Technical Requirements Document (TRD) Altitude Chamber 082824.pdf

Altitude Chamber with 810H Rapid Decompression Capability

CHAMBER SPECIFICATIONS:

1. Interior Dimensions: 48" wide x 48" deep x 48" high, clear usable workspace

2. Exterior Dimensions: The building where the Altitude Chamber will be located has 8’6” height restriction and 9’6” width restriction. The Altitude Chamber may be longer, but must be no taller than 8’6” and no wider than 9’6” to fit through the doorway.

A. Engineered drawings will be provided within 60 days after award and prior to manufacture of the equipment and will contain all final chamber dimensions, utility requirements, connection points, all port locations, and accessories to assist in facilities planning.

B. If remote equipment is required dimensional specifications must be provided within 60 days after award to determine suitable location and/or requirements of exterior concrete pad.

3. Refrigeration System: Cascade configuration: Refrigerants must be nontoxic "OZONE FRIENDLY", and nonflammable.

4. Heating System: Electric resistance heating

5. Electrical Service: 480 volts, 3 phase, 60 hertz

PERFORMANCE SPECIFICATIONS:

1. Temperature Range: -65°C to 100°C (-85°F to +212°F)

2. Temperature Control Tolerance: The chamber must be capable of maintaining ± 1°C after stabilization.

3. Temperature Transitions: The chamber with electric heating and mechanical refrigeration will be capable of performing the following temperature transition rates based on an empty chamber at site level altitude:

A. 100°C to -65°C in 55 minutes or less (3°C per minute average rate of change) B. -65°C to 100°C in 55 minutes or less (3°C per minute average rate of change)

4. Altitude Range: Sea level to 100,000 feet

5. Altitude Control Tolerance: ±500 feet to 50,000 feet altitude and ±1% of setpoint at altitudes over 50,000 feet

6. Altitude Performance:

A. Site Level to 65,000 feet in 20 minutes or less.

B. Site Level to 100,000 feet in 45 minutes or less.

7. Altitude Performance with Rapid Decompression Capability: Mil-810H (Change 1), Method 500.6, 4.5.4 Procedure III: 8,000 feet to 40,000 feet in 15 seconds or less and must hold 40Kft for 10 minutes.

COMBINED ENVIRONMENTAL TESTING:

1. Altitude / Temperature: Cycling or steady state temperature testing between +100°C and -65°C at any altitude between site level and 65,000 feet.

CHAMBER DESCRIPTION:

1. Internal Liner:

A. The chamber liner will be constructed at a minimum of 12-gauge, series 300, high nickel content stainless steel, suitably reinforced to act as the vacuum vessel and assuring rustproof quality.

B. The liner will be welded on all seams to ensure a hermetic seal while operating in a vacuum state.

C. Provisions will be made at all liner seams and corners to allow for thermal expansion during temperature cycling operation.

D. The chamber will be provided with an LED interior light controlled from an external control switch.

E. The chamber will be provided with two (2) 6” stainless steel access ports. The ports will be sealed to the internal liner. The ports will have a flanged, bolt-on, machined aluminum cover.

F. Stainless steel Shelf pilasters spaced every 6 inches will be welded to the interior of the chamber and will be rated to 150 lbs.

G. Three (3) removable, Heavy duty, polished stainless steel wire shelves will be provided.

Shelves to be rated to 75 lbs. each.

H. All interior parts exposed to the chamber environments will be constructed of corrosion-resistant materials.

2. Chamber Exterior:

A. The exterior of the chamber will be manufactured of heavy-duty steel framework with sheeted panels.

B. Panels covering serviceable components will be equipped with quick release fasteners for ease of access.

C. Removable panels will be equipped with gasket seals to prevent ambient air and moisture migration into the insulation space during low temperature operation, thereby eliminating frost build-up and subsequent saturation of the insulation.

D. The chamber exterior will be finished in an industrial enamel textured finish paint if sheet metal is used for exterior panels.

E. The chamber will either be skid mounted, rest on casters, or adjustable feet.

3. Door and Hardware:

A. A front-opening, hinged door of the same construction as the chamber will give full access to the chamber workspace. A pressure/vacuum gasket will maintain a positive seal under all chamber operating conditions while an inner silicone gasket will maintain the initial thermal/moisture seal.

B. The hinges and manual handwheel latches will be of heavy-duty design and constructed of corrosion-resistant or plated materials.

C. A heavy-duty multi-pane viewing window with a safety cage will be provided. The multi-pane window will be heated and incorporate integral desiccant to ensure dryness and minimize internal fogging at low temperature operation.

