Technical_Requirement_Document_for_SSS_Redacted.pdf

Technical Requirement Document

For

Reconfiguration of the Vibration Environmental Chamber Box, Duct Work, and Support

Structure

Table of Contents

Sections Page

Section 1

Background……………………………………………………………………….. 3

Description………………………………………………………………………… 3

Objectives…………………………………………………………………………. 3

Section 2

2.1 Reconfiguration and Design Plan (CLIN 0001)………………………………… 4

2.2 Procurement of Materials (CLIN 0002)…………………………………….. 5

2.3 Transport and Delivery (CLIN 0003)………………………………………. 5

2.4 Commercial Drawings/Models (CLIN 0004)……………………………… 6

2.5 Fabrication of Parts, Ductwork, Support Structure, Transition Sections, Connectors, and Power lines (CLIN 0005)……………………………………… 6

2.6 Installation (CLIN 0006)…………………………………………………… 8

2.7 Acceptance Testing (CLIN 0007)………………………………………….. 8

Section 3

Definitions & Acronyms…………………………………………………………. 9

Appendixes

Appendix A ……………………………………………………………………….. 10

Appendix B ……………………………………………………………………….. 11

Appendix C ……………………………………………………………………….. 12

Section 1

1.1 Background: West Desert Test Center (WDTC) Has procured a new 3-inch displacement multi-shaker vibration system that can be coupled together and used as one system in both the vertical or horizontal positions or it can be separated and used as two different systems in both the vertical and horizontal positions. An environmental chamber box (ECB) is required to be placed around the test items during vibration testing in both vertical and horizontal positions and in both configurations (coupled together or separated). The ECB will need to be reconfigured to support the new vibration system in two different positions.

i.e. lift and right single separated vibration systems in the vertical position. A new ECB will need to be designed and fabricated for the horizontal positions both lift and right horizontal positions.

1.2 Description: WDTC has a 2-inch displacement vibration system that can be operated in both the vertical and horizontal positions. When this vibration system is operated an ECB is placed over the test item and the ECB is connected to an environmental conditioning system, which provides hot, cold, and humidity conditions as required, to the ECB. The connection is made with 18–inch diameter ductwork with 4-inchs of foam insulation between the inside and outside metal ductwork. The sections of insulated ductwork are connected from the main ductwork to the ECB by way of transitioning ductwork that is constructed of the type of material as the main ductwork. The floor of the ECB can be configured to fit around the vibration head expander, when in the vertical position, with no more than a 1 to 1 ½ inch gap between the opining in the ECB floor and the head expander.

This configuration provides 2 –inch of free movement of the vibration head expander in the vertical direction. The ECB can be reconfigured to provide the same type of coverage in the horizontal position. This accomplished by removing a section of the flooring of the ECB and replacing it with a differently configured floor section. However, the gap between the front and back of the slip table and the floor of the ECB is about 2 to 2 ½ inch to allow for the 2-inch displacement movement of the slip table. A different insulated transition ductwork is all so required for this configuration. The ECB is supported with a network of scaffolding that can be configured to support the ECB in the vertical or horizontal position. However, this 2-inch displacement vibration system is being replaced with a new Multi-Shaker 3-inch displacement vibration system that is comprised of two separate vibration systems that can be operated separately or coupled together to function as one larger vibration system. The ECB that is used on the old vibration system will be reconfigured to operate with the new Multi-Shaker vibration system. The new vibration system will be located on a different reaction mass located in the same building as the old vibration system that the ECB is now operated on.

1.3 Objective: The objective of this document is to provide the specification, basic layouts, and requirements for the reconfiguration of the old ECB floor to function in the vertical position, design a new ECB unit to function in the horizontal position, ductwork, and support structure to work with the new vibration system. It is all so the objective to utilize the same installed environmental conditioning system and ductwork that is used to connect the environmental conditioning unit to the main transitioning connection point located in building 3133. It is all so an objective to ensure that the same air flow is provided to both ECB units using the old environmental conditioning system.

Section 2

2.1 Reconfiguration and Design Plan (CLIN 0001)

2.1.1 The contractor shall develop and provide a plan for the reconfiguration of the old ECB floor inserts to work with the new vibration system in the vertical positions only, design and fabrication of a new ECB unit to work with the new vibration system in the horizontal positions only, ductwork, and support structure for both ECB units. The system shall provide environmental control to the vertical ECB (VECB) and the horizontal ECB (HECB) units when positioned in the two (2) different positions of the multi-shaker vibration system, and provide the required clearance for vibration operation and environmental conditions.

