Att3-BSDC-Spec-YTC.pdf

DISTRIBUTION LIST STATEMENT D:

Limited to DoD and DoD contractors only.

Performance Specification

For

Sand and Dust Environmental Test Chamber for the Yuma Test Center (YTC)

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

Sand and Dust for YTC

PRF-PT-693

Revision Number

Date Log of Changes Made and Description of

Reason Changes Approved By

1.0 16 May 17 Initial Draft

1.1 18 May 17 Remove site utility upgrades and pad

Table of Contents

1. SCOPE

1.1 Background

2. APPLICABLE DOCUMENTS

3. REQUIREMENTS

3.1 System 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 Air Circulation Equipment

3.1.16 Site Preparation

List of Tables

Table 3.1.8.a Sand Concentration Level

Performance Specification

For

Sand and Dust Environmental Test Center for the Yuma Test Center (YTC)

1. SCOPE.

This Performance Specification describes the technical requirements for a Blowing Sand and Dust Chamber (BSDC) for the Yuma Test Center (YTC). The BSDC is comprised 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 BSDC 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 will be constructed for the purpose of performing blowing dust and sand testing. The chamber shall be required to 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, Instrumentation Management Office (PM ITTS, IMO) provides test instrumentation to the test and evaluation community, and is the materiel developer for Sand and Dust Environmental Test Chamber Modernization at ATC.

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 System Performance Requirements.

The Sand and Dust chamber solution shall consist of one chamber that will provide a blowing dust and sand test capability. The Test Chamber 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 satisfy the given specifications, and the equipment 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 and provide the appropriate test conditions for a minimum of six and one-half hours.

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

BSDC shall meet requirements in the following paragraphs.

3.1.1 Operating Environment

a. The YTC chamber installation site is an outdoor yard. The delivered equipment shall be designed and manufactured to meet all requirements in this document while the equipment is exposed to outdoor conditions, including but not limited to rain, wind, solar effects, temperature and dust, regardless of the time of year.

YTC has a subtropical desert environment, with Koppen climate classification:

BWh.

b. Configuration 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. All exterior surfaces of the equipment shall be primed and painted with exterior grade white paint suitable for the respective surfaces, and which shall be impervious to effects of fluids such as cleaning solutions, hydraulic fluids, or synthetic oils. Surfaces that are normally not painted, such as aluminum condenser fan enclosures, are excluded from this requirement.

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 guards shall be used to prevent hot piping from unintentional touches from personnel.

3.1.2 Compatibility with Ammunition and Explosives

a. The BSDC shall meet the requirements of the Department of the Army Pamphlet 385-64 Safety, Ammunition and Explosives Safety Standards, Chapter 17 Electrical Hazards and Protection.

b. 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 installed 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.

c. 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 constructed on modular, skid mounted structures allowing for 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. It 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 assembled height of the BSDC shall not exceed 20 feet. The footprint shall not exceed the dimensions of the concrete pad that supports it.

e. The BSDC modules shall be placed on a level concrete surface of sufficient size and thickness to support the entire system.

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. All required conditions shall be met in the test cell.

a. The size of the chamber’s test cell shall be eight feet by six feet by six feet (depth by height by width).

b. The cross sectional area perpendicular to the flow of air shall be six feet by six feet (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 1000-pound 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.

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

3) User defined settings and recipe parameters shall include rotation angle for tests where the table will not continuously rotate, and rotation rate for when the test item will be continuously rotated during the test.

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, located approximately no more than five feet above ground level.

2) A cleaning mechanism shall be provided to remove particulates from the inside surface of the viewing window to provide visual monitoring of test items.

3) The door seal shall prevent escape of particle materials from the chamber when the door is closed.

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

5) An 11” x 4” x ¼” thick plate shall support welding the security hasp onto the chamber.

f. The test compartment shall have interior lighting.

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

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

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 chamber, and one instrumentation port 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 to seal the test compartment during operation.

2) Access ports shall not extend into the usable space on the interior of the environmental chamber.

3) The side ports shall 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 60oF up to 180oF during operation with a 500-pound steel thermal load.

a. Temperature change rate shall be controllable to 5 oF per minute or less, per

MIL-STD 810G requirements.

b. Chamber temperature shall have a tolerance of +/- 3.6 oF across the entire operating range.

c. The BSDC shall be able to transition from 73°F up to 180°F and 180°F down to

73°F at a minimum rate capability of 2°F per minute as a measure of average ambient air temperature change rate at the control thermocouple with a 500-pound 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 10% relative humidity.

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 provide a uniform airflow though the cross section of the test cell.

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

c. The velocity shall be variable between zero and a minimum of 3,520 ft/min

(17.9 m/s).

d. The test 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 must be able to maintain the set-point concentration level to the tolerance shown in Table 3.1.8a.

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 10.6 g/m3 of dust is used for the set point.

c. The chamber shall provide a uniform sand and dust concentration throughout the cross section of the test cell.

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

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

f. 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.

g. 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 a quantity of sand and dust needed to demonstrate and support full chamber operations.

3.1.9 BSDC Controls.

The BSDC shall include 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. In addition to local operation, the control display unit shall accept remote computer entered commands for operations.

e. The system shall be designed such that no data is lost due to test interruptions

(e.g., Emergency-Stop, Manual Shut Down, Malfunction, Power Outage and ‘make up’ time) to minimize the loss of data.

f. 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. The data records shall be plotted against time and suitable for insertion 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.

g. The data shall also be available for output to a downloadable file 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-Stop buttons, with one at the control panel and the others located at equidistant extremes from the control panel.

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 shall be verifiable to a reference standard that satisfies MIL-STD-810G, CN1 testing tolerances and accuracies.

d. The BSDC shall use Fahrenheit scale for default temperature display.

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 shutdown and not attempt to restart in the event of an

AC power interruption or abnormal AC power (e.g. 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 systems.

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 U.S. 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. Gauges and sight glasses shall be provided for maintenance of the refrigeration system and be clearly visible.

3.1.14 Heating System.

The heating capacity shall be sufficient to maintain the required test conditions, and shall be controlled by a silicon control rectifier (SCR) rather than contactors.

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

b. The electric heating elements shall be explosion proof rated.

c. Heater Sheath Temperature Safety to comply with explosive safety regulations shall be an independent heater sheath temperature cut-off device with a manual reset, which is independent from all other safeties.

d. 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.

e. Humidity Control shall consist of a Desiccant Wheel or equivalent as necessary to control humidity.

3.1.15 Air Circulation Equipment

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

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

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 Site Preparation

The Government is responsible for installation of the concrete pad and site power modifications to support operation of the BSDC. The Contractor shall provide engineering drawings and obtain YPG Department of Public Works approval prior to installation of the equipment.