V-22 IQA Draft SOW Market Research 0.6.pdf

MARKET RESEARCH

FOR A

V-22 PROP ROTOR INPUT QUILL GEARBOX TEST STAND

In addition to an estimate on cost and project duration, the government requests focused feedback on the existing facility space and available utilities. Our objective is to install this test stand within the current spaces, aiming for minimal modifications while maintaining the test stand's functionality and sustainability. Please identify any deficiencies and highlight any minimum requirements that the existing facilities fail to meet. Specific areas of interest include Section 2.3.1. Foundation Requirements, 2.3.2. Existing Power, 2.3.3.

Existing Footprint, and 2.8 Schedule.

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1. SCOPE

2. REQUIREMENTS

TURNKEY DELIVERY

TEST REQUIREMENTS

TEST CELL GENERAL DESIGN CRITERIA AND LIMITATIONS

MODES OF OPERATION

HOST COMPUTER AND TEST APPLICATION REQUIREMENTS

PROGRAMMABLE LOGIC CONTROLLER (PLC)

TEST STAND REQUIREMENTS

SCHEDULE

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1. SCOPE

This specification details the Government’s minimum requirements for a test stand capable of testing both left-hand and right-hand V-22 PropRotor Gearbox Input Quill Assemblies. This includes all mechanical, electrical, software, and control systems as well as ancillary subsystems required to test either PropRotor (PRGB for the V-22 Aircraft) Input Quill. This will be a turnkey delivery including all parts and labor required for machine functionality including installation, commissioning, performance testing, and calibration to enable the government to produce aircraft components upon Government acceptance. This test stand will be located in Building 4497, Fleet Readiness Center East (FRC East or FRCE), MCAS Cherry Point, NC. Definitions & Available Space

For purposes of this document, the term commercial gearbox(s) refer to the gearbox assembly provided by the contractor to test the aircraft gearbox. The complete contractor delivered system shall be referred to as the test stand. The room in which the test stand is placed will be referred to as the test cell. The test stand will be controlled from the operator’s station in the control room. The aircraft gearbox is referred to as the Unit Under Test, or UUT. FRCE has three spaces available for the location of this test stand. A control room, a test cell, and an equipment space (if required).

2. REQUIREMENTS

Turnkey Delivery

“Turnkey” is defined as all parts and labor required for machine functionality including installation, commissioning, performance testing, and calibration to enable the government to produce aircraft components upon Government acceptance.

Test Requirements

2.2.1. Test Procedure/Manual

The developed system shall test the following Unit Under Test(s) (UUT) Part Numbers in accordance with Test Procedures located in Technical Manuals listed below in Table 1:

Table 1 - Technical Manual

Document UUT Part Number

Acceptance Test Specification For Input Quill Assembly

901-044-055

901-044-056

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2.2.2. FST Testing Requirements

The developed system shall meet the requirements as specified in the document listed below in Table 2.

Table 2: - FST Technical Requirements

Document UUT Part Number

Additional FST Stand-alone IQA testing requirements

901-044-055

901-044-056

2.2.3. UUT Orientation

The UUT may be orientated either vertically or horizontally. Horizontal orientation shall be with the internal oil reservoir facing down. Vertical orientation shall be with engine input shaft facing down. Preference shall be given to the orientation that lends itself to ease of installation/removal.

Test Cell General Design Criteria and Limitations

2.3.1. Foundation Requirements

The building test cell floor is 6” thick concrete. This site does not permit the use of a mechanical space or sump below grade.

2.3.2. Existing Power

The transformer feeding the building is an industrially fed 480V (+/- 10%), 750KVA transformer. Historical PEAK Amperage demand for that transformer has been 254A.

There should be approximately 650A @ 480V available for use.

2.3.3. Existing Footprint

Available space is shown in drawing V-22 Proprotor IQA Test Stand-QD101.

2.3.4. Ballistic Requirement for Rotating Shafts

Minimal ballistic shielding is included in the facility. The contractor shall provide ballistic protection against catastrophic failure of any rotating assemblies.

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2.3.5. UUT Installation Equipment

The contractor shall provide lifting and installation gear to load/unload the UUT into the test stand for testing. The test cell currently has two (2) ½ ton overhead cranes. If the contractor’s design requires modifications to the existing cranes, or if the contractor deems existing cranes inadequate for their design, contractor shall provide replacement cranes and/or components. Final contractor design and installation shall be approved by the government.

2.3.6. Environmental Conditions

The test cell cooling philosophy of the building is that only the control room area is conditioned. The existing building climate control heating/cooling for the control room space is sized for the sq.ft. of the space and assumes no additional heat load. The test cell where the test stand will be located is not conditioned at all. The equipment located in the test cell shall be designed to operate in the following conditions: 32-115 °F temperatures and 0-100% Relative Humidity (condensing). Control room items shall be designed to operate in the following conditions: 65-85°F Temperatures and 0-90% Relative Humidity (non-condensing). Equipment in the test cell may be subjected to occasional oil spray, frequent oil mist, and occasional water splashing.

