Att2-BSDC-Spec-ATC.pdf

DISTRIBUTION LIST STATEMENT D:

Limited to DoD and DoD contractors only.

Performance Specification

For

Sand and Dust Environmental Test Chamber for the Aberdeen Test Center (ATC)

U.S. Army Program Executive Office for

Simulation, Training and Instrumentation

12350 Research Parkway

Orlando, FL 32826-3276

Version 1.1

18 May 2017

Prepared By: ________________________ Concurrence: ________________________

MITCHELL PRIMAS DEREK VICK

IMO Systems Engineer IMO Chief Engineer

Date: _______________

Prepared By: ________________________

GLENN DAENS

IMO Lead Acquisition Logistician

DaensG Typewritten Text 25 May 2017 derek.s.vick Typewritten Text 30 May 2017

PrimasM Typewritten Text 25 May 2017

PrimasM Typewritten Text

PrimasM Typewritten Text

Sand and Dust for ATC PRF-PT-689

Revision Number

Date Log of Changes Made and Description of

Reason Changes Approved By

0.1 20 April 17 Initial Draft

1.0 25 April 17 Final for review

1.1 18 May 17 Revised to remove Contractor responsibility for concrete pad and site preparation

Table of Contents

1. SCOPE

1.1 Background

2. APPLICABLE DOCUMENTS

3. REQUIREMENTS

3.1 Performance Requirements

3.1.1 Operating Environment

3.1.2 Compatibility with Ammunition and Explosives

3.1.3 Modular Construction

3.1.4 Test Cell Characteristics

3.1.5 Temperature

3.1.6 Humidity

3.1.7 Air Velocity

3.1.8 Dust Concentration

3.1.9 BSDC Controls

3.1.10 Interlocks

3.1.11 Instrumentation

3.1.12 Power

3.1.13 Refrigeration System

3.1.14 Heating System

3.1.15 Circulating Air Blower/Fan

3.1.16 Sound Attenuation

3.1.17 Pollution Control

List of Tables

Table 3.1.8.a Sand Concentration Level

Performance Specification

For

Sand and Dust Environmental Test Center for the Aberdeen Test Center (ATC)

1. SCOPE.

This Performance Specification describes the technical requirements for a Blowing Sand and Dust Chamber (BSDC) for the Aberdeen Test Center (ATC). The BSDC is composed of an insulated test chamber, control system, Industrial Hygiene system (self-cleaning), data collecting system, control system, and other equipment necessary to control and maintain the desired chamber conditions. The chamber shall have the capability to perform MIL-STD-810G, CN1, Method 510.6 Procedures I and II with control of the chamber temperature, humidity, dust and sand concentration and air velocity. The configuration of the chamber and equipment compartment shall satisfy the given specifications, and the equipment shall meet the standards of performance and quality as specified. The environmental test chamber described below shall perform tests in accordance with MIL-STD-810G, “Environmental Engineering Considerations and Laboratory Tests”, Method 510.6, Procedure I (Dust) and Procedure II (Sand).

1.1 Background.

The U.S. Army Program Executive Office for Simulation, Training and Instrumentation, Project Manager for Instrumentation, Targets and Threat Simulators and SOF Training Systems (PM ITTS), Instrumentation Management Office (IMO) provides test instrumentation to the test and evaluation community, and is the materiel developer for the BSDC as part of the Applied Environments Modernization (AEM) project.

2. APPLICABLE DOCUMENTS.

MIL-STD-810G, CN1 “Environmental Engineering Considerations and Laboratory Tests”, Method 510.6, Procedure I (Dust) and Procedure II (Sand).

3. REQUIREMENTS

3.1 Performance Requirements.

The BSDC shall consist of one chamber that will provide a blowing dust and sand test capability. The BSDC shall contain an insulated test cell, control system, Industrial

Hygiene system (self-cleaning), data collecting system, and other equipment necessary to control and maintain the desired chamber conditions. Users shall be able to control the chamber temperature, humidity, sand and dust particle concentration, and air velocity. The configuration of the chamber and equipment compartment shall meet the standards of performance and quality as specified.

a. The BSDC shall provide the capability to perform tests in accordance with MIL- STD-810G, CN1 “Environmental Engineering Considerations and Laboratory Tests”, Method 510.6, Procedure I – Blowing Dust and Procedure II Blowing Sand upon delivery and installation.

b. After initial set points are defined and entered into the BSDC controller and particle media is loaded, the BSDC shall be able to operate without intervention for a minimum 90 minutes during sand testing and six hours during dust testing. The only exception to this will be for the addition of particle media to ensure proper particle concentration during test. The BSDC shall display particle concentration on the Control and Display Unit.

c. In addition to meeting the MIL-STD-810G, CN1 test profile requirements, the

BSDC shall be required to meet the requirements in the following paragraphs.

