Updated SOW for Test Cell Upgrade.pdf

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1. Scope of Work

1.1. This Statement of Work (SOW) establishes the minimum requirements for the purchase, design requirements, delivery, installation, and verification of replacement data acquisition systems and supply piping upgrades for existing Test Cell Pneumatic Test Console Systems or Test Cells with equipment and accessories specified herein, and training on the maintenance, calibration, programming, and use of the replacement systems. The Test Cell Systems are currently used to functionally test high pressure high temperature air control valves and turbines as required per relevant Technical Order (T.O.) instructions. The overall project shall be considered a whole and complete procurement, i.e. the project shall only be considered complete when final acceptance requirements have been met and approved by the appropriate Government POCs, and operational training has been conducted.

1.2. Background

1.2.1. The Test Cells described in this document are intended for use in the

Aerospace Repair Industry. The Data Acquisition Systems shall replace the existing data acquisition systems. The current system is comprised of a computer with Windows 2000 operating system, Agilent data acquisition components, MicroMod controllers, and programming. High Temperature/High Pressure supply piping modifications are required to provide increased productivity of the test process and longevity of the system. The Test Cells are operated in at Tinker Air Force Base (TAFB) OK 73145.

1.2.2. Each of the Test Cells is composed of an Operator Console, Transmitter Enclosure, and Overhead Interface Bulkhead Enclosure. Each Test Cell has a dedicated high pressure high temperature piping system located above the Test Cell connected to a main air supply. Two different piping systems are configured. Test Cells utilize a dual channel system that incorporates two separate and independent piping sources.

Test Cell utilize a single channel piping system. The size of the piping systems utilizes either a 4 inch or 6 inch piping flow section.

2. Requirements

2.1. General

2.1.1. Period of Performance: The Contractor shall complete all work associated with this Statement of Work no later than thirty-six (36) months of contract award date.

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2.1.9.2. The Contractor shall furnish all chemicals required for the Test Cell

System Upgrade. All other fluids required prior to test stand acceptance shall be provided by the Contractor and properly disposed of by Contractor following acceptance.

2.1.9.3. The Government reserves the right to reject use of any chemicals and request alternative(s) be proposed for completion of the installation.

2.1.9.4. Proper use, storage and removal of any chemical required during commissioning of test stand shall be coordinated with the Tinker Unit Environmental Coordinator (UEC). UEC info will be made available to Contractor by Government POC, as needed.

2.1.10. Prohibited Materials:

2.1.10.1. Mercury restriction: The components shall contain neither mercury nor mercury compounds or be exposed to free mercury during manufacture.

2.1.10.2. Asbestos restriction: Asbestos and materials containing asbestos shall not be used on or in the Test Cell System.

2.1.10.3. Polychlorinated Biphenyl (PCB) restriction: The use of polychlorinated biphenyl on or in Test Cell System is prohibited.

2.1.10.4. Lithium restriction: Lithium batteries used in the computer system are exempt from this requirement.

2.1.11. ODC Restrictions: Class I ozone depleting substances in accordance with section 602(a) of the Clean Air Act Amendments 1990, 42 USC 7671a(a) as implemented by 40 CFR 82 Protection of Stratospheric Ozone, shall not be contained within or used on this equipment.

2.1.12. Environmental Protection and Safety:

2.1.12.1. The Contractor shall be knowledgeable of and comply with all applicable federal, state and local laws, regulations, instructions and requirements regarding environmental protection and occupational safety and health. The Contractor shall comply with any laws, instructions or regulation changes during the term of this contract.

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2.1.13. Other Environmental Compliance: Contractor shall comply with all environmental requirements as stipulated in Appendix H.

2.1.14. Identification/Instruction Plates: All words on instruction and/or identification plates shall be in the English language. The plate(s) shall be corrosion resistant and securely affixed to the test stand. The words and numbers shall be engraved, etched, embossed or stamped in boldface print on a contrasting background. Lettering shall be a minimum of 18-point font and the plates shall be sized accordingly to accommodate all standard text in this point size.

2.2. Design and Construction:

2.2.1. The Test Cells are utilized for performance testing of overhauled military aircraft components. The Test Cells utilize high pressure high temperature air to simulate jet engine bleed air conditions. The test cells are designed for operation and control of 350 psig air at 1000 degrees Fahrenheit with flows ranging from 0.5 to 600 pound per minute. These systems, combined with low pressure pneumatic and electrical systems, are required to provide performance testing of the End Items.

2.2.2. The Government will provide the original drawings for viewing during any solicitation site visits for review. The original drawing is for reference only.

2.2.3. The Government will provide a hard copy of the original drawings for the Test Cell System to the Contractor after award of the contract. The Contractor shall be responsible for making a copy of the drawings and returning the original drawings to the Government.

2.2.4. The Contractor shall be responsible for verifying the accuracy of the drawings for the purpose of the design and installation of the Test Cell System Upgrade.

2.2.5. Construction:

2.2.5.1. The Test Cell System Upgrade shall utilize components that are new, without defects, commercial-off-the-shelf (COTS), and free of repairs.

2.2.5.2. Quality of materials used in the upgrade shall be equivalent to or superior to those used in the existing upgraded Test Cells .

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2.2.5.3. The Test Cell System Upgrade shall include all components, parts and features necessary to meet the performance requirements specified herein.

2.2.5.4. The Test Cell System Upgrades shall utilize identical data acquisition components, monitors, pressure transmitters, temperature transmitters, temperature sensors, power supplies, and programming languages based on the current upgraded Test Cells Any deviations will require Government approval.

2.2.6. Labeling/Identification:

2.2.6.1. The Contractor shall provide label tags for each of the new high pressure high temperature process air components. The tags for all process piping components shall be fabricated from stainless steel and the identifying number stamped or laser etched onto the tag. The tag shall be connected to the hardware utilizing stainless steel wire. The tags shall be a minimum of 0.75 inches high by 2 inches wide. The lettering shall be a minimum of 0.25 inches high.

2.2.6.2. The Contractor shall provide label tags for each of the Test Cell upgrade components. The labels shall be black phenolic with white lettering.

The tag shall be attached utilizing stainless steel wire. The tags shall be a minimum of 0.75 inches high by 2 inches wide. The lettering shall be a minimum of 0.25 inches high.

