inspected per ASME BPVC Section VIII, by qualified NDE personnel. The Contractor shall submit all weld inspection certifications to AEDC upon completion.

4.4. CLIN 3: Installation/Demolition/Verification

4.4.1. General

i. Contractor Personnel shall be U.S. Citizens, who possess a REAL ID, and are eligible to handle CUI information.

ii. Contractor Personnel shall be trained in accordance with AEDC Tunnel 9 Safety/Operational Policies prior to start of work.

iii. Contractor shall organize and complete any lifting operations needed to remove/install equipment. The contractor may utilize AEDC cranes and rigging equipment as long as use is permitted by Tunnel 9 Operations but must supply their own equipment as required (in the event that Tunnel 9 equipment is unavailable or non-applicable).

4.4.2. Demolition

i. An Outage Readiness Review (ORR), in coordination with AEDC personnel, shall be conducted prior to start of demolition. Approval will be required to proceed into demolition/installation.

ii. Contractor shall remove identified legacy hardware that is no longer needed for the new system design. Hardware shall be appropriately removed from service and disposed of.

iii. Contractor shall conduct thorough clean-up of the affected area post-demolition.

iv. Following demolition activities, AEDC will perform a pre-installation site assessment to verify that no out-of-scope damage has occurred.

4.4.3. Installation

i. Contractor shall complete any remaining assembly of system on-site (pipefitting, field welding, mounting, etc.) and install system in its designed configuration within and around the designated Tunnel 9 equipment enclosure.

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AEDC shall wire/connect system components to Electrical Breakers, PLC’s and Motion Controller and integrate components into the Control System.

ii. Any field-welding shall be completed by a qualified individual in accordance with ASME 31.1 Section 127 or other applicable internationally recognized organization (AWS, ISO, DIN etc.). Welds shall be visually inspected per ASME 31.1 Section 136.4.2 by NDE Personnel (qualified in accordance with ASME 31.1 Section 136.3.2). Contractor shall provide AEDC with a weld inspection certification verifying all tubing/piping field-welded have been inspected.

iii. All components listed on the Bill of Materials shall be tagged or marked with a Component ID number that corresponds with the Schematic.

iv. Contractor shall inspect & provide a certificate of conformance the assembly was correctly installed per schematic and assembly drawings.

v. Contractor shall provide a detailed maintenance plan and operations manuals for the system and applicable individual components.

vi. Contractor shall conduct thorough clean-up of the affected area post-installation.

vii. Upon completion of installation and prior to verification, AEDC will inspect components and any associated equipment for any visible damage, general cleanliness, craftsmanship, and adherence to final drawings.

4.4.4. System Verification

i. Contractor and AEDC representatives shall collaborate to create a System Test Plan (STP) document and Commissioning Plan and conduct a Verification Readiness Review (VRR) post-installation of system, and prior to commissioning of completed assembly. The verification shall include, but may not be limited to, the following Pre-commissioning and Commissioning tasks. Any modifications to the established responsibilities or specific verification tasks require mutual concurrence and shall be formally documented within the STP. AEDC reserves the right to witness all tests.

Contractor shall modify components and associated equipment of the assembly as needed after failed tests and repeat all tests until the system meets test requirements.

ii. Contractor shall be responsible for ensuring that the Hydraulic System provided meets all requirements in accordance with all documents listed in Section 3 Applicable Documents.

iii. Following completion of the System Test Plan and Verification stage, Contractor shall collaborate with AEDC to hold a Functional Configuration Audit (FCA) with Site Management to ensure objectives were met based on system requirements.

4.4.5. Pre-Commissioning (Cold Checks)

Page-16 Distribution A.