4. Cascade Refrigeration System:

A. Refrigeration systems must include: oil separator, air-cooled condenser, refrigeration pressure transducers, head pressure control, liquid line sight glass & driers, suction and discharge service valves, pressure relief valves, evaporator, liquid line solenoid valves, liquid injection systems, high-side vapor tank, cascade condenser, and industrial Scroll compressors.

B. Vapor receivers will be used in the discharge side of the low-stage refrigerant circuit. These receivers will be designed to hold the entire low-stage refrigerant charge without the pressures exceeding 250 PSIG. Inlet and outlet valves on these receivers shall permit pumping the entire refrigerant charge into the receiver while making repairs or changing parts on the low-stage system.

C. All refrigerant joints will be sil-fos or silver soldered (no soft solder is to be used).

Compressors will be spring mounted for smooth and quiet operation. Refrigerant lines will be clamped to prevent rattling and chaffing.

D. If remote equipment is required:

a. Dimensional specifications must be provided 60 days after award to determine suitable location and/or requirements of exterior concrete pad.

b. All field piping and connections will be completed on site and leak tested at a pressure of 250 PSIG and must hold without loss for 24 hours.

c. Refrigeration system will be evacuated to a pressure of 200 microns or less prior to final charging of refrigeration system.

E. The refrigerant systems will be designed to operate continuously or intermittently.

Refrigerant systems will be capable of being shut down for extended periods of time without requiring special servicing.

F. Non-explosive "OZONE FRIENDLY" refrigerants will be used.

G. Copper tube, aluminum fin evaporators coils will be used.

H. Evaporator temperatures shall be controlled by blocking the refrigerant flow with solenoid valves located in the refrigerant liquid lines. Bypass solenoids will allow the refrigerant to bypass the evaporator and enter the suction line. Liquid refrigerant will be mixed with hot discharge gases to prevent over-heating the compressors during the off-cooling cycle. The liquid and bypass solenoids will be operated by signals from the temperature controller.

5. Heating system:

A. Heating will be accomplished by electric resistance heater elements. The elements shall respond rapidly to instrument demand with minimum residual heating effects minimizing overshoot. The heaters will be baffled from the test space to prevent direct radiation to the items on test. The heaters will be easily accessible for maintenance or removal.

B. The heating system will be automatically electrically locked out at altitudes above 65,000 ft to prevent shorting out due to lack of air flow.

6. Conditioning Section:

A. Cooling coils, heating elements and other related conditioning components will be properly baffled and shall not protrude into the workspace.

B. Blowers will be used to provide air circulation within the conditioned area and shall be designed to assure proper air distribution and prevent air stratification throughout the chamber.

C. The conditioning section will be located on the rear wall. Conditioned air will be supplied to the workspace from the top rear wall, blown towards the front of the workspace, and distributed down through the workspace and returned at the lower rear wall.

7. Circulator Motors: Heavy duty ball bearing type motors will be used to drive the air blowers.

These motors shall be located outside the temperature conditioned space. If the blowers will be driven by means of extended stainless-steel shafts. Seals must be installed to maintain the vacuum integrity of the chamber.

8. Electrical System:

A. One principal 480 volt, 3 phase, 60 hertz, 300-amp power source will be available from existing panel located in building 3131 for chamber operation. Any other voltages required will be derived from this main supply by means of transformers.

B. If remote equipment is required, all field wiring, conduit, and connections will be completed on site and service disconnect/s installed.

C. Fuses, circuit breakers, and thermal overloads will be provided to protect circuits and components.

D. Motor starters, heater contactors, relays and other electrical components will be grouped together and enclosed in a power distribution panel. Motors and heaters will be arranged to provide balanced electrical circuits.

E. All electrical components and wiring will conform to National Electrical Code.

INSTRUMENTS AND CONTROLS:

1. The following instruments and controls will be provided to monitor and control the internal chamber environments. Instruments will be mounted and housed in a NEMA-1 control panel attached to the side of the chamber.