2.2.6.3. The Contractor shall provide a new nameplate affixed to the front upper right side of the Operator Console. The words shall be a minimum of

0.25 inches in height and maximum of 0.5 inches in height. The nameplate shall contain the following information: nomenclature, manufacturer’s name, manufacturer’s model designation, manufacturer’s serial number, date of upgrade and contract number.

2.2.7. High Pressure High Temperature Process Piping System

2.2.7.1. The Contractor shall upgrade each of the Test Cells to include one additional pressure control valve, one additional bleed control valve, one additional exhaust silencer and ductwork, and one plenum exhaust hood for each individual piping system for each upgrade. The existing piping schematics are shown in Figures 1.1 and 1.3. The upgraded system schematics are shown in Figures 1.2 and 1.4. The ‘- X’ in the valve identifying labels is replaced with the Test Cell Numbers. The ‘-YZ’ in the valve identifying labels is replaced with the Channel number for ‘Y’ and the upstream valve ‘A’ and

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Figure 1.1 – Existing Piping / Valve Schematic – Single Channel

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Figure 1.2 – Upgrade Piping / Valve Schematic – Single Channel

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Figure 1.3 – Existing Piping / Valve Schematic – Dual Channel

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Figure 1.4 – Upgrade Piping / Valve Schematic – Dual Channel

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2.2.7.8. Flange Bolts

2.2.7.8.1 The Contractor shall replace all valve studs and nuts for all valves and expansion joints.

2.2.7.8.2 The Contractor shall use threaded studs and heavy hex nuts for all ANSI Class flange connections. All studs shall conform to the latest version of ASTM A193 and be ASTM Grade B7.

All heavy hex nuts shall conform to the latest version of ASTM A194 and be ASTM Grade 7.

2.2.7.8.3 All threaded studs shall be sized based on the ANSI Class flange connection hole diameter.

2.2.7.8.4 All threaded studs shall have a minimum of four threads exposed on each side of the flange nuts.

2.2.7.8.5 The Contractor shall not use any grade hex head bolts.

2.2.7.9. Process Piping Insulation

2.2.7.9.1 The Contractor shall remove the existing black rubber piping insulation covering on each of the Test Cell upgrades.

The removal shall consist of the ambient and hot branch lines for each of the Test Cells starting at the main air supply line connections. The removal shall consist of the vertical inlet supply piping in each of the Test Cell.

2.2.7.9.2 The Contractor shall provide and install new banded aluminum jackets to cover the pipe insulation exposed by the removal of the black rubber piping insulation cover.

2.2.7.9.3 The Contractor shall not install aluminum jackets on manual valves, control valves, orifice sections, or expansion joints.

2.2.7.10. Process Piping Valve and Joint Insulation Blankets

2.2.7.10.1 The Contractor shall provide new removable insulation blankets for all control valves, orifice sections, and expansion joints for each of the Test Cell upgrades.

2.2.7.10.2 The Contractor shall provide one inner and one outer insulation blanket for each of the control valves, orifice sections, and expansion joints.

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2.2.7.10.3 The insulation blankets shall match the existing Test Cell insulation blanket material and construction utilizing stainless steel connectors and wire.

2.2.7.10.4 The Contractor shall remove the existing black rubber piping insulation covering the vertical Test Cell Inlet Supply piping inside the Test Cell on each of the Test Cell upgrades.

2.2.7.10.5 The Contractor shall provide and install new banded aluminum jackets to cover the pipe insulation exposed by the removal of the black rubber piping insulation cover on the Inline Supply piping for each of the Test Cell upgrades.

2.2.7.10.6 The Contractor shall not insulate the ambient or hot manual isolation valves.

2.2.7.11. Silencer Insulation

2.2.7.11.1 The Contractor shall utilize aluminum foil coated insulation for all new insulation for the silencer and ductwork to the exhaust plenum.

2.2.7.11.2 The Contractor shall use material to match the configurations in the upgraded Test Cells

2.2.8. Test Cell Sound Insulation

2.2.8.1. The Contractor shall provide sound deadening insulation in the existing ceiling strut channel for each of the Test Cell upgrades. The existing strut channel is continuous and allows sound to transfer between cells.

2.2.8.2. The Contractor shall install the insulation on each side of the Test Cell ceiling at all ceiling strut channel locations for each of the Test Cell upgrades. The Contractor shall ensure all voids in the ceiling strut channel are filled.

2.2.9. Orifice Plate Flow Sections

2.2.9.1. The Contractor shall provide and install new orifice plates and ring joint seals for each of the Test Cell upgrades.

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2.2.10.3. All fittings shall be stainless steel. All fittings shall be rated for 350 psig working pressure and 200 degrees Fahrenheit. All tubing and fittings shall comply with the latest version of ASME 31.1 Power Piping and ASME 31.3 Process Piping.

2.2.10.4. The Contractor shall utilize compression or 37-degree flare Joint Industrial

Council (JIC) type fittings.

2.2.10.5. The Contractor shall not use push on fittings for any application.

2.2.11. Hoses:

2.2.11.1. All hoses shall be rated for a minimum 350 psig working pressure and

200-degree Fahrenheit temperatures and utilize swivel JIC 37 degree flare or compression end connections. All hoses shall be labeled on each end with a metal band which indicates the maximum working pressure, size, material, material manufacturer, material manufacturer’s part number and length. All hose internal and external material shall be compatible with air. All hoses shall comply with the latest version of the National Fluid Power Association, ASME 31.1 Power Piping and ASME 31.3 Process Piping.

2.2.11.2. The Contractor shall not use plastic hose for any application.

2.2.12. Strainers

2.2.12.1. The Contractor shall remove all debris for the ambient and hot air line strainers located at the manual isolation valves for each of the Test Cell upgrades.

2.2.12.2. The Contractor shall provide new Flexitallic spiral wound ANSI class high temperature gaskets rated for air at 1000 deg. Fahrenheit. The gaskets shall be the designed for the ANSI Class flanges being utilized.

2.2.13. High Pressure High Temperature Valves

2.2.13.1. The Contractor shall replace all manual and control valves in each of the f Test Cells in accordance with Tables 1.0, 1.1, 1.2, 1.3, and 1.4.

2.2.13.2. The Contractor shall provide the valve quantities and valve models specified in accordance with Tables 1.0, 1.1, 1.2, 1.3, and 1.4. The existing valves have been tested and proven. Identical replacement valves based on the current valve serial numbers are required to ensure

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Identical replacement valves are required to maintain form, fit, and function of the Test Cell systems. Valves in Tables 1.0, 1.1, 1.2, 1.3, and 1.4 and identified as ‘Replace’ are new replacement valves.