Per AEDC-IRA-26-1719

i. Contractor shall test and verify that all hardwired safety interlocks without hydraulic pressure applied and assist AEDC in simulating hardware faults (e.g., tripping a level switch) to verify that the control system correctly identifies the fault and executes the programmed safe-state logic. AEDC personnel shall ultimately be responsible for verifying all software-based safety interlocks within the control system.

ii. Contractor shall verify and document that all hydraulic accumulators have been properly pre-charged with dry nitrogen to the design-specified pressure prior to introducing hydraulic fluid into the lines.

iii. The Contractor shall demonstrate that the hardware physically executes the required functions when prompted by the AEDC control system (e.g., a "dump valve" physically opening when the software sends the trigger signal).

iv. Contractor shall visually inspect newly installed equipment for interference with translation of the dynamic structure and surrounding equipment enclosure prior to dynamic testing during Commissioning

4.4.6. Commissioning (Hot Checks)

i. Contractor shall conduct a low-pressure leak test of the completed assembly to check for major leaks before proceeding to full system pressure.

ii. Contractor shall pressurize the fully integrated hydraulic (and pneumatic, if applicable) system to the maximum normal operating pressure. The system shall be held at pressure and inspected to verify zero external leakage.

iii. Contractor and AEDC shall conduct system shut-down test. The Contractor shall power off the HPU and document that the system achieves a safe state, and that all stored hydraulic energy (including accumulators) is bled down to a zero-energy state as required by the design.

iv. Contractor shall systematically bleed all trapped air from the hydraulic lines, manifolds, and the primary actuator cylinder to ensure fluid stiffness and prevent cavitation prior to dynamic operations.

v. Contractor shall perform a high-velocity fluid flush of all installed field piping and hoses (bypassing sensitive valves/cylinders). The system shall achieve a verified fluid cleanliness level of ISO 4406 16/14/11 or better. Compliance shall be demonstrated via a certified Fluid Analysis Report prior to operational handover.

vi. The Contractor shall functionally validate the operation of all system relief valves, verifying and documenting both the cracking pressure and full-flow bypass pressure to ensure safe system boundaries.

vii. Contractor shall independently operate the offline filtration and cooling loop to verify functional performance. The Contractor shall demonstrate that the auxiliary pump achieves the design flow rate, the heat exchanger maintains

Page-17 Distribution A.

Per AEDC-IRA-26-1719 the reservoir fluid temperature within specified design limits, and the filter differential pressure (DP) indicators or interlocks function correctly. Results shall be documented in the STP.

viii. AEDC and the Contractor shall conduct functional testing of the out-of-scope legacy auxiliary systems. The Contractor’s responsibility is to verify the new HPU and intermediate piping/valving provides stable, specified hydraulic power to these circuits. AEDC personnel shall execute the control logic to actuate legacy auxiliary systems, verifying that their operational speeds, holding forces, and overall functionality have not been degraded by the system upgrade.

ix. AEDC personnel shall slowly articulate the primary motion assembly and integrated structures through their complete operational limits. The Contractor shall verify and document that the newly installed hydraulic assembly maintains sufficient physical clearance throughout the entire range of motion, ensuring no component interference, binding, or hose stretching occurs.

x. Prior to final acceptance, the Contractor shall conduct a physical Maintainability Demonstration for AEDC personnel. The Contractor shall physically demonstrate the execution of critical maintenance tasks as outlined in their provided Operations and Maintenance (O&M) manuals.

This demonstration must prove that tasks can be performed safely, with standard tools, and without requiring the removal of unrelated major components. Required demonstrations shall include, but are not limited to:

• Safe isolation, bleeding, and Lockout/Tagout (LOTO) of system.

• Removal and replacement of all filter elements (pressure, return, and offline loop), demonstrating adequate clearance and fluid containment.

• Drawing a fluid sample from designated test ports.

• Accessing and adjusting the main system relief valves and pump compensators.

• Configuring system for flushing.

xi. AEDC shall complete an initial tune of the proportional valve, demonstrating that the primary actuator cylinder achieves the required speeds, accelerations, and positional accuracies under operational load scenarios with basic move commands.

During this tuning/performance testing phase, Contractor shall:

• Provide on-site technical and engineering support to monitor hardware performance and address any mechanical or hydraulic issues.

• Demonstrate that the supplied hydraulic hardware (including the HPU, proportional valve, and cylinder) operates within its designed pressure and flow envelopes and maintains mechanical and

Page-18 Distribution A.