2.1.1.1 The contractor’s developed design plan shall provide for the reconfiguration of the old ECB unit that will provide a clearance of no more than 2 to 2 ½ -inches on each side of the head expander when the vibration system is in the vertical position. The reconfigured floor insert for the old ECB shall be made to work with the new vibration system in the single shaker configuration when in the vertical positions only. The contractor shall design and fabricate a new ECB unit to work with the new vibration system and the old conditioning system in the horizontal positions only.

2.1.1.2 The contractor’s developed design plan shall provide for connecting the main feeder ductwork which provides environmental control to both the ECB units to the new location and the two (2) different positions that the VECB and HECB could be located during operation of the multi-shaker vibration system. The plan shall also provide how the transitioning section shell be connected to both ECB units in each of the different positions.

The plan shall also provide for the return air from both ECB units back to the conditioning unit and to connect into the main air return ductwork.

2.1.1.3 The contractor’s developed design plan shall provide for the structural support required to support both ECB units in the different positions and the ECB’s weight. The estimated weight of the old ECB is about 8000 pounds. The estimated weight of the new HECB is unknown at this time. However, based on the area and configuration of the new vibration system requires the HECB to be smaller in size and construction to the old ECB the weight could be estimated to be somewhat less than the old ECB unit.

2.1.1.4 The contractor’s developed design plan shall provide the design and construction of an HECB unit for the horizontal positions for single shaker configuration.

The HECB unit shall be connected to the air supply and return air supply system that is used for the VECB unit that is used in the vertical position.

2.1.1.5 The HECB unit shall be constructed of the same type of materials and basic construction and as close to the same size as possible as that of the old ECB unit. The HECB unit shall have doors the same as on the old ECB unit used for the vertical positions, but will be located on the front end of the HECB. The HECB shall have the same clearance from the slip table as the old ECB has on the head expander.

2.1.1.6 In order to ensure that all aspects and requirement are fully understood by the vendor an onsite visit shall be conducted.

2.1.1.7 The contractor shall develop a system that will provide and average air flow of 2100 ft per min. across the face of the ductwork where it is connected to the two (2) different ECB units.

NOTE: None of the ductwork, floor inserts, or support structure cannot interfere with the operation of the multi-shaker vibration system and any of the different positions.

2.2 Procurement of Materials (CLIN 0002)

2.2.1 The contractor shall provide an inventory list of all materials required to perform fabrication, design of the VECB, required ductwork, transitions section, louvers, hangers, support structure, insulation, sheet metal, bolts, nuts, and all other materials required.

2.2.2 The contractor shall procure all materials required to reconfigure, design, fabricate, test and install all parts and equipment required to meet the requirements of this Technical Requirements Document (TRD).

2.2.3 The contractor shall schedule with the government point of contact (POC) upon procurement of the required materials for inspection and inventory of the listed material before invoicing the government.

2.2.4 The contractor shall provide the required CO2 line, electrical line and quick disconnect connections for each line to be run to the new location for both ECB units. The new lines shall be of sufficient length to be connected to the VECB or HECB in any of the positions without interfering with vibration operations.

2.3 Transport and Delivery (CLIN 0003)

2.3.1 The contractor shall transport all completed ductwork, structural supports, VECB floor sections, HECB unit, transition sections, materials, tools, and equipment required to comply with the requirements of this document.

2.3.2 If the contractor requires the old ECB unit to be located at his/her facility for work to be done, the contractor must provide transportation from DPG to his/her facility and back to DPG. The contractor shall provide the required transportation of the HECB unit to DPG.

2.4 Commercial Drawings/Models (CLIN 0004)

2.4.1 The contractor shall provide two (2) hard copies and one copy on CD or DVD of comprehensive Operation and Maintenance manuals including available sub-contractor manuals for each system for Commercial Off-The-Shelf (COTS) Manuals and associated Supplemental Data. These manuals shall incorporate:

a. A comprehensive technical overview of each sub-system i.e. blowers, electrical connections, air flow system and any other system used in the as built design and fabrication of the vibration chamber floor opening, HECB unit, ductwork and support structure.

b. Step by step instructions for setting up, operating, and placement and connection when the chamber is placed in each of the six different locations and the operation of any sub systems.

2.4.2 The contractor shall provide two (2) hard copies and one copy on CD or DVD of comprehensive as built drawings and wiring diagrams sufficient for setting up the systems, understanding the functions of each component, and performing basic trouble shooting operations for each sub-system, and Commercial Drawings Models and Associated parts list.