2. 12” minimum color touch screen controller, Including:

A. 4 channels of PID control with Product Temp Control B. User definable graphical trending of program & process data real time C. Data logging of up to 64 configurable inputs with virtual unlimited file storage D. Data can be exported as .csv file and .png image E. Up to 32 configurable digital inputs (24 vdc) & outputs (2a max resistive, 80VA inductive) F. Settings for chamber systems monitor and preventative maintenance

3. 2-Altitude (Pressure) Transducers: Absolute pressure transducers will be used to control and monitor the chamber internal pressure. Linear pressure signals will be converted by the control system to display and program altitude in Kft increments. (0.0 - 100.0 Kft)

4. 2-RTD’s: RTD’s will be used to control and monitor the chamber internal temperature. Linear temperature signals will be converted by the control system to display and program temperature in user definable degrees Fahrenheit or Celsius. (-100℉ - 212℉)

5. Datalogging / Recording: Continuous data-logging of set-point, process variables, and/or any other monitored variable will be incorporated into the control system. Data is exported as a .csv file to front panel USB, or via desktop sharing for storing or formatting as needed.

6. Refrigeration System Monitoring/Logging: The chamber will be equipped with refrigeration pressure transducers, and thermocouples. All refrigeration pressures and temperatures can be monitored in real time and logged by the control system.

7. Flanged Bolt-on Port Covers: The port covers will serve as pass-through for instrumentation and various power sources. The port covers will be rated for ultra-low pressure/vacuum. Flanged port covers will include the following:

A. 1 – powered 120-volt, 15-amp receptacle B. 2 – powered USB receptacles C. A minimum of 6 – Thermocouple receptacles, must be integrated into the control/data logging system.

SAFETY FEATURES:

1. Product Safeguard: A separate product temperature input with user definable under/over temperature limits provides failsafe shutdown in the event of an under/over temperature condition. Alarm contacts will be provided to provide alarm notification and/or to de-energize the system.

2. Pressure Relief Valve: A pressure relief valve will be installed in each of the refrigeration systems to prevent excessive pressure build up.

3. High/Low Pressure Cut-outs: High/Low pressure cut-outs will be installed in each of the refrigeration systems, factory set to prevent the compressors operating beyond recommended levels.

4. Motor Overload: Compressors will be equipped with inherent motor overload protectors.

5. Fan guard openings: All fans must have guards with openings no larger than 3/8 of an inch, including compressor fans (where provided).

6. Refrigerants: All refrigerants must be non-toxic, non-flammable

7. Circulator Interlock: The heaters and refrigeration systems will not be energized until the circulator motor contactor is energized to prevent damage due to lack of air flow.

8. Master Heat Contactor: A master heat contactor will be wired in series with the instrument-controlled heat contactors. This device does not cycle with instrument demand but will be controlled by the over-temperature safety limit. This will minimize an over temperature condition due to welded contacts on the heat contactors.

9. Under/Over Temperature Safety Limit: Minimum and maximum temperature parameters will be factory set to protect the chamber from exceeding design limits.

DOCUMENTATION:

1. Instruction Manuals, Schematics, and Installation Drawings: Three sets of operator and maintenance instruction manuals will be provided. Default values of operator configurable points will be included in the manuals. Manufacturer data sheets are to be incorporated into the manuals. Electrical and mechanical schematics are to be provided for general maintenance.

Installation and interconnection drawings are to be included in the manual. A complete parts list with manufacturer part numbers will be included in the manual.

INSTALLATION:

6. Award Recipient Responsibilities: Any required electrical power, piping, conduit, and field connections to the chamber and supporting equipment are the award recipient’s responsibility.

The award recipient is also responsible for all transportation of the chamber to the installation site. Once the equipment is off-loaded and in position, award recipient will be responsible for the installation of any components removed for shipping, interconnection of any remote equipment, leak testing, and pre-charge the refrigeration system in preparation for start-up.

Engineered drawings will be supplied prior to manufacture of the equipment and will contain all final chamber dimensions, utility requirements, connection points, all port locations, and accessories to assist in facilities planning.

7. DPG Responsibilities: DPG will be responsible for off-loading the chamber and moving it to its final location. DPG will also be responsible for the final tie-in and wiring terminations to the existing 480 volt panel located in Building 3131.

START-UP/COMMISIONING:

1. Performance Verification: Upon completion of installation, the chamber must demonstrate the ability to meet the performance criteria listed in the PERFORMANCE SPECIFICATIONS section.

2. Safety Verification: Upon completion of installation, the chamber must demonstrate the ability to shutdown in the event of criteria: 1, 3, 4, 7, 8, and 9 of the SAFETY FEATURES section.

TRAINING:

1. Operational Training: A complete demonstration/training of the user interface will be conducted on-site to a minimum of 6 operators. Training will include: overview of system and location of key components, general maintenance procedures, programming of all user definable settings and setpoints, trending/graphing of all monitored points and inputs, alarm reset procedures, and data acquisition and export process.