3.1.1 Operating Environment

a. The BSDC shall be located and operated in unconditioned spaces (limited heat and no air-conditioning) with ambient temperature above freezing to 46.1oC.

b. Design and construction of the BSDC shall provide the equipment and thermal insulation needed for maintaining the test environment defined in MIL-STD

810G, CN1.

c. The exterior finish shall be suitable to withstand an industrial laboratory environment and impervious to fluids such as cleaning solutions, hydraulic fluids, and synthetic oils.

d. Material types and grades shall provide a 25-year minimum equipment life expectancy.

e. Insulation shall be used on cold piping to reduce condensation and guard(s) shall be used to prevent hot piping from unintentional touches from personnel.

3.1.2 Compatibility with Ammunition and Explosives

a. Safety hazard classification for chamber: Compliance with NEC and NEMA Regulations. Chamber interior wiring is to meet Class 1, Group C, D, Division 2 and Class 2, Group E, F, G, Division 2 requirements. One explosion proof light shall be placed inside the test chamber to provide lighting. Lighting shall be located in the chamber upper rear corner out of the main workspace area.

Sheathed temperature-limited heaters shall be used in the heating system.

Non-sparking fans shall be used.

b. A high security hasp NSN 5340-01-196-2547 shall be welded to the test compartment door so that the test compartment can be locked.

3.1.3 Modular Construction

a. The BSDC shall be of modular construction facilitating offsite construction and testing, transport, and reassembly on-site with a minimum of field connections needing to be made. The design shall consider the possibility of relocating the BSDC after the initial installation.

b. The BSDC shall be designed to facilitate repair, replacement, and troubleshooting of system components. For example, replacement of fans, compressors, thermocouples, etc. shall not require disassembly of modules for access.

c. Access doors and hatches shall be used where appropriate.

d. The main footprint of the BSDC shall require an area of approximately 9 meters by 9 meters. The height of the BSDC shall be 6 meters or lower. Additional areas may be allocated to sub components of the BSDC (air compressor, chiller, dust hopper, etc.) that support the main body. The Contractor shall be responsible for conducting a pre-design site visit to determine additional space requirements.

3.1.4 Test Cell Characteristics.

The BSDC shall provide the capability to perform tests in accordance with MIL-STD- 810G, CN1 “Environmental Engineering Considerations and Laboratory Tests”, Method 510.6, Procedure I – Blowing Dust and Procedure II – Blowing Sand upon delivery and installation. The temperature, humidity, air velocity, particle media, and particle concentration level requirements of MIL-STD-810G, CN1 shall be uniform across the front face of the 1.9 meters by 1.9 meters cross sectional area perpendicular to the flow of air as defined below.

a. The size of the chamber’s test cell shall be at a minimum 2.5 meters by 1.9 meters by 1.9 meters (depth by height by width).

b. The cross sectional area that will be perpendicular to the flow of air shall be 1.9 meters by 1.9 meters (height by width).

c. The test cell shall have continuous welded seams so that moisture, oil, or other fluids cannot seep into the insulation.

d. The test compartment floor shall support a minimum 907-kilogram test load on a rotating test table.

1) The test table shall be controlled during operation of the BSDC using controls that are positioned outside the test compartment without opening the door to enter the chamber.

2) The test table shall allow for mounting of a fixture plate and shall be grounded.

e. The BSDC main door shall open to allow complete access into the chamber’s test cell volume.

1) The door shall include a two foot wide by two foot high viewing window into the chamber, the center of which will be located approximately 1.6 meters above ground level. The window shall be equal distance from the sides of the test cell.

2) A cleaning mechanism shall be provided to remove sand and dust from the inside surface of the viewing window.

3) A seal on the door shall prevent the escape of particle material from the chamber during operation.

4) The door shall be electrically grounded to the chamber.

5) A 27.9 cm x 10.1 cm x 0.6 cm (h x w x d) thick plate will allow it to be welded to the security hasp onto the chamber.

f. The test cell shall have interior lighting.

1) The lights shall be positioned to provide uniform light distribution inside the test cell.

2) The lights shall not protrude into the usable interior space of the test cell.

3) The lights shall be controlled by a manual switch located on the control display unit.

4) Lighting shall be spark/explosion proof.

5) Lighting shall be located out of main workspace area.

g. The BSDC test cell shall include three instrumentation ports, each four inches in diameter, on both sides of the cell, and one directly above the center of the test table.