Valves in Tables 1.0, 1.1, 1.2, 1.3, and 1.4 and identified as ‘Add’ are new additional valves.

2.2.13.3. The Contractor shall ensure that all new Hot Control Valves (HCV) are equipped with fail close/air to open actuators. All HCV valves were originally configured with fail open/air to close actuators. The current operation of the HCV actuators is fail close/air to open.

2.2.13.4. Any deviation from the specified valves shall require the Contractor to perform a piping stress analysis of the entire high piping system to ensure compliance with the requirements of ASME 31.1 Power Piping Code and ASME B31.3 Process Piping Code. The Contractor shall provide all piping stress analysis documentation to the Government for approval. The Contractor shall provide performance testing of end items to verify the valve deviation meets or exceeds the original valve performance.

2.2.13.5. Any valve deviations will require Government approval.

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Table 1.0 – Test Cell – High Pressure High Temperature Valves

Valve ID Manufacturer Model Serial Number Size Signal Qty.

Channel 1

AISO-3-1 Flowserve Valdisc Replace 162643.001-4 2 inch Manual 1

HISO-3-1 Flowserve Valdisc Replace 162643.004-5 3 inch Manual 1

ACV-3-1 Flowserve Mark I Replace 162643.008-5 2 inch 4–20 ma 1

HCV-3-1 Flowserve Mark I Replace 162643.010-5 2 inch 4–20 ma 1

PCV-3-1A Flowserve Mark IX Replace 186710.001-2 2 inch 4–20 ma 1

PCV-3-1B Flowserve Mark IX Add 186710.001-2 2 inch 4–20 ma 1

BCV-3-1A Flowserve MaxFlo Replace 162643.023-4 2 inch 4–20 ma 1

BCV-3-1B Flowserve MaxFlo New-Add 162643.023-4 2 inch 4–20 ma 1

Channel 2

AISO-3-2 Flowserve Valdisc Replace 162643.001-4 2 inch Manual 1

HISO-3-2 Flowserve Valdisc Replace

8016204.001 3 inch Manual 1

ACV-3-2 Flowserve Mark I Replace 162643.008-4 2 inch 4–20 ma 1

HCV-3-2 Flowserve Mark I Replace 162643.010-4 2 inch 4–20 ma 1

PCV-3-2A Flowserve Mark IX Replace

292921.003 2 inch 4–20 ma 1

PCV-3-2B Flowserve Mark IX Add

292921.003 2 inch 4–20 ma 1

BCV-3-2A Flowserve MaxFlo Replace 162643.023-3 2 inch 4–20 ma 1

BCV-3-2B Flowserve MaxFlo Add 162643.023-3 2 inch 4–20 ma 1

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Table 1.1 – Test Cell – High Pressure High Temperature Valves

Valve Tag ID Manufacturer Model Serial

Number Size Signal Qty.

AISO-4-1 Flowserve Valdisc Replace 162643.001-6 2 inch Manual 1

HISO-4-1 Flowserve Valdisc Replace 162643.004-7 3 inch Manual 1

ACV-4-1 Flowserve Mark I Replace 162643.008-7 2 inch 4–20 ma 1

HCV-4-1 Flowserve Mark I Replace 162643.010-7 2 inch 4–20 ma 1

PCV-4-1A Flowserve Mark IX Change and Replace 162643.014-1

2 inch 4–20 ma 1

PCV-4-1B Flowserve Mark IX Add 162643.014-1 2 inch 4–20 ma 1

BCV-4-1A Flowserve MaxFlo Replace 162643.024-2 2 inch 4–20 ma 1

BCV-4-1B Flowserve MaxFlo Add 162643.024-2 2 inch 4–20 ma 1

AISO-4-C2 Flowserve Valdisc Replace 162643.001-5 2 inch Manual 1

HISO-4-C2 Flowserve Valdisc Replace 162643.004-6 3 inch Manual 1

ACV-4-2 Flowserve Mark I Replace 162643.008-6 2 inch 4–20 ma 1

HCV-4-2 Flowserve Mark I Replace 162643.010-6 2 inch 4–20 ma 1

PCV-4-2A Flowserve Mark IX Change and Replace 162643.014-1

2 inch 4–20 ma 1

PCV-4-2B Flowserve Mark IX Add 162643.014-1 2 inch 4–20 ma 1

BCV-4-2A Flowserve MaxFlo Replace 162643.023-4 2 inch 4–20 ma 1

BCV-4-2B Flowserve MaxFlo Add 62643.023-4 2 inch 4–20 ma 1

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Table 1.2– Test Cell – High Pressure High Temperature Valves

Valve ID Manufacturer Model Serial Number Size Signal Qty.

AISO-5-1 Flowserve Valdisc Replace 162643.002-3 3 inch Manual 1

HISO-5-1 Flowserve Valdisc Replace 162643.005-5 4 inch Manual 1

ACV-5-1 Flowserve Mark I Replace 162643.007-2 3 inch 4–20 ma 1

HCV-5-1 Flowserve Mark I Replace 162643.009-3 3 inch 4–20 ma 1

PCV-5-1A Flowserve Mark IX Replace 186710.002-2 3 inch 4–20 ma 1

PCV-5-1B Flowserve Mark IX New-Add 186710.002-2 3 inch 4–20 ma 1

BCV-5-1A Flowserve MaxFlo Replace 162643.024-4 2 inch 4–20 ma 1

BCV-5-1B Flowserve MaxFlo Add 162643.024-4 2 inch 4–20 ma 1

AISO-5-2 Flowserve Valdisc Replace 162643.002-2 3 inch Manual 1

HISO-5-2 Flowserve Valdisc Replace 162643.005-4 4 inch Manual 1

ACV-5-2 Flowserve Mark I Replace 162643.007-1 3 inch 4–20 ma 1

HCV-5-2 Flowserve Mark I Replace 162643.009-2 3 inch 4–20 ma 1

PCV-5-2A Flowserve Mark IX Replace 186710.002-3 3 inch 4–20 ma 1

PCV-5-2B Flowserve Mark IX Add 186710.002-3 3 inch 4–20 ma 1

BCV-5-2A Flowserve MaxFlo Replace 162643.024-3 2 inch 4–20 ma 1

BCV-5-2B Flowserve MaxFlo Add 162643.024-3 2 inch 4–20 ma 1

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Table 1.3 – Test Cell – High Pressure High Temperature Valves