Per AEDC-IRA-26-1719 structural integrity (ensuring zero leakage, secure mountings, and no excessive vibration, etc.) while operating within approved design limits.

xii. AEDC personnel will operate the facility enclosure to achieve near-vacuum conditions. During this facility operation, the AEDC & Contractor shall jointly:

• Monitor and validate the signal quality of all supplied sensors, LVDTs.

• Verify operation of the Proportional Valve validating functionality of onboard electronics executing multiple command profiles.

• Monitor facility enclosure for any vacuum leaks around ports for hydraulic tubing/piping and if applicable, designed enclosures for valve on-board electronics.

Contractor shall be responsible for repairing/replacing any compromised seals, failed sensors or on-board valve electronics due to vacuum environment.

xiii. Contractor shall verify that all valves and actuators achieve their design-specified mechanical positions (e.g., spring-return to null, fail-in-place) immediately upon loss of electrical power or command signal, independent of software control.

xiv. Contractor shall compile and deliver a comprehensive Commissioning Report to serve as the final project handover document. This report shall include the fully executed System Test Plan (STP), documented results of all pre-commissioning and commissioning checks, and all required compliance certificates.

4.4.7. Performance Testing

i. AEDC shall conduct comprehensive performance validation to ensure the system adheres to pre-defined motion profiles and the design envelope specified in the SRD. This stage shall include the iterative refinement and optimization of controller tuning parameters to achieve peak operational responsiveness and stability. The Contractor shall provide remote technical consultation and on-site corrective maintenance in the event of hardware non-conformance or failure.

5. Acceptance:

5.1. Government requires 30 days to review submitted design package and other CLIN 1 submittals.

5.2. Government requires 14 days to review submitted component test certifications and other CLIN 2 submittals.

5.3. After 4.4.6 is complete, the Government will require 60 days to accept the installation & equipment. During this time, AEDC will complete all testing & tuning

Page-19 Distribution A.

Per AEDC-IRA-26-1719

(including testing while at vacuum) in 4.4.7. During this time, the contractor will support AEDC when questions arise during the testing about the system or any components.

6. Submittals:

This Section serves a summary of submittals detailed in Section 4 Requirements.

6.1. CLIN 1 Engineering Design

6.1.1. Preliminary Design Package

6.1.2. Critical Design Package

6.1.3. Final Hydraulic Schematic with Bill of Materials

6.1.4. 2D Drawings or 3D model of Assembled System

6.1.5. Fabrication Drawings of Custom Components (Cylinder, Manifolds, etc.)

6.1.6. Data Sheets for Commercially Available Items

6.1.7. Final Calculation Package & Simulation Results

6.2. CLIN 2 Part Procurement

6.2.1. Actuating Cylinder

i. Hydrostatic Pressure Test

ii. Weld Inspection (if applicable)

iii. Material Certification

iv. Certification of Conformance (Drawing Compliance)

v. Calibration for Sensors/Transducers

6.2.2. Proportional Valve

i. Calibration/Performance Report (Linearity, Pressure vs. Flow Curve, Step

Response etc.)

ii. Calibration for Pressure Transducers

iii. Material Certification (Manifold)

iv. Certification of Conformance (Manifold Drawing Compliance)

6.2.3. Piping/Tubing/Hose Connections

i. Piping/Tubing Material Certification(s)

ii. Piping/Tubing Certification of Conformance(s)

iii. Piping/Tubing Weld Inspection(s)

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Per AEDC-IRA-26-1719

iv. Hose Hydrostatic Pressure Test(s)

6.2.4. Offline Filtration Loop

i. Functional Test Report

ii. Calibration for Switches/Sensors/Transducers

6.2.5. Hydraulic Power Unit (HPU)

i. Functional Test Report

ii. Certification of Conformance (Assembly Dimension Compliance)

iii. Calibration for Switches/Sensors/Transducers

iv. Cleanliness Report

6.2.6. Accumulators

i. Design/Inspection/Tested - U-Stamp

6.3. CLIN 3 Installation Verification

6.3.1. Demolition

i. Outage Readiness Review (ORR)

6.3.2. Installation

i. Weld Inspection (Field Welding Conducted)

ii. Certification of Conformance (Conformance of Final Assembly to Schematic and Assembly Drawings)

6.3.3. Verification

i. Verification Readiness Review (VRR)

ii. Commissioning Report & System Test Plan

iii. Functional Configuration Audit (FCA)

6.3.4. Warranty: The Contractor shall provide a one-year warranty for each component/assembly, stating that it is free from any manufacturer defects. The warranty period shall begin after acceptance at AEDC.