1) The access ports shall be supplied with removable covers on the outside of the environmental chamber that will seal the test cell during operation.

2) Access ports shall not extend into the usable space on the interior of the test cell.

3) The side ports will be six inches above the finished floor height of the test cell interior.

3.1.5 Temperature.

The BSDC shall be capable of controlling and maintaining a test compartment operating temperature range from 15.6oC up to 82.2oC during operation with a 227 kilograms steel thermal load.

a. Temperature change rate shall be controllable to 2.8°C /minute or less per MIL-

STD 810G requirements.

b. Chamber temperature shall have a tolerance of +/- 2 oC across the entire operating range.

c. Recovery time: The BSDC shall transition from 22.8°C up to 82.2°C and 82.2°C down to 22.8°C at a minimum rate capability of 1.1°C per minute as a measure of average ambient air temperature change rate at control thermocouple with 227 kilograms, steel thermal load at an air velocity of 1.5 m/s (+/- 1.0 m/s).

3.1.6 Humidity.

The BSDC shall be capable of controlling and maintaining the humidity level inside the test compartment to less than 30% relative humidity throughout all other environmental conditions specified.

a. A direct readout sensor (not a dry/wet bulb) shall be used to measure humidity.

b. The sensor shall operate over the required temperature range for humidity control and shall not be degraded or damaged over the operating temperature of the chamber.

3.1.7 Air Velocity.

The BSDC shall have variable control over the air velocity in the test compartment.

a. The chamber shall be designed to provide a uniform airflow though the cross section of the test cell.

b. The Contractor shall demonstrate airflow uniformity is within 10% throughout the cross section.

c. During sand testing, air velocity shall be variable between 40 mph (18 m/s) and a minimum of 65 mph (29 m/s). During dust testing, air velocity shall be variable between zero and a minimum of 1750 ft/min (8.9 m/s).

d. The air velocity tolerance shall be maintained at +/- 10% of the specified value under steady state conditions (after the set-point air velocity attained with no control changes).

e. The chamber shall be able to ramp and hold the air velocity steady between minimum and maximum test air velocities within two (2) minutes.

3.1.8 Dust Concentration.

The BSDC shall deliver sand and dust particles to test items positioned in the test cell.

a. Sand composition is defined in MIL-STD-810G, Test Method 510.6. The BSDC shall be equipped with controls to adjust the sand concentration from a minimum of 0.18 g/m3 to a maximum of at least 2.20 g/m3. The chamber controls shall be able to maintain the set-point concentration level to the tolerance shown in the table below.

Table 3.1.8.a Sand Concentration Level

Set Point Range Tolerance

0.18 – 0.80 g/m3 - 0.00 / + 0.20 g/m3

0.81 – 1.80 g/m3 + 0.30 g/m3

1.81 – 2.20 g/m3 + 0.50 g/m3

b. Dust composition is defined in MIL-STD-810G, CN1, Test Method 510.6. The

BSDC shall be equipped with controls to adjust the dust concentration from a minimum of 2 g/m3 to a maximum of at least 25 g/m3. The chamber controls shall be able to maintain the set-point concentration level to within + 1.0 g/m3 when the typical 10.6 g/m3 of dust is used for the set point.

c. The chamber shall not take longer than five (5) minutes to adjust and hold at any concentration level throughout the operating range.

d. The system shall utilize gravimetric metering of sand and dust to establish test concentrations rather than direct reading of concentration via a sensor.

e. Recycling of sand and dust material shall be utilized to maintain test concentrations within the test cell while limiting the total amount of dust stored to perform complete, uninterrupted testing. If necessary, the particle media feeding hopper shall be safe for personnel to reload during test operations without additional protective clothing and equipment.

f. The BSDC shall be fully compatible with various sand and dust compositions as defined in in MIL-STD-810G, CN1. The BSDC shall be tested and delivered with the sufficient sand and dust to demonstrate and support full chamber operations.

3.1.9 BSDC Controls.

The BSDC shall provide a discrete package for controlling chamber operation and displaying set-point and all environmental parameters.

a. The control display unit shall control all operations of the chamber as defined in this document.

b. The control and display unit shall have the means to manually enable/disable the following functions: control power, dust/sand feed, circulator fan, light, heaters, cooling system, and dehumidifier.

c. A visual indication shall be provided for the status of each function.

d. The BSDC shall be designed to minimize the loss of data due to an interruption of BSDC operation (e.g., emergency stoppage, interlock stoppage, manual shut down, malfunction, power outage).

e. The chamber shall utilize a system to digitally record, store, and locally display the following data: system faults status (e.g., emergency stoppage, interlock status, temperature safeties, equipment safeties, etc.), temperature, humidity, particle concentration, material feed rate and air velocity to be plotted against time and inserted into reports or other documents as required. It is desired but not required that the same information be available for recording, storage, and display through a remote computer connection.

f. The data shall be available for output to a file that can be downloaded from the control unit in comma separated values (CSV) format.