Valve ID Manufacturer Model Serial

AISO-13-1 Flowserve Valdisc Replace 162643.002-1 3 inch Manual 1

HISO-13-1 Flowserve Valdisc Replace 162643.005-1 4 inch Manual 1

ACV-13-1 Flowserve Mark I Replace 162643.007-7 3 inch 4–20 ma 1

HCV-13-1 Flowserve Mark I Replace 162643.009-1 3 inch 4–20 ma 1

PCV-13-1A Flowserve Mark IX Replace

162643.016 3 inch 4–20 ma 1

PCV-13-1B Flowserve Mark IX New-Add

162643.016 3 inch 4–20 ma 1

BCV-13-1A Flowserve MaxFlo Replace 162643.026-3 2 inch 4–20 ma 1

BCV-13-1B Flowserve MaxFlo Add 162643.026-3 2 inch 4–20 ma 1

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Table 1.4 – Test Cell – High Pressure High Temperature Valves

2.2.14. Expansion Joints

2.2.14.1. The Contractor shall replace each of the high-pressure high temperature piping expansion joints for each of the Test Cell Upgrades in accordance with Table 2.0.

2.2.14.2. The Contractor shall provide the expansion joint quantities and expansion joint drawing numbers specified in in accordance with Table 2.0. The existing expansion joints were utilized in the piping stress analysis and have been tested and proven. Identical replacement expansion joints are required to ensure no additional testing or development is required to verify the test system. Identical replacement expansion joints are required to maintain form, fit, and function of the Test Cell systems.

2.2.14.3. Any deviation from the specified expansion joints shall require the

Contractor to perform a piping stress analysis of the entire high pressure piping system to ensure compliance with the requirements of ASME 31.1 Power Piping Code and ASME B31.3 Process Piping Code. The Contractor shall provide all piping stress analysis documentation to the Government for approval.

Valve ID Manufacturer Model Serial

AISO-14-1 Flowserve Valdisc Replace

100915.5 3 inch Manual 1

HISO-14-1 Flowserve Valdisc Replace 162643.005-2 4 inch Manual 1

ACV-14-1 Flowserve Mark I Replace

100915.2 3 inch 4–20 ma 1

HCV-14-1 Flowserve Mark I Replace

100915.1 3 inch 4–20 ma 1

PCV-14-1A Flowserve Mark IX Replace 186710.002-1 3 inch 4–20 ma 1

PCV-14-1B Flowserve Mark IX Add 186710.002-1 3 inch 4–20 ma 1

BCV-14-1A Flowserve MaxFlo Replace 162643.026-4 2 inch 4–20 ma 1

BCV-14-1B Flowserve MaxFlo Add 162643.026-4 2 inch 4–20 ma 1

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2.2.15.9. The enclosure shall house 2 each panel mount USB connections on the exterior.

2.2.15.10. The Contractor shall provide a door activated light in the enclosure.

2.2.15.11. The Contractor shall provide a spare 120 VAC duplex receptacle in the enclosure.

2.2.15.12. The Contractor shall provide all tubing, hose, connections and electrical hardware for connection of all hardware in the enclosure.

2.2.15.13. The enclosure shall match the design of the existing Test Cells

2.2.15.14. Any deviations will require Government approval.

2.2.16. Valve Pneumatic Control Systems

2.2.16.1. Pressure Control Valves

2.2.16.1.1 The Contractor shall provide a new pneumatic control system for each of the existing and new additional Pressure Control Valves for each of the Test Cell upgrades.

2.2.16.1.2 The Contractor shall remove the existing pressure control valve enclosures for each of the Test Cell upgrades.

2.2.16.1.3 The Contractor shall replace existing stainless steel pneumatic control system interconnection stainless steel tubing for the new Pressure Control Valves (PCV).

2.2.16.1.4 All required modifications shall be rated for a minimum of

350 psig working pressure at 200 degrees Fahrenheit. The pneumatic system and all components shall comply with the latest version of ASME 31.1 Power Piping and ASME 31.3 Process Piping.

2.2.16.1.5 The Contractor shall provide one each Proportion Air

Controller, Part Number QB1SANICZP320PSG, Norgren pressure regulator, Part Number 11-008-130, Norgren mounting bracket, Part Number 18-001-003, and required power supplies and stainless steel interconnect connections and tubing for each of the Pressure Control Valves (PCV) for each of the Test Cell upgrades. The new components shall be identical to the configurations in Test Cells

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2.2.17.1.8 Each pressure transmitter shall be capable of setup and adjustment without additional equipment or tools. The setup and adjustment buttons or controls shall be located on the pressure transmitter.

2.2.17.1.9 Each pressure transmitter shall be rated for a minimum of ten percent (10%) over pressurization from maximum designed working pressure.

2.2.17.1.10 The accuracy in Tables 3.0, 3.1, 3.2, and 3.3 reflects the square root of the sum of the squares of the Non-Linearity, Hysteresis, and Repeatability specifications of each transmitter.

2.2.17.1.11 The Contractor may utilize the existing pressure transmitter’s air and electrical connections.

2.2.17.2. Pressure Transmitter Relocation

2.2.17.2.1 The contractor shall relocate pressure transmitters EB, PGOA, DPOAA, DPOAB, and CPI-A from the current location in the Transmitter Enclosure to the Mezzanine Enclosure on the Test Cell mezzanine for upgrades to Test Cell and

2.2.17.2.2 The contractor shall relocate pressure transmitters EB, PGOA, DPOAA, DPOAB, CPI-A, PGOB, DPOBA, DPOBB, CPI-B from the current location in the Transmitter Enclosure to the Transmitter Enclosure on the Test Cell mezzanine for upgrades to Test Cell

2.2.17.2.3 The Contractor shall install the new available air pressure (PT-AV-

1) transmitter in the enclosure on the Test Cell mezzanine for each of the Test Cell upgrades.

2.2.17.2.4 The contractor shall provide JIC flared connections at each pressure transmitter for calibration connections. The connections shall be stainless steel.

2.2.17.2.5 The Contractor shall provide all new wiring and air connections to the relocated pressure transmitters.

2.2.17.2.6 The Contractor shall provide new factory mounting brackets for each of the relocated and new pressure transmitters for each of the

Test Cell upgrades.