2.3.7. Test Cell Space Cooling

Contractor shall provide a means of cooling the test cell to remove excess heat while the test stand is running. This shall include either replacing the existing inlet louvers/exhaust fans with new louvers and fans of the same form/fit/function or modifying the existing louver/fan envelop as required to install suitable means of maintaining the test cell at OEM recommended temperature conditions. This shall be controlled thermostatically. Existing facility has two 24”x24” intake louvers at ground level and two ceiling mounted exhaust fans. Any additional cooling required to keep the test stand space at recommended temperatures while the test stand is in operation shall be provided by contractor.

2.3.8. Cooling System

Contractor shall provide a complete cooling system to adequately maintain the correct operating temperature of the test stand to permit year-round operation. There is no existing cooling available at the building location. All work performed on the cooling system shall comply with FRC East Instruction 5090.1G (Par. 2.2.2, Environmental Compliance Manual).

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2.3.8.1.Cooling Tower/Air Cooled Chiller

The contractor shall install a suitably sized cooling tower or air-cooled chiller to support the test stand.

2.3.8.2.Process Valves and Piping

Contractor shall install all required piping, valves, etc. for the test stand cooling system. Process piping will be installed in accordance with ASME B31.3. Piping shall be leak tested upon completion IAW ASME B31.1. All components that make up the cooling system shall be corrosion resistant inside and out.

2.3.8.3.Water Filtration, Continuous Circulation

Contractor shall install a suitably-sized filtration system utilizing ProMoss™ with hydrogen peroxide generation to limit particle size such that none of the plumbing components will be fouled by contaminated industrial cooling water. Industrial cooling water filtration system shall have a means of automatically backflushing (cleaning) the system as well as a means of indicating a clogged filter. The test system shall post an alarm when the pressure drop is approaching the point of where the filter needs to be cleaned and the test stand shall not run if the pressure drop is beyond the acceptable limit. This alarm shall post visually with an industrial rated tower light and at the operator’s console.

2.3.8.3.1. Water Treatment and Passivation

All treatment must meet UFC 3-230-13. Contractor to provide passivation treatment for all new heat transfer equipment. Provide all materials, labor, and equipment necessary to bring heat transfer equipment in conformance with the equipment manufacturer’s specific requirements. Perform all work in accordance with the equipment manufacturer's published diagrams, recommendations, and equipment warranty requirements. Contractor shall provide written documentation, detailing, how treatment was executed and completed to meet the equipment manufacture’s chemical treatment requirements such as initial treatment, cleaning, and passivation. Provide written documentation detailing how sustainment treatment must be performed to realize the full life expectancy of the equipment.

2.3.8.4.UUT Heat Exchangers

Contractor shall maintain a set point of ±4°F oil temperature as measured at the intake of the UUT. The contractor shall demonstrate that no configuration change or settings are necessary at different ambient conditions (summer or winter, for

Page 7 V-22 PROP ROTOR INPUT QUILL GEARBOX TEST STAND example). These setpoints shall be controlled by the system based on testing requirements stated in section 2.1.

2.3.8.5.Oil Thermal Regulation Control System

The contractor shall utilize temperature controls actuated by the test system at the operator’s console control systems to maintain commercial gearbox oil temperatures while the stand is running. If valve is available with optional mechanical gauge, gauge shall be installed and visible to either the control room window or camera system.

2.3.9. Available Compressed Air

Where required for operation of the equipment the contractor shall connect the equipment to the existing compressed air system at FRC East, Cherry Point. The contractor shall reconnect to existing piping. Install all new piping parallel and perpendicular to the building structure. New piping installation shall not block or restrict any existing or new equipment operation or maintenance access. Provide all engineering details, calculations and drawings with the Site Preparation and Installation Plan submittal. Provide all details to install the compressed air piping, which shall include pipe size, piping material, weights, dimensions, calculations etc. Provide detailed information as to the Equipment required SCFM (Volumetric Flow Rate at standard conditions), pressure (psi), cleanliness and dryness for the compressed air. The contractor shall provide all compressed air requirements, materials and equipment with the Site Preparation and Installation Plan. The piping installation shall meet or exceed the current Department of Defense construction criteria as defined in UFC 3-420-02. The contractor shall provide a single point connection to the Equipment with a lockable shutoff valve that meets or exceeds the 29 CFR 1910 regulations.

2.3.9.1.Compressed Air Quality

The contractor shall make provisions to filter, dry, humidify, lubricate, amplify, and regulate the existing FRC East facility compressed air to meet the new equipment manufacturer's compressed air quality requirements and recommendations. The existing compressed air pressure available is normally 80 psi but will fluctuate between 75 psi to 100 psi. Due to age and condition of the existing piping, the existing air quality is unknown. The contractor shall assume that all compressed air qualities to be of the lowest quality that is useable as compressed air. The contractor shall design the proper stages in filtration to minimize pressure drop across all filters. All filtration used shall be monitored by a differential pressure gauge with color indicators. The contractor shall install adequate course and fine filtration for particle removal. The contractor shall install

V-22 PROP ROTOR INPUT QUILL GEARBOX TEST STAND Page 8 adequate filters, separators, and dryers to remove moisture, water particulates, water and water vapor. The contractor shall install adequate filters, separators, and dryers to remove oil vapor and fine aerosols. Additionally, the contractor shall design and protect the new equipment from any wet saturated compressed air conditions because on occasion, the FRC East may experience a catastrophic compressed air dryer failure at the central plant compressed air location.