6.3.5. Submittal Table:

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Per AEDC-IRA-26-1719

No. Section Reference Submittal Description Due 1 4.2.1.ii Preliminary Design Package Prior to CDR

2 4.2.1.ii Critical Design Package Prior to Phase 2 (Procurement)

3 4.2.1.xviii Hydraulic Schematic & BOM Prior to Phase 2 (Procurement)

4 4.2.1.xviii 2D Assembly Drawings or 3D Model Prior to Phase 2 (Procurement)

5 4.2.1.xviii Fabrication Drawings for Custom Components Prior to Phase 2 (Procurement)

6 4.2.1.xx Data Sheets for Commercially Available Components

Prior to Phase 2 (Procurement)

7 4.2.1.xiv Final Calculation and Simulation Report Prior to Phase 2 (Procurement)

8 4.3.2.i Cylinder Pressure Test Prior to Outage Readiness Review (Demolition)

9 4.3.2.ii Cylinder Weld Inspection (If applicable) Prior to Outage Readiness Review (Demolition)

10 4.3.2.iii Cylinder Material Certification Prior to Outage Readiness Review (Demolition)

11 4.3.2.iii Cylinder Certification of Conformance Prior to Outage Readiness Review (Demolition)

12 4.3.2.v Cylinder Calibration of Transducers/Sensors Prior to Outage Readiness Review (Demolition)

13 4.3.3.ii & 4.3.3.iii Proportional Valve Calibration/Performance Report

Prior to Outage Readiness Review (Demolition)

14 4.3.3.v Proportional Valve Calibration of Transducers Prior to Outage Readiness Review (Demolition)

15 4.3.3.iv Prop. Valve Manifold Material Certification Prior to Outage Readiness Review (Demolition)

16 4.3.3.iv Prop. Valve Manifold Certification of Conformance

Prior to Outage Readiness Review (Demolition)

17 4.3.4.ii Piping/Tubing Material Certifications Prior to Outage Readiness Review (Demolition)

18 4.3.4.ii Piping/Tubing Certification of Conformance(s) Prior to Outage Readiness Review (Demolition)

19 4.3.4.iii Piping/Tubing Weld Inspection(s) Prior to Outage Readiness Review (Demolition)

20 4.3.4.i Hose Hydrostatic Pressure Test(s) Prior to Outage Readiness Review (Demolition)

21 4.3.5.i Offline Filtration Loop Functional Test Report Prior to Outage Readiness Review (Demolition)

22 4.3.5.ii Offline Filtration Loop Calibration for Switches/Sensors/Transducers

Prior to Outage Readiness Review (Demolition)

23 4.3.6.i HPU Functional Test Report Prior to Outage Readiness Review (Demolition)

24 4.3.6.iii HPU Certification of Conformance (Assembly Dimension Compliance)

Prior to Outage Readiness Review (Demolition)

25 4.3.6.ii HPU Calibration for Switches/Sensors/Transducers

Prior to Outage Readiness Review (Demolition)

26 4.3.6.iv HPU Cleanliness Report Prior to Outage Readiness Review (Demolition)

27 4.3.7.i 4.3.7.ii & 4.3.7.iii Accumulator Inspection/Test Data (U-Stamp) Prior to Outage Readiness

Review (Demolition) 28 4.4.2.i Outage Readiness Review (ORR) Prior to Installation

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Per AEDC-IRA-26-1719

No. Section Reference Submittal Description Due 29 4.4.3.ii Weld Inspection(s) (Field Welding) Prior to Verification

30 4.4.3.iii Certification of Conformance (Conformance of Final Assembly to Schematic and Assembly Drawings)

Prior to Verification

31 4.4.4.i Verification Readiness Review Prior to…