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2.2.17.2.7 The Contractor shall provide hose connections for the pressure transmitter that match the connections in the existing Transmitter Enclosure. The connections shall allow for disconnections and connections for Calibration.

Current ID New ID Description Range Accuracy

Qty.

Test Cell

EB PT-AT-1 Pressure Transmitter 16-32 in HgA ±0.10% of Full Scale 1

PGOA PT-OP-C1 Pressure Transmitter 0-350 psig ±0.10% of Full Scale 1

DPOAA PT-OL-C1 Pressure Transmitter 0-100 in H2O ±0.10% of Full Scale 1

DPOAB PT-OH-C1 Pressure Transmitter 0-240 in H2O ±0.10% of Full Scale 1

CPI-A PT-CP-C1 Pressure Transmitter 0-350 psig ±0.10% of Full Scale 1

PG1 PT-PG-1 Pressure Transmitter 0-350 psig ±0.10% of Full Scale 1

PG2 PT-PG-2 Pressure Transmitter 0-350 psig ±0.10% of Full Scale 1

PG3 PT-PG-3 Pressure Transmitter 0-350 psig ±0.10% of Full Scale 1

PG4 PT-PG-4 Pressure Transmitter 0-350 psig ±0.10% of Full Scale 1

DP1 PT-DP-1 Pressure Transmitter 0-5 psid ±0.10% of Full Scale 1

DP2 PT-DP-2 Pressure Transmitter 0-30 psid ±0.10% of Full Scale 1

DP3 PT-DP-3 Pressure Transmitter 0-30 psid ±0.10% of Full Scale 1

DP4 PT-DP-4 Pressure Transmitter 0-30 psid ±0.10% of Full Scale 1

Table 3.0 – Existing Test Pressure Transmitters

Test Cells

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ID

New ID Description Range Accuracy

Qty.

Per Cell

EB PT-AT-1 Pressure Transmitter 16-32 in HgA ±0.10% of Full Scale 1

PGOA PT-OP-C1 Pressure Transmitter 0-350 psig ±0.10% of Full Scale 1

DPOAA PT-OL-C1 Pressure Transmitter 0-100 in H2O ±0.10% of Full Scale 1

DPOAB PT-OH-C1 Pressure Transmitter 0-240 in H2O ±0.10% of Full Scale 1

CPI-A PT-CP-C1 Pressure Transmitter 0-350 psig ±0.10% of Full Scale 1

PGOB PT-OP-C2 Pressure Transmitter 0-350 psig ±0.10% of Full Scale 1

DPOBA PT-OL-C2 Pressure Transmitter 0-100 in H2O ±0.10% of Full Scale 1

DPOBB PT-OH-C2 Pressure Transmitter 0-240 in H2O ±0.10% of Full Scale 1

CPI-B PT-CP-C2 Pressure Transmitter 0-350 psig ±0.10% of Full Scale 1

PG1 PT-PG-1 Pressure Transmitter 0-350 psig ±0.10% of Full Scale 1

PG2 PT-PG-2 Pressure Transmitter 0-350 psig ±0.10% of Full Scale 1

PG3 PT-PG-3 Pressure Transmitter 0-350 psig ±0.10% of Full Scale 1

PG4 PT-PG-4 Pressure Transmitter 0-350 psig ±0.10% of Full Scale 1

DP1 PT-DP-1 Pressure Transmitter 0-5 psid ±0.10% of Full Scale 1

DP2 PT-DP-2 Pressure Transmitter 0-30 psid ±0.10% of Full Scale 1

DP3 PT-DP-3 Pressure Transmitter 0-30 psid ±0.10% of Full Scale 1

DP4 PT-DP-4 Pressure Transmitter 0-30 psid ±0.10% of Full Scale 1

Table 3.1 – Existing Test Pressure Transmitters

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Current ID New ID

Description

Range Accuracy Qty.

Per Cell

N/A PT-OP-C2 Pressure Transmitter 0-350 psig ±0.10% of Full Scale 1

N/A PT-OL-C2 Pressure Transmitter 0-100 in H2O ±0.10% of Full Scale 1

N/A PT-OH-C2 Pressure Transmitter 0-240 in H2O ±0.10% of Full Scale 1

N/A PT-CP-C2 Pressure Transmitter 0-350 psig ±0.10% of Full Scale 1

Table 3.2 – Flow Channel 2 Additional Pressure Transmitters

Current ID New ID Description Range Accuracy Qty.

Per Cell

N/A PT-AV-1 Pressure Transmitter 0 -350 psig ±0.10% of Full Scale 1

N/A PT-PA-1 Pressure Transmitter 0-50 in HgA ±0.10% of Full Scale 1

N/A PT-PG-5 Pressure Transmitter 0-150 psig ±0.10% of Full Scale 1

N/A PT-DP-5 Pressure Transmitter 0-5 psid ±0.10% of Full Scale 1

Table 3.3 – Additional Pressure Transmitters

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Description Range Manufacturer Part Number

Pressure

Transmitter 0-150 psig Siemens 7MF03001QE015AM2-Z B20+C11+E00

Pressure Transmitter 0-350 psig Siemens 7MF03001TE015AM2-Z B20+C11+E00

Pressure Transmitter 0-100 H2O Siemens 7MF03401GN015AM2-Z B20+C15+E00

Pressure Transmitter 0-240 H20 Siemens 7MF03401HN015AM2-Z B20+C15+E00

Pressure Transmitter 16-32 HgA Siemens 7MF03201PE015AM2-Z B20+C15+E00

Pressure Transmitter 0-50 HgA Siemens 7MF03201PE015AM2-Z B20+C15+E00

Pressure Transmitter 0-5 psid Siemens 7MF03401HN015AM2-Z B20+C15+E00

Pressure Transmitter 0-30 psid Siemens 7MF03401PN015AM2-Z B20+C15+E00

Table 3.4 – Pressure Transmitter Part Numbers

2.2.17.3. Resistance Temperature Detector Sensors

2.2.17.3.1 The contractor shall provide new replacement Resistance Temperature Detector (RTD) temperature sensors in accordance with Tables 4.0 and 4.1 for each of the Test Cell upgrades. Tables 4.0 and 4.1 indicates the quantity of temperature sensors required for each Test Cell upgrade. Table

4.0 indicates the required RTD temperature sensors for the Single Source Test Cell upgrades. Table 4.1 indicates the RTD temperature sensors required for the Dual Source Test Cell upgrades.