2.3.9.2.Compressed Air Piping Cleaning and Flushing Procedures

Prior to joining and installation of piping or tubing, the contractor shall thoroughly clean interiors of new pipe sections, tube, and components. In steel pipe, loosen scale and other foreign matter by rapping sharply and expel by wire brush and swab. Blow out both steel pipe and copper tube and components with compressed air at 100 psig or more. Maintain cleanliness by closure of pipe/tube openings with caps or plugs. Before making final terminal connections, blow out complete system with compressed air at 100 psig or more.

Modes of Operation

The developed test system shall be capable of testing in both manual and automatic modes.

The operator shall be able to select the mode of operation.

2.4.1. Manual Testing

Operation of the test stand in manual mode shall be possible by selectable menu option in the DACS (Data Acquisition and Control System). The manual mode shall allow full control of all test stand functions with complete monitoring of all critical parameters to provide automatic shutdown due to operating limits being exceeded. At any time during automatic testing the operator shall have the ability to interrupt the automatic test sequence and switch to the manual mode. Once the manual mode is invoked, the only automatic operation possible is stand shutdown due to critical stand parameter operating limits being exceeded. All alarm functions and shutdowns routines shall operate in the manual mode.

2.4.2. Manual Controls

The contractor shall provide tactile manual controls for the manual input of speed, and each individual torque. All manual controls shall be of an industrial, ruggedized style with redundant non-contact (such as Hall Effect) position sensors for additional safety. Each controlled parameter shall have its own individual manual control. Indicators shall be provided in close proximity of the controls to reflect the selected set point for each control.

All controls shall be clearly labeled. Controls shall have an integral dead-man switch to prevent inadvertent actuation. Manual operation shall require no more than one hand to

Page 9 V-22 PROP ROTOR INPUT QUILL GEARBOX TEST STAND operate each individual set point, and shall only require simple hand movements to actuate.

For example, pushing a joystick forward to a set point is acceptable.

2.4.3. Automatic Testing

The system shall be capable of automatic testing of the components listed in 2.2.1. The contractor shall develop and implement a Data Acquisition and Control System (DACS) that shall fully control gearbox testing. This includes data collection and test stand operation (for example, Speed/Torque/Oil Temp/Time Intervals) to automatically and without user intervention achieve:

a) The test points required in 2.2.1 including required temperature UUT soak times

b) Safe and controllable ramp rates

c) Continuous UUT, commercial gearbox, and test cell parameters monitoring and recording

d) Alarming and safe automatic shutdown upon a safety excursion.

2.4.4. Automatic Testing Initiation

Automatic Testing shall be initiated by the test stand operator via touch screen or mouse/cursor manipulation of a "sequence start" selection on the DACS.

2.4.5. Bump-less Mode Change

Transfers between automatic mode and manual shall be seem-less and bump-less.

2.4.6. Failsafe Operation

The contractor shall develop the system to ensure that the system/subsystems/components fail in a failsafe operation. All electrical, pneumatic, software, and hydraulic systems shall be designed for fail-safe operation. The design and development of all electronic equipment shall provide fail-safe features for safety of personnel during the installation, operation, maintenance, and repair or interchanging of a complete equipment assembly or component parts thereof. Electrical systems shall be insulated, isolated, shielded, and grounded for operating safely.

Definition: Fail-Safe. The design feature of a part, unit, system or equipment which allows the item to fail only into a non-hazardous mode with respect to the individual item and the system as a whole.

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2.4.7. System Refresh Rate

Design the control and acquisition system to safely acquire and process data to ensure safe operation or 20 samples or scans per second (excluding temperature measurement), whichever is greater.

Host Computer and Test Application Requirements

The contractor shall utilize server/workstation class of computer designed for high reliability/availability. At a minimum, the system shall have redundant power supplies and the ability to hot-swap hard drives.

2.5.1. Computer Minimum Specifications

The new computer shall have the following minimum specifications:

System Minimum Requirements

Processor 8 processing cores, 3.2 GHz Base Frequency

RAM 32 GB, DDR4 min.

Storage Quantity 2, 2 TB, Solid State, Min write speed of 500 𝑀𝑀𝑀𝑀 𝑠𝑠� .

Optical Drive 24X, DVD-RW

Power Supplies Quantity 2, Redundant

Peripherals Optical Mouse, Keyboard

Form Factor Workstation or 19” Rack

Number of Monitors Two (2)

Monitor Size Minimum of 34 inches

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Printer Laser, 30 𝑝𝑝𝑝𝑝𝑝𝑝𝑝𝑝𝑠𝑠 𝑚𝑚𝑚𝑚𝑚𝑚� , 2.5.1.1.Maximum Allowable CPU Usage

The overall average CPU usage, as defined by the Windows Task Manager, shall not exceed 35%, with the test application active, while testing an UUT. In addition, no individual processing core shall exceed an average of 50% with the test application active, while testing an UUT.