2.4.3 The contract shall identify all safety features and safety precautions relevant to maintaining and operating each sub-system safely and provide one hard copy and one copy on CD or DVD.

2.5 Fabrication of Parts, Ductwork, Support Structure, Transition Sections, Connectors, and Power lines (CLIN 0005)

2.5.1 Ductwork – The contractor shall fabricate or procure the required ductwork, and materials required to provide all parts required to comply with the requirements of the

TRD, and the installation of the required ductwork, support structure, transition sections, floor inserts, connectors, and power lines.

a. The inside of all the ductwork shall be constructed of 18 gage steel solid constructions.

b. All ductwork shall have 4-inches of foam insulation between the steel inner layer and the outer layer shall be 18 gage sheet metal painted.

c. The inside diameter of the supply air and return air ductwork shall be the size required to provide the required air flow.

d. The outer layer of the ductwork shall be sealed so that water does not degrade the insulation and it shall be primed and painted with high grade gloss white paint with UV protection.

e. The ductwork shall provide an average air flow of 2100 ft/min. across the face of the ductwork where it is connected to the VECB and/or the HECB unit.

2.5.2 Support Structure

a. The support structure shall be secured to the floor and will be modular in construction and of steel beams having the capacity to support the VECB or the HECB in a stable position during vibration testing.

b. The support structure shall be able to be reconfigured to support the VECB unit or the HECB in any of the different positions as required.

c. The support structure shall be able to support a maximum of 15,000 pounds in any of the positions.

d. All support structure parts shall be primed and painted with high grade gloss white paint.

e. The support structure shall have locking pins that will secure the VECB or HECB unit in to place when mounted to the support structure in any of the positions.

2.5.3 Transition Sections

a. Each transition section shall be constructed the same as the main ductwork in accordance with (IAW) paragraphs 2.5.1 a through c of the TRD.

b. Each transition section shall be constructed with quick disconnects for attaching the transition section to the both ECB units and the main ductwork system. The connection shall not have air leakage around the area where the transition section joins the main ductwork or the ECB units.

c. Each transition section shall be equipped with lifting eyes so that each section may be raised and placed into position with overhead crane.

2.5.4 Connectors, and Power lines

a. Both ECB units are to be connected to an electrical power line, CO2 line, and data lines that provides power to the ECB units for lights and data lines used for data collection, and CO2 line for conditioning during vibration testing. The contractor shall disconnect the power line, CO2 line, and data lines form the old ECB unit and install quick disconnect connections for each of the identified lines for both ECB units.

b. The contractor shall provide the same quick disconnect connections for each of the identified lines, in paragraph 2.5.4.a above, to both ECB units.

2.5.5 Floor inserts - The contractor shall fabricate the required VECB floor inserts required to provide the required clearance of the single head expander in the vertical positions, with VECB connected to the ductwork Air feed duct and return air duct. The same requirement shall be required for the HECB unit with the slip table system.

2.6 Installation (CLIN 0006)

2.6.1 The contractor shall provide and install the supply air and return air ductwork with hangers as required to safely support the ductwork.

2.6.2 The contractor shall install the ductwork so that it doesn’t interfere with the operation of the overhead crane.

2.6.3 The contractor shall install the required electrical lines, CO2 lines, and data lines as required to support both ECB units in any of the required positions.

2.6.4 The contractor shall install the required support structure as required.

2.6.5 The contractor shall provide and install louvers as required to control and direct air flow to both ECB units as required.

2.7 Acceptance Testing (CLIN 0007)

2.7.1 The contractor shall operate the environmental conditioning system with the VECB and HECB units installed in both vertical and horizontal position for 5 hours in the high temperature of 160oF.

2.7.2 The contractor shall operator the environmental conditioning system and CO2 system with the VECB and the HECB units installed in both vertical and horizontal position for 5 hours in the low temperature of -60oF.

2.7.3 The contractor shall collect the air flow data to the both ECB units during each test run and provide the data to the end user.

2.7.4 All testing will be observed by the government POC and the end user of both ECB units.

Section 3

Definitions & Acronyms

COTS - Commercial Off-The-Shelf

DPG - Dugway Proving Ground

ECB - Environmental Conditioning Box

HECB - Horizontal Environmental Chamber Box

IAW - In Accordance With

POC - Point Of Contact

TRD - Technical Requirements Document

VECB - Vertical Environmental Chamber Box

WDTC - West Desert Test Center

APPENDIX A

APPENDIX B

APPENDIX C