2.2.17.3.2 The Contractor shall provide new additional RTD temperature sensors for each of the Single Channel Test Cell upgrades in accordance with Table 4.2.

2.2.17.3.3 The RTD temperature sensors shall be Tolerance Class A.

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2.2.17.3.4 The contractor shall provide disconnections for calibration of the RTD temperature sensors at the rear of the Operator Console and in the Transducer Enclosure. The Contractor shall provide panel mount connections for calibration of the RTD temperature sensors on the Overhead Interface Bulkhead Enclosure and Mezzanine Enclosure. The connections shall be Omega Engineering part number OTP-U-M and part number TPJ-U-F or equivalent. Each part number set is required for four (4) each RTD connections.

The panel mount connections are required to facilitate calibration.

Any deviations will require Government approval.

2.2.17.3.5 The Contractor configuration shall match the upgraded Test Cell

2.2.17.3.6 The RTD/transmitters shall be capable of being displayed on the

End Item test screens.

ID New ID Temperature Sensor Range Quantity

COLD-1 TT-AT-C1 RTD 0 – 1000 deg. F 1 HOT-1 TT-HT-C1 RTD 0 – 1000 deg. F 1

BLND-1 TT-CT-C1 RTD 0 – 1000 deg. F 1 TDCTP TT-TR RTD 0 – 250 deg. F 1 CONTP TT-CO RTD 0 – 250 deg. F 1

Table 4.0 – Existing Test Temperature Sensors

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COLD-1 TT-AT-C1 RTD 0 – 1000 deg. F 1 HOT-1 TT-HT-C1 RTD 0 – 1000 deg. F 1

BLND-1 TT-CT-C1 RTD 0 – 1000 deg. F 1 COLD-2 TT-AT-C2 RTD 0 – 1000 deg. F 1 HOT-2 TT-HT-C2 RTD 0 – 1000 deg. F 1

BLND-2 TT-CT-C2 RTD 0 – 1000 deg. F 1 TDCTP TT-TR RTD 0 – 250 deg. F 1 CONTP TT-CO RTD 0 – 250 deg. F 1

Table 4.1 – Existing Test Temperature Sensors

N/A TT-CT-C2 RTD 0 – 1000 deg. F 1

Table 4.2 – Additional Channel 2 Test Temperature Sensor

2.2.17.4. Test Thermocouples

2.2.17.4.1 The Contractor shall provide hardware and software to connect the eight (8) existing J-Type test thermocouple connections in the Overhead Interface Bulkhead Enclosure in each of the Test Cell upgrades to the new data acquisition system. The Test Thermocouples are listed in Table 4.3.

2.2.17.4.2 The Contractors shall provide new data acquisition hardware for each of the eight (8) J-Type Thermocouple connections in each of the Test Cell upgrades.

2.2.17.4.3 Each of the thermocouples shall be capable of being displayed on the End Item test screens.

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Current ID New ID Temperature Sensor Range

TT-1 TT-T1 J-Thermocouple 0 – 1000 deg. F TT-2 TT-T2 J-Thermocouple 0 – 1000 deg. F TT-3 TT-T3 J-Thermocouple 0 – 1000 deg. F TT-4 TT-T4 J-Thermocouple 0 – 1000 deg. F TT-5 TT-T5 J-Thermocouple 0 – 1000 deg. F TT-6 TT-T6 J-Thermocouple 0 – 1000 deg. F TT-7 TT-T7 J-Thermocouple 0 – 1000 deg. F TT-8 TT-T8 J-Thermocouple 0 – 1000 deg. F

Table 4.3 – Test Temperature Sensors

2.2.17.5. Operator Interface Control Panel

2.2.17.5.1 The Contractor shall provide a new operator interface control panel for each of the Test Cell upgrades.

2.2.17.5.2 The new operator interface panel be constructed utilizing a 5U rack mount panel.

2.2.17.5.3 The Contractor shall provide ten (10) each encoders for automatic and manual control of pressure and temperature, and manual bleed control for each of the three (3) Dual Channel Test Cells, Test Cell 3, Test Cell 4, and Test Cell 5. The encoders shall be BEI part number H20DB-25-SS-1024-ABC-28V/V- EM16 and match the encoders in Test Cells

2.2.17.5.4 The Contractor shall provide eight (8) each encoders for automatic and manual control of pressure and temperature, DC voltage control, and manual bleed control for each of the two (2) Single Channel Test Cells, Test Cell 13 and Test Cell 14. The encoders shall be BEI part number H20DB-25-SS-1024-ABC- 28/V-EM16 and match the encoders in Test Cells

2.2.17.5.5 The operator interface control front panel for Test Cells 13 and 14 shall be designed in accordance with Figure 2.0. The operator interface control front panel for Test Cells shall be designed in accordance with Figure 2.1. The operator

SOW – Test Cell System Upgrade Phase 2 – 23 June 2025 Page 35 of 106 interface front panel shall utilize a minimum 1/8-inch-thick unfinished brushed aluminum rack mount panel. Each operator interface control panel shall be labeled in accordance with Figure 2.0 or 2.1. The lettering shall be engraved in the panel.

The lettering shall be identical to the existing operator interface panel. The engraved lettering shall be gloss black.

2.2.17.5.6 The new operator control interface panels shall match the existing updated panels of Test Cells in design, manufacture, and hardware with the exception of the additional quantity of controls required for Test Cells

2.2.17.5.7 The contractor shall provide and install a green LED light next to each encoder. The light shall be on when the encoder is active.

2.2.17.5.8 The “On” and “Off” buttons shall be momentary and have an internal light. The light shall be on when the button is in an active state.

2.2.17.5.9 The “Emergency Stop” button shall be a red mushroom type button with a twist or pull required to disengage. The button shall have an internal light. The light shall be on when the button is in an active state.

2.2.17.5.10 The contractor shall utilize BEI cable part number 31186-1610 to connect the encoders to the PLC system.

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Figure 2.0 – Operator Interface Control Panel Layout

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Figure 2.1 – Operator Interface Control Panel Layout

2.2.18. Power Supplies

2.2.18.1. End Item DC Power Supplies

2.2.18.1.1 The Contractor shall provide two (2) each new DC power supplies for each of the Test Cell upgrades. The power supplies shall be utilized for End Item testing.