2.5.1.2.Maximum Allowable RAM Usage

The system shall have at least 50% of its physical memory available with the test application active, while testing an UUT, as defined by the Windows Task Manager, or the requirements described in 2.5.1, whichever is greater.

2.5.1.3.Maximum Allowable Storage Usage

The system shall employ dual hard drives. The hard drives shall have a minimum of 70% free disk space after all applications have been loaded or the requirements described in 2.5.1, whichever is greater.

2.5.1.4.Computer Warranty

The computer system shall come with the manufacturer’s standard warranty. The contractor shall provide a placard detailing the computer warranty details and expiration date. The contractor shall affix the placard to the computer.

2.5.2. Microsoft Office

The Host Computer shall have the current, full version of Microsoft Office installed. The contractor/developer is responsible for procuring MS Office licenses thru DoD POC.

Versions of Microsoft Office shall not be dependent on an internet connection or require any subscription service.

2.5.3. Test Application Software General Requirements

The contractor shall provide Test Application Software with the following minimum functionality:

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2.5.3.1.Access Control

The system shall implement a password-based scheme of controlling system access levels based on user groups. Protection shall be implemented at the Operating System level and compatible with the requirements listed in 2.4 et seq.

2.5.3.1.1. User Groups

The system shall have the following user groups with password protection controls:

User Access Description

Administrator The administrator shall be given all available access privileges.

Operator The operator shall be given access to all test programs and tasks relating to testing. The operator shall not have operating system access.

Calibration Technician

The calibration technician shall be given access to calibration and related tasks only.

Maintenance Technician

The maintenance technician shall be given access to all tasks relating to hardware or software maintenance.

2.5.3.1.2. Operating System Functionality

Disable the task bar and “start menu” for all users, except users in the Administrator and Maintenance Technician groups. The system shall not permit users that are not in the Administrator or Maintenance Technician groups to run programs other than the Test Application detailed in this specification.

2.5.3.2.Test Application Programming Language

The contractor shall provide one (1) licensed copy of the programming environment used to develop the system Test Application code, licensed to the government. Included with this requirement is any add-ons or “tool boxes” utilized in conjunction with the core software to develop the Test Application Program.

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2.5.3.3.Compilation

The final accepted Test Application software version shall be installed as a compiled executable. The contractor shall provide the “as delivered” version of the compiled source code. In addition, the contractor shall provide an automated installation utility to install the software. This executable and installation utility will be tested as stated in section 0.

2.5.4. Test Program Sets (TPS) Requirements

The TPS refers to the portion of the software that directly controls the application of speed, torque, temperature, etc. as required by the testing requirements in section 2.2.1. The TPS shall be created with the philosophy of creating a sub program that is easy to modify and/or create to handle the UUT test procedure. The TPS test requirements are routinely “tweaked” by the aircraft OEM. Therefore, additional tests in the TPS shall be able to be created, removed, or modified by users with Administrator-level access with relative ease.

Common changes include a modification to min/max torque values and torque set points and oil temperature set points. NOTE: At no time will these TPS modifications exceed the maximum testing requirements as specified in section 2.1.

2.5.5. UUT Info

Prior to beginning the UUT test sequence, the operator shall be prompted to enter gearbox type, run type, serial number, oil drum lot number, operators name(s) and comments. Part numbers, etc. shall be available from a pull-down menu. All operator inputted fields shall be sanitized to only allow standard characters to be inputted, i.e. no %, &, #, etc.

2.5.6. Data Collection and Storage

The software shall automatically and manually record test data. In manual mode, the operator is in control of when to store data points, unless the technical manual (see 2.2.1) requires data recording at specific intervals. If the technical manual (see 2.2.1) requires data storage at intervals, the software shall automatically store data at these intervals without operator intervention. In automatic mode, the developed software shall be in control of data storage/collection and intervals without operator intervention. Each successful execution of an automated test sequence shall be recorded and stored in memory as a file. This file shall include all run data and stand parameters for the entire duration of the test, as well as include a time/date stamp that indicates start/finish time in hours/minutes/seconds as well as day, month, and year.

2.5.6.1.Backup

The system shall provide utilities to backup and restore archived records.

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2.5.7. Report Generation

The software shall provide report generation for the purpose of printing and archival on the local Host Computer.

2.5.7.1.Media

The software shall produce reports in electronic or hard copy format at the operator’s option. The electronic format shall be Microsoft Excel compatible, and Portable Document Format (pdf).

2.5.7.2.UUT Test Report

The software shall produce a hard copy report of the test sequence results. The reports shall be customizable to reflect future changes in the test procedure or test sequence requirements. The report shall include a field for test specific operator comments.

2.5.7.3.Print Preview

Provide a user optional print preview option to view reports in a What You See is What You Get (WYSIWYG) format before printing.

2.5.7.4.Access

The report generation module shall be accessible via the Test Application menu or the selected UUT TPS and at the conclusion of UUT testing.

