Questions and Answers (1-4).docx

Questions and Answers

Q: On page 4, Section A. a/b. gives information on the current Yates and SATEC actuators. Are you able to provide more detailed information since we are providing new hoses?

1. What is the size and type of fittings on the pressure, return and drain ports of these 3 actuators?

A: The actuator connections are quick connect connections. The connectors are Parker 6602-12-12 for the actuator input and return. Rated flow is 28 GPM.

Q: On page 5, section C.c. states that the contractor is responsible for "training on the use of the hydraulic testing system to Government employees no later than September, 30th, 2020."

1. Since “we” would not be supplying a new controller or test software (RFQ references an Instron 8800 controller) is it expected that our service engineer provide training only on the use of “our” Hydraulic Power Unit? Or should we also train on the use of the Instron software if possible?

A: Training will be for Hydraulic Power Unit, new manifold, and its integration to the controller.

Q: On page 5, section B.b. states that the Hydarulic Power Unit (HPU) can be installed either on ground level or in the basement.

1. Is there really no preference by as to which option we should quote? Should we offer both in our proposal?

A: Basement option is preferred, but both options are being reviewed as the basement option requires re-routing of water that would be done by our local facility staff. If there is a price difference for the 2 options, please include 2 separate prices.

1. If installing in the basement, is it preferable to have hydraulic hardline installed to route the flow from the pump upstairs? Or should we continue with flexible hydraulic hoses as previously discussed?

A: Hardline would be preferred, but either option would be acceptable, given the solution can pump the hydraulic fluid through the 2 ¾” holes in the structural load floor.

Q: Is it acceptable if our HPU operates independently from the Inston controller? We have a built-in control station on the HPU that allows the user to turn on/off.

A: The current Instron controller is functional, so would be preferred. However, the vendor is welcome to suggest, as an option, that the HPU is controlled by their own controller if it can meet the system requirements.

Q: I assume that the new Hydraulic Service Manifold (HSM) needs to be controlled by the existing Instron controller. Can you please confirm?

A: That is correct. The Manifold and actuators will be controlled by the controller.

Q: Is it possible to provide a sketch or lab layout drawing?

A: Yes. See attached.

Q: Do you have any information on the HPU voltage output of the current Instron 8800 controller? A: Instron 8800 Controller is more specifically a Labatronic 8800 Tower with the ability to control up to 4 actuators. The HPU is started by a separate control, which communicates with the 8800 controller. The current hydraulics has terminals for 115 VAC, 24 VAC, and 24 VDC. The control logic, interlocks and failsafe indicators operate from an internal 24 VDC power module. Please design accordingly.

Q: The SOW refers to an "enhanced system" with total new hydraulic system flow requirements capable of feeding the existing actuators (listed as GFE) and the enhanced system. What is the maximum flow and pressure required for the enhanced system?

A: The system in the RFQ is intended to be functional for the current needs, with the ability to upgrade for expected future needs. The other three actuators, as mentioned in the SOW, will most likely have the same flow as the Yates actuator.

Q: Per SOW, water cooling is required. What is the available water flow and temperature for cooling at each of the two HPU locations?

A: The incoming water is in a 2.5” diameter pipe with 1” insulation. Current hydraulics is rated at 100 GPM @ 70 degrees F @ 40 psi. Please assume the incoming water temperature is not chilled. Water is site supplied, so please assume that the flow will need to be increased.

Q: Are motor starters required on the two HPUs?

A: Remote start/stop options, which can be in the form of the controller, and an onboard start/stop on the unit are desired.

Q: Are any instruments (pressure, temperature or flow electronic sensors) required on the HPUs? Nothing is referenced in the SOW. Most of our basic systems would have simple analog pressure gauge and temperature bar in sight glass on reservoir.

A: The SOW states “Connections to monitor the performance (e.g. Temperature and pump flow) of the hydraulic system in real time.” At minimum this can be limit switches that can be