2.2.18.1.2 One DC power supply shall be capable of 0-40 VDC output. The power supply shall be capable of delivering 15 amps at 40 VDC.

The DC power supply shall have a maximum line regulation voltage of 10 millivolts for 0–100% load variation, with constant nominal AC input voltage and temperature. The DC power supply shall have a maximum load regulation voltage 10 millivolts for 0–100% load variation, with constant nominal AC input voltage and temperature.

The power supply shall have a maximum output ripple and noise of 30 mV from 20 Hz to 10 MHz. The power supply shall have a remote voltage programming accuracy of 100 mV or better. The power supply shall conform to UL publications UL61010-1. The

SOW – Test Cell System Upgrade Phase 2 – 23 June 2025 Page 38 of 106 power supply shall be mounted in the existing 19-inch rack Test Cell console. The DC power supply shall be Sorensen Model DLM 40-15 R.

2.2.18.1.3 One DC power supply shall be capable of 0-300 VDC output. The power supply shall be capable of delivering 4 amps at 300 VDC.

The DC power supply shall have a maximum combined line and load regulation voltage of 0.4 % or better for 0–100% load variation, with constant nominal AC input voltage and temperature.

The power supply shall have a maximum output ripple and noise of 40 mV from 20 Hz to 10 MHz. The power supply shall have a remote voltage programming accuracy of 300 mV or better. The power supply shall conform to UL publications UL61010-1. The power supply shall be mounted in the existing 19-inch rack Test Cell console. The DC power supply shall be Sorensen Model DCS 300-4E.

2.2.18.1.4 The DC Power Supplies shall duplicate the part numbers in Test

Cells . Any deviations will require Government approval.

2.2.18.1.5 The Contractor shall provide all necessary hardware for a rack mount installation in the Operator Console.

2.2.18.1.6 The Contractor shall remove the existing DC power supply and install the new DC power supplies.

2.2.18.1.7 The Contractor shall modify existing wiring as required to connect to the new DC power supplies.

2.2.18.1.8 The Contractor shall install blank panels and relocate existing components to ensure no gaps in the console.

2.2.18.1.9 The Contractor shall provide and install Phoenix Contact MACX

MCR-VDC Model Number 2906242 DC Voltage transducer to connect to the PLC for HMI indication for the 0-40 DC Power Supply. The range shall be between 0 and 40 VDC. The accuracy shall be 0.25% full scale or better.

2.2.18.1.10 The Contractor shall provide and install Phoenix Contact MACX

MCR-VDC Model Number 2906242 DC Voltage transducer to connect to the PLC for HMI indication for the 0-300 DC Power Supply. The range shall be between 0 and 300 VDC. The accuracy shall be a 0.25% full scale or better.

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2.2.18.1.11 The Contractor shall provide and install new hardware to measure the DC amperage supplied to the End Item. The accuracy shall be 0.25% full scale or better.

2.2.18.1.12 The DC power supply shall interface with the data acquisition system to enable the required voltage to be set and automatically controlled for End Item testing.

2.2.18.2. Control DC Power Supplies

2.2.18.2.1 The Contractor shall provide one (1) each new control DC power supply for each of the Test Cell upgrades.

2.2.18.2.2 The DC power supply shall connect to the existing wiring for control.

2.2.18.2.3 One DC power supply shall be capable of 0-40 VDC output. The power supply shall be capable of delivering 15 amps at 40 VDC.

The DC power supply shall have a maximum line regulation voltage of 10 millivolts for 0–100% load variation, with constant nominal AC input voltage and temperature. The DC power supply shall have a maximum load regulation voltage 10 millivolts for 0–100% load variation, with constant nominal AC input voltage and temperature. The power supply shall have a maximum output ripple and noise of 30 mV from 20 Hz to 10 MHz. The power supply shall have a remote voltage programming accuracy of 100 mV or better. The power supply shall conform to UL publications UL61010-1. The power supply shall be mounted in the existing 19-inch rack Test Cell console.

The DC power supply shall be Sorensen Model DLM 40-15 M13 R.

2.2.18.2.4 The DC Power Supply shall duplicate the part number in Test

Cells Any deviations will require Government

2.2.18.2.5 The Contractor shall provide all necessary hardware for a rack

2.2.18.2.6 The Contractor shall remove the existing control DC power supply and install the new control DC power supply.

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2.2.18.2.7 The Contractor shall modify existing wiring as required to connect to the new DC power supply.

2.2.18.2.8 The Contractor shall install blank panels and relocate existing

2.2.18.3. AC Power Supply

2.2.18.3.1 The Contractor shall provide one (1) each new AC Power Supply for each of the Test Cell upgrades. The power supply shall be utilized for End Item testing.

2.2.18.3.2 The AC power supply shall be rated for a minimum of 500 VA output. The power supplies shall be capable of a minimum output voltage range of 5 to 400 VAC rms. The power output shall be single phase. The power supplies shall be capable of an adjustable minimum output sine wave frequency range of 16 to 1,200 Hz. The power supplies shall be capable of a minimum voltage accuracy of plus or minus 0.3% and a minimum resolution of 0.1 Vrms. The maximum total harmonic distortion shall be less than 3% at 400 Hz.

The power supplies shall have a minimum frequency accuracy of plus or minus 0.06% of the maximum frequency and shall be capable of a minimum resolution of 0.1 Hz. The power supplies shall be capable of operating within all required parameters with a single phase input voltage of 100 to 125 VAC or 200 to 240 VAC and an input frequency of 47 to 440 Hz. The AC power supply shall be Ametek Programmable Power Model AST0501A1B-E000A0A.

2.2.18.3.3 The AC Power Supply shall duplicate the part number in Test Cells

Any deviations will require Government

2.2.18.3.4 The Contractor shall provide all necessary hardware for a rack

2.2.18.3.5 The Contractor shall remove the existing AC power supply and install the new AC power supply in place.

2.2.18.3.6 The Contractor shall install blank panels and relocate existing

2.2.18.3.7 The Contractor shall provide and install new hardware to measure the AC voltage supplied to the End Item. The range shall be between 0 and 130 VAC. The accuracy shall be 0.25% full scale or better.

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2.2.18.3.8 The Contractor shall provide and install new hardware to measure the AC frequency supplied to the End Item. The range shall be between 0 and 450 Hz. The accuracy shall be 0.25% full scale or better.