2.5.7.5.Menu

The report generation module shall allow the user to select desired reports via a “drill-down” type menu system.

2.5.7.6.Historic Data

The system shall have the capability to generate all reports on historic UUT runs and current runs.

2.5.7.7.Configurability

An administrator shall have the ability to modify and create new reports without the need to recompile the software or directly modify source code. A means of configuring the reports shall be provided.

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2.5.8. Alarms

Provide alarm enunciation. All current alarms shall be visible at any given time. The alarm shall be listed by mnemonic and current value. The current value shall update live. When the alarm returns to a normal state, it shall be removed from the enunciation screen after operator acknowledgment. Enunciation shall be listed as First In, First Out (FIFO) order.

The contractor shall be responsible for defining alarm conditions in the software and taking automated action, where applicable, to ensure the safety of personnel, equipment, and the

UUT.

2.5.8.1.Alarm Severity

Contractor shall implement two levels of alarms. A “caution” or “warning” alarm requires an indication that a parameter is out of tolerance without performing any action other than operator notification. A “critical” alarm indicates that a parameter’s out of tolerance has increased so far outside its “caution” limits that an immediate stand shutdown in required. An alarm condition, either “critical” or “caution”, shall clearly identify to the operator which parameter is out of tolerance.

An alarm condition requiring a stand shutdown shall clearly indicate to the operator that the stand is automatically performing a safe, automatic, shutdown.

2.5.8.2.Logging

Alarms shall be logged to an event log. The system shall log any action taken because of an alarm and what event triggered the alarm.

2.5.8.3.Triggering

Alarms shall be capable of triggering an automated procedure. The contractor shall provide procedures to safely deal with alarms.

2.5.8.4.Hierarchy

A hierarchical alarm method shall be employed to prioritize alarm events and prevent higher priority alarms that trigger a procedure from being interrupted by a lower priority alarm.

2.5.8.5.Limits

The alarm/caution display shall display all events that exceed a set limit value. The contractor shall configure the limits. Limits shall be easily configurable and not require a re-compilation of the system.

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2.5.8.6.Damage Prevention

Alarms shall be configured to trigger with associated action before damage is done to the UUT or test stand (for example: sufficiently triggered before over torque or over temp limits to allow the UUT to transition to a safe state before any hard limit or time limit is exceeded).

2.5.8.7.Logs

The software shall create a text log of major events that occur during testing, including errors. The log entries shall be time stamped for troubleshooting.

2.5.9. Front Panel Displays

For this specification, a display is defined as that portion or area of a monitor that has clearly defined boundaries and is reserved for a specific type of operator display format.

The DACS shall allow for the selection and display of multiple display pages on multiple monitors. These displays provide data to operators and facilitate data input. A display page shall contain UUT and or Test Stand parameters as well as icons for test stand control. A display may or may not take up an entire monitor. The contractor shall optimize the layout of the display screens to present the operator an efficient annunciation system.

2.5.9.1.All Parameters

All parameters used and read by the system shall be indicated on at least one display.

2.5.9.1.1. Prominence

The critical display shall be most prominent of all screens. During testing the critical display shall be fixed and immovable, always on top.

2.5.9.1.2. Indication

The critical display screen shall use analog type gauges (such as bar charts) for parameters that are suited to rate of change indications. When an analog type gauge is used, a digital indicator shall also be used.

2.5.9.1.3. Layout

The critical display screen shall be uncluttered and easily scanned by test cell operators.

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2.5.9.2.Critical Display

One display shall be dedicated to presenting the operator data critical to the safe operation of the test stand/cell. The operator shall not have the ability to remove this display from view. This display may or may not take up an entire monitor.

2.5.9.3.Misc. Displays

The system shall supply miscellaneous screen displays as required for systems calibration, maintenance, and configuration utilities. Every channel read into the system shall be viewed on at least one prebuilt display.

2.5.9.4.Test Sequence Display

The software shall have a test sequence display screen that shall provide the operator interface, display, and control for the unit test sequences.

2.5.9.5.Visibility of Critical and Alarm Screens

The description, limit value and current value of Critical UUT or test stand alarms will be displayed to the operator instantaneously and immediately be visible to the operator regardless of what screens are currently visible or “topmost”.

2.5.9.6.Alarm Annunciation

All data presented in a display, with an alarm condition associated with it, shall have its alarm state annunciated in the display via changing of color.

2.5.9.6.1. Warning/Caution Colors

The Warning/Caution (alarm) annunciation state of numeric data, rims of gauges, color of bar chart style indicators shall dictate the parameters/data’s background color. Data/parameters that are in a normal condition shall have a background color of black, grey, white, or other neutral color. Data/parameters that is in a caution state shall have a background of yellow. Data/parameters in a “critical” alarm condition shall have a background color of red. Data/parameters with no alarm condition associated with it shall be colored per data existing in a normal condition.

2.5.9.7.Alarm Summary

The contractor shall provide a dedicated display that will provide an alarm summary. The alarm summary shall display all parameters that are currently in an alarm or caution condition. This display may or may not take up an entire monitor.

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2.5.9.7.1. Fixed

The warnings display shall always be displayed during unit testing and shall be fixed and unmovable. Display shall not be “minimizable” or otherwise obstructed with other Windows popups.

2.5.9.7.2. Information Displayed

The warnings display shall, as a minimum, display the parameter name, limit value exceeded, current measured value.

2.5.9.8.Real Time Plots

At least one screen shall be configurable to display real time plots, with appropriate X-Y axis labeling, to display test points. Plots shall be configured as a strip chart plot. Plots shall be printable and readable in black and white or copied using a black and white copier. The printed background color shall be white. Limit lines shall be selectable displayed on the plots using polynomial line definitions or look-up tables for limit lines.

2.5.9.9.Facilities Overview

The contractor shall provide a screen that displays a facility and test stand overview depiction. Actual values shall be overlaid on a line drawing or similar representation of the facility to aid in quick recognition of signal location, i.e.

industrial cooling inlet temperature would be shown over a line drawing of the test system between the cooling tower and the test stand. This screen shall be fixed to one monitor.

2.5.9.10. Shutdown Annunciation

Should a parameter exceed a critical alarm value, and the system automatically transitions to a safe state, the system shall clearly annunciate to the operator what parameter caused this reaction.

2.5.9.11. Display Refresh Rates

Display refresh rates are defined below. These refresh rates definitions represent the rate at which data changes on the displays, NOT the system, acquisition, PLC or control refresh rates.

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2.5.9.11.1.1. Text/Numerical Display Refresh Rates

For data displayed as numerical text, the refresh rate of the data on the screen shall be at least four (4) times per second and no greater than eight (8) times per second. The least significant digit shall update slow enough to remain readable.

2.5.9.11.1.2. Graphical Display Refresh Rates

For data displayed graphically (Charts, Graphs, Dials, Gauges, Bar Chart Style Indicators, etc.), the refresh of the data on the screen shall be at least ten (10) times per second.

2.5.10. Calibration Software

The software shall have a calibration utility to guide the calibration technician though the calibration process. This utility will be accessible to qualified calibration personnel via a password protected, unique calibration login. The software shall scale raw data input values into appropriate engineering units, as determined by individual channel requirements. The software shall scale and/or calibrate individual channels using the calibration constants developed using the calibration function of this application.

2.5.10.1. Function

The calibration utility shall scale/calibrate data channels and set units to engineering values. The calibration utility shall allow technicians to verify cardinal points without having to scale the parameter.

2.5.10.2. Method

The test system shall use software calibrations and not rely on trim pots, etc. The calibration utility shall have a selectable method of calibration. The methods shall be polynomial fit (selectable order), look-up table, and linear fit. The software shall compute the calibration transfer function automatically.

2.5.10.3. Significant Digits

The calibration software shall display the full DAQ resolution. Do not round displayed readings in the calibration screen. At a minimum and in addition, the calibration software shall display at least one additional significant digit more than the calibration tolerance (for example, if the calibration tolerance is 0.002 lbs., the calibration software must display at least 0.0023). This requirement only applies to the calibration software section of this document.

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2.5.10.4. Live Data Reading

The calibration utility shall display a live data reading. The value shall be the value used for calibration calculations.

2.5.10.5. Number of Data Points

The calibration utility shall allow a user selectable number of calibration data points.

2.5.10.6. Storage Prompt

The calibration utility shall provide a user prompt and verification to store calibration data to disk. The system shall not store calibration data to disk without a calibration technician accepting this prompt.

2.5.10.7. History

The calibration utility shall store all the current calibration and the previous calibration cycles. This history shall be used and archived for trending.

2.5.10.8. Report

The calibration utility shall provide a calibration report of single, multiple, or entire channel calibration information. A calibration report shall include latest calibration information, selectable (Calibration technician optional) historical calibration information, and determine sensor offset and drift.

2.5.10.9. Backup Calibration

The calibration utility shall provide a means to backup and restore calibration information.

2.5.10.10. Due Dates

The software shall not enforce calibration due dates, annunciate due dates, prevent the use of the stand out of calibration due date, or in otherwise handle calibration due dates.

2.5.10.11. Calibration Laptop

The contractor shall provide a calibration laptop. The system shall be compatible to use a program such as “PC Anywhere” or AT&T’s VNC to remotely control the host computer for all calibration tasks. The terminal shall have an Ethernet connection to

Page 21 V-22 PROP ROTOR INPUT QUILL GEARBOX TEST STAND the host computer. The contractor shall provide adequate Ethernet cable to reach all calibratable parameters and properly rated Ethernet outlets where required inside the test cell.

2.5.11. Data Storage/Archival

The software shall store data generated during the test sequences, either automated data stores or user store events. The software shall have capability to export the database into a human readable, plain text, ASCII spreadsheet compatible format.

2.5.11.1. Test Records

The system shall have a means of storing and archiving test records used to determine the RFI (Ready for Issue) condition of the asset being tested. Records shall be linked with current date/time, serial number, type of unit, operator name, and other relevant information.

2.5.11.2. Streaming Data

The test system shall record and store data continuously while a unit is being tested.

2.5.11.2.1. Rate

The function shall be able to record and store data at a minimum of 4Hz.

2.5.11.2.2. Duration

The record function shall record each full test. The system shall have the means of automatically determining if a test is underway and turn on and off the recording of streaming data.

2.5.11.2.3. Records Recorded

The system shall record all parameters capable of being displayed to an operator in this data stream.

2.5.12. Run Data Retention

The software shall have the capability of retaining relevant variables between runs. If the host run mode is shutdown or the host crashes while testing, the software shall “remember” the last state of variables such as run time, operator, part number, serial number, work order number, etc.

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2.5.13. Software Configurability

The software shall have the ability to be configurable without recompiling or directly modifying any programmable interpreted code. This feature of the software will be accessible to an administrator via a password protected, unique engineering / administrator login.

2.5.13.1. TPS Creation/Modification

The software shall provide means of creating new or modifying existing TPS.

2.5.13.2. Significant Digits

The number of digits displayed before or after the decimal shall be selectable. By default, all values displayed to the operator shall adhere to the rules of significant digits/figures (with the exception of calibration screens). The number of significant figures is the number of digits needed to express the number to within the uncertainty of measurement. For example, if a quantity had been measured to be 1.234 ±0.002, four figures would be significant. No more figures should be given than are allowed by the uncertainty. For example, a quantity written as 1.567±0.1 is incorrect; it should be written as 1.5±0.1. Calibration users shall see the full DAQ resolution.

2.5.13.3. Channel Names

The software shall utilize channel names in all functions to refer to physical channels. Channel name definitions shall utilize a short mnemonic name for easy reference and an associated long name for more descriptive definition of the channel. The data displays shall be able to select displaying any combination of mnemonic (shortened versions of a channel name), long name, and units along with the associated channel value. All labeling shall be consistent throughout the entire test system (including the PLC, and field labeling). When applicable, the mnemonic shall be named in accordance with the nomenclature stated in the section 2.1.

2.5.13.4. Screen Print

The software shall provide the capability to do a screen print of each displayed screen on a screen-by-screen basis. The screen print shall be scaled and rotated automatically to fit an 8.5 x 11 paper. Screen prints shall be legible when printed in black and white or when copied using a black and white copier.

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2.5.14. Data Smoothing (Time Averaging)

The software shall, as a component thereof, have an adjustable channel averaging function used for steady state test recording. The purpose of the data smoothing function is to average the natural UUT oscillations observed during a steady state running condition.

This reference to time averaging is not intended to apply to the PLC.

2.5.14.1. Selection

The software shall have a means to select channels to be included in Data Smoothing function.

2.5.14.2. Duration

The Data Smoothing function shall be selectable from at least 0-60 seconds.

2.5.14.3. Implementation

Only the administrator shall have the capability of choosing the type of average and its parameters Averaging shall be administrator selectable middle third, or regular averaging. The Data Smoothing function shall utilize a selectable “middle third” method of averaging the channel data. The data smoothing function shall utilize a selectable weighted average. The data smoothing function shall utilize a regular average with a selectable period. Only the administrator shall have the capability of choosing the type of average and its parameters.

2.5.14.4. Use

The Data Smoothing function shall be used for test recording and evaluation at steady state conditions. Critical displays and real time data functions shall not use the data generated by the smoothing function. The contractor shall provide a list of channels for proposed time averaging. Do not time average a parameter used to determine RFI (Ready for Issue) status on a tested unit unless approved by the Government.

2.5.15. Channel Tare

Individual channels shall have the ability to be designated to have a tare function applied to them. If a channel has been designated for tare, the channel shall have the ability to be “zeroed” under operator or TPS control. An example of taring is the zeroing of oil pressures to account for head pressure. This shall not affect calibration data. The Government shall approve any channels being tared.

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2.5.16. UUT Vibration Safety Display

The contractor shall display all UUT vibration measurements as broadband measurements in keeping with the vibration safety limits as specified in Table 3.

Table 3: Vibration Safety Limits

Channel Description Channel Direction Alarm (IPS)* Shutdown (IPS)*

Engine Normal North-South 2.00 2.30

Engine Lateral East-West 2.00 2.30

Engine Axial Up-Down 2.25 2.50 *IPS=Inches Per Second

2.5.17. Read I/O in all Drives

The system shall be capable of reading I/O (Tags) in all the drives. All faults in the drives shall be annunciated by the host computer as appropriate warnings/cautions. The contractor shall survey and select appropriate tags to be displayed as channels in the host computer for the purpose of troubleshooting.

2.5.18. Hour Meters

The system shall incorporate separate hour meters that track the amount of time major mechanical subsystems have been in an operational or an on state. The hour meters shall be resettable by engineering or maintenance personnel. Hour meters shall be implemented in software, with each component using a dedicated hour meter. Hour meter display shall be viewable by all system users but resettable only via Administrator or Maintenance users.

Programmable Logic Controller (PLC)

The PLC shall be used for low level system control. The PLC system shall maintain and achieve set points provided by the Host Computer, but not generate set points (except for emergency operation). The PLC is responsible for all safety interlocks and emergency operation. The PLC shall not contain programming of the actual test sequence, storage of calibration coefficients (but may load them from an external source), pass/fail values or determinations.

2.6.1. PLC Programming Languages

The contractor shall provide the one (1) copy of the programming environment used to develop the system PLC code, licensed to the government. Included with this requirement

Page 25 V-22 PROP ROTOR INPUT QUILL GEARBOX TEST STAND is any add-ons or “tool boxes” utilized in conjunction with the core software to develop the Test Application Program.

2.6.2. PLC to Remain in Control upon Subsystem Failures

In a system that uses PLC and Human Machine Interface (HMI) (including Host Computers) during machine operation, the PLC shall always be in control of all processes.

If the PLC loses communication with the HMI, the machine will fall into a safe situation, such as standby if the stand is not operating or perform a safe and orderly shutdown if the stand is operating, and the process will wait until contact is re-established before the process can resume. The PLC shall maintain safe control of the test system in the event of any other sub-system failure.

2.6.3. Feedback from System Commands

The system shall provide feedback for all system commands to ensure the commanded action occurred. (For example, if the system commands a pump on, the system must also monitor the state of the pumps operation, [i.e. pressure, current], providing feedback on its operational state). The system shall detect if a command has not occurred and issue an alarm or notification to the operator. The contractor shall provide any/all hardware required to accomplish this.

Test Stand Requirements

2.7.1. Remote I/O Cabinets/Enclosures

All new equipment shall be installed per manufacturer recommended practice. Enclosures shall be stainless steel and be NEMA rated for the environmental conditions found in the test cell.

2.7.1.1.Vibration Isolation

All new remote I/O enclosures shall be vibration isolated from the rest of the test stand.

2.7.2. Remote Display

Contractor to provide one separate remote touch screen display in an environmental enclosure.

This display will primarily be used to provide critical stand information to artisans working in the test cell but will also be used for troubleshooting stand issues and shall be located near the UUT installation location. Final location of the display shall be given in detail before or at the 80% design review. Display shall be NEMA rated for the environmental conditions found in the test cell. The display must be mounted in such a way as to be protected from

V-22 PROP ROTOR INPUT QUILL GEARBOX TEST STAND Page 26 the industrial environment of the test cell. Enclosure shall have provisions for adding a mouse and keyboard by utilizing watertight USB bulkhead fittings or similar.

2.7.3. Thermal Management, Enclosures

All I/O cabinets and other enclosures shall have the means of monitoring internal temperature. Alarms shall be implemented to prevent operation outside manufacture’s recommended temperature limits. All enclosures shall be designed to provide thermal management, ensuring all internal electronics operate within their recommended temperature envelop. Enclosures shall be selected to be compatible with installed component manufacturers’ recommendations for environmental enclosures. Cooling may be active or passive. Whenever possible, enclosures shall utilize passive environmental controls. Passive environmental control is preferable to active control, and minimal active control is preferable to more complex methods, for example: a fan-less ventilated enclosure that meets component manufacturer’s recommendations is preferred; however, if active cooling is required, adding a fan to the enclosure is preferred over adding an enclosure air conditioner. Enclosures acting as wire passthroughs only are excepted from this requirement.

2.7.4. Remote Oil Level Monitoring

The system shall monitor oil levels in all oil tanks and take appropriate action when low oil levels are detected. Tanks shall read quantity in percentage full and/or gallons, simple indicator lights are not acceptable.

2.7.5. Implement Door Safety Indicating

The test software shall monitor the state (open/closed) of all doors (personnel and equipment) allowing access to the test cell. The contractor shall provide all necessary hardware, etc.

2.7.6. Test in Progress Lights

A “Test in Progress” Light shall be installed at all interior and exterior personnel doors into the test chamber (control room to test cell door is excluded from this requirement). All Test in Progress Lighting shall be located at eye level. All Test in Progress Lighting shall automatically light when a test is being performed. Any external warning lights are to be weatherproof and clearly visible in broad daylight. Warning lights shall automatically light when a test is being performed. The signs shall be of a style similar to Signal Tech, “Test in Progress; Do Not Enter” sign, Item Number: 1844 (BLB1212R-A268).

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2.7.7. Operator Station

Contractor shall provide an operator’s station/desk to support the new test system host computer as well as the required monitors, controls, and video screens. Operator’s view out of the test cell window may only be minimally obstructed.

2.7.7.1.Operator Station Chairs

Contractor shall also provide two (2) chairs for the station.

2.7.8. Stand Safety and Emergency Operations

2.7.8.1.Emergency Stop

The contractor shall provide an emergency stop system in accordance with ISO 13850 - Safety of Machinery- Emergency Stop – Principles for Design. The emergency stop system shall be capable of being operated by system software and manually in the form of a prominent red mushroom button(s) located such that the operator can quickly activate it. Push buttons shall be located, at a minimum, in the control room, in the center of the test stand area in close proximity to the UUT, and by each personnel door allowing access to the test cell area.

2.7.8.2.Communication Monitoring (Heart-beat)

The Host Computer, PLC, and DAQ (at a minimum) shall be monitored for communication loss and unresponsiveness.