3.1.10 Interlocks

a. An independent controlled high heat limit interlock shall be provided to prevent over temperature of the BSDC or damage to heating elements.

b. An interlock shall be provided to prevent operation of the BSDC when the fan is not operating.

c. A material feed interlock shall stop the conveyor in the event of a jam.

d. The chamber shall include a safety interlock capability to prevent start up while maintenance is being performed.

e. The chamber shall include a minimum of three emergency stops including one at the control panel, and the others located at equidistant extremes from the control panel. The emergency stop will completely shut down the BSDC and de-energize the system. The emergency stops shall be protected from accidental activation.

f. The main door shall have an integrated safety switch that disables all chamber systems if opened during operation.

3.1.11 Instrumentation.

The BSDC shall measure and control the temperature, humidity, air velocity, and particle concentration levels.

a. Particle concentration, temperature, humidity and air velocity monitoring instrumentation shall be provided, and the measured values shall be displayed and available for output.

b. All instrumentation installed on the chambers must be able to be calibrated with

NIST traceable instruments.

c. Particle concentration instrumentation and calibration methods must be verifiable to a reference standard that satisfies MIL-STD-810G, CN1 testing tolerances and accuracies.

d. The display shall have the capability to switch between Imperial and metric units.

3.1.12 Power.

The BSDC shall operate on 240 VAC, three-phase, 60 Hz power.

a. A main power disconnect with an externally accessible switch shall be provided on the machinery cabinet.

b. A terminal block shall be provided to connect the supplied power cable.

c. The electric power terminals shall be clearly marked.

d. The electrical power cabinet shall be accessible from above for the main power connections conduit.

e. All wiring used in the BSDC shall meet NEC standards.

f. The BSDC shall not be damaged by application of electric power with reverse phase rotation.

g. The BSDC shall not be damaged with one or two phases of the three-phase AC power missing (Blown Fuses).

h. All BSDC systems shall shut down and not attempt to restart in the event of an AC power interruption or abnormal AC power (blown fuse on one or more phases).

i. A manual reset shall be required to restart the system.

j. All circuits in the BSDC including the control and display unit shall be protected with circuit breakers or fuses.

3.1.13 Refrigeration System.

The chamber shall use mechanical refrigeration system(s).

a. All pressure vessels shall be ASME certified.

b. The refrigeration system shall be air cooled or standalone water cooled and operated from the same 240 VAC, 3-phase, 60 Hz power as the rest of the system.

c. The refrigeration systems shall have protection for high and low pressure, low oil pressure, and high discharge temperature.

d. A pressure relief valve shall be provided for the refrigeration system(s).

e. An enunciation light shall indicate refrigeration trips with a reset button for re-setting the tripped safety.

f. The refrigerants used shall be in accordance with the US Environmental

Protection Agency’s Significant New Alternatives Program for Refrigeration and Air Conditioning. Refrigerants shall meet the most recent requirements regarding Global Warming Potential. Chlorofluorocarbons shall not be used.

g. Refrigerants types shall be marked on the nameplate of the compressor and refrigeration charge information shall be marked on the machinery cabinet.

h. All gauges and sight glasses shall be provided for maintenance of the refrigeration system and clearly visible.

3.1.14 Heating System.

The heating capacity shall be sufficient to maintain the required test conditions.

a. The system’s heating equipment shall be powered by 240 VAC, 3 phase, 60 Hz.

b. Electrically operated sheathed temperature-limited heaters shall be used with an independent heater sheath temperature cut-off device with a manual reset, which is independent from all other safeties.

c. A visual indication that an over-temperature condition has occurred shall be provided on the device, or provided and labeled on the main control panel.

3.1.15 Circulating Air Blower/Fan.

The BSDC shall have an internal blower or fan to circulate air within the test cell.

a. The blower/fan motor shall be located external to the test cell.

b. The blower/fan shall circulate air to maintain uniform temperature, humidity, air velocity and particle density within the test cell as defined above.

3.1.16 Sound Attenuation.

The steady state noise levels emitted from the BSDC shall be less than 80 dB. This limit pertains to all operations and functionality.

3.1.17 Pollution Control.

The BSDC shall have an industrial hygiene pollution control capability that automatically activates during operation. The BSDC shall have the capability to redirect the captured particles to a sealed storage container. The chamber shall have a vacuum port with a 50-foot hose and attachments for general housekeeping.