2.2.18.3.9 The Contractor shall provide and install new hardware to measure the AC amperage supplied to the End Item. The accuracy shall be 0.25% full scale or better.

2.2.18.4. Vibration Sensor

2.2.18.4.1 The Contractor shall interface with one each (1) existing Bruel &

Kjaer accelerometer Part Number 4371V for each of the

2.2.18.4.2 The hardware shall provide for a minimum range of 0 to 15 G’s

RMS indication.

2.2.18.4.3 The Contractor shall provide and install vibration hardware for each of the Test Cell upgrades. The hardware for each Test Cell shall include one (1) each Piezotronics ICP Signal Conditioner Part number 682A02, one (1) each Laurel Electronics Analog Input transmitter part number LT21RMV2, one (1) each Piezotronics 10 mV/pC In-Line Charge Converter Part Number 422E52, one (1) each Krohn-Hite Corporation GPIB Programmable Analog Filter part number 3988, one (1) each Keysight and one (1) each Phoenix Contact Power Supply part number 2902991.

2.2.18.4.4 The Contractor shall provide the required factory rack mount hardware for the Analog Filter and install in the Operator Console.

2.2.18.4.5 The Contractor shall provide one (1) each Pomona 2249-C-360 BNC cable, one (1) each Pomona 2249-C-360 BNC cable, one (1) each Pomona 2249-C-360 BNC cable for connection of the vibration hardware to the Analog Filter.

2.2.18.4.6 The Contractor shall install the new Pomona 2249-C-360 BNC cable in the Test Cell overhead raceway from the Overhead Interface Bulkhead Enclosure to the Operator Console. The cable shall connect to the Analog Filter in the Operator Console.

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2.2.18.4.7 The Contractor shall provide all additional interconnect hardware and cables required for connection between vibration components and the data acquisition system to ensure an operational system.

2.2.18.4.8 The hardware shall duplicate the part numbers in Test Cells

. The Government will approve any proposed equivalent part numbers.

2.2.18.5. Speed Sensor

2.2.18.5.1 The contractor shall provide all required hardware and programming to interface with one each existing Honeywell Part Number 901114-1-2 magnetic speed sensor for each of the

2.2.18.5.2 The hardware shall provide for a minimum range of 0 to 150,000 rpm indication.

2.2.18.5.3 The Contractor shall provide and install speed data acquisition hardware for each of the Test Cell upgrades. The hardware for each Test Cell shall include one (1) each Flow Technology Signal Conditioner, part number PA04-3-A-0000 B6, one (1) Acopian Power Supply part number 10AB75C1G3, one

(1) Krohn-Hite Amplifier part number FMB3002AC, one (1) McMaster Carr Enclosure part number 7360K692, one (1) McMaster Carr Enclosure Panel part number 7360K55 and one (1) each Red Lion Frequency to Analog Converter part number

IFM0001.

2.2.18.5.4 The Contractor shall provide all additional interconnect hardware and cables required for connection between speed components and the data acquisition system to ensure an operational system.

2.2.18.5.5 The hardware shall duplicate the part numbers in Test Cells

. Any deviations will require Government approval.

2.2.19. Emergency Stops:

2.2.19.1. The Contractor shall connect to the existing three (3) emergency stop circuits.

2.2.19.2. The emergency stop buttons shall remove all power from the system identical to the current emergency stop functions.

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2.2.19.3. All emergency stops shall be hard wire controlled.

2.2.19.4. All high pressure high temperature control valves shall close on activation of any emergency stop. All bleed valves shall open on activation of any emergency stop.

2.2.20. Data Acquisition

2.2.20.1. The Contractor shall provide one each (1) new data acquisition system for each of the Test Cell upgrades. Each system shall be standalone for each Test Cell upgrade.

2.2.20.2. The Contractor shall use a computer and a programmable logic controller (PLC) for the data acquisition system. The analog to digital converter shall be sixteen (16) bit or better. The data acquired shall be for automatically and manually controlling test parameters, displaying the test data on the LCDs, and printing the test screens to printer. The data acquisition system shall be capable of displaying all transmitter, sensor, and transducer inputs. The PLC hardware shall duplicate the components of Test Cell . Any deviations will require Government approval.

2.2.20.3. The minimum update response time of the data acquisition system shall be 100 milliseconds.

2.2.20.4. All computer components shall be mounted in a standard 19 inch rack mount enclosure with a 4U height. The motherboard of the computer shall be an ATX form.

2.2.20.5. The Contractor shall ensure adequate ventilation of all computer components and PLC equipment.

2.2.20.6. The test stand shall use only a PLC for all control loops.

2.2.20.7. The Contractor shall provide two (2) USB connections on the Transmitter enclosure and two (2) USB connections on the Mezzanine Enclosure for each of the Test Cell upgrades.

The Contractor shall use Schneider Electric part number XB5PUSB3 or equivalent. Any deviations will require Government

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2.2.20.8. The Contractor shall provide two (2) each computer keyboards, two (2) each computer mice, and two (2) computer mouse pads for each of the

2.2.20.9. The Contractor shall provide one (1) custom keyboard/mouse enclosure for each of the Test Cell upgrades. The custom rack mount keyboard/mouse enclosures shall be identical to the existing enclosure on Test Cells

2.2.20.10. The Contractor shall provide a total of one (1) each spare computer with duplicate components.

2.2.20.11. The Contractor shall provide a minimum of four (4) spare PLC analog input channels for 4 – 20 mA signals. The Contractor shall provide all wiring and terminals for connection to the inputs in the Transmitter Enclosure.

2.2.20.12. The Contractor shall provide a minimum of four (4) spare PLC analog input channels for 0 – 10 volt DC signals, four (4) spare PLC analog input channels for 43-20 mA signals, and four (4) spare PLC analog output channels for 0 – 10 volt DC signals The Contractor shall provide all wiring and terminals for connection to the inputs.

2.2.21. LED Touch Screen Displays

2.2.21.1. The Contractor shall provide three (3) each LED touch screen displays for each of the Test Cell upgrades.

2.2.21.2. Each LED displays shall be touch screen, nineteen (19) inch minimum and capable of plus or minus eighty-five (85) degree wide side to side viewing angles with a minimum of one thousand twenty four by seven hundred sixty eight (1024 x 768) resolution. The displays shall have at a minimum seven hundred fifty to one (750:1) contrast ratio, seven hundred fifty (750) Nits brightness and lifetime of forty thousand (40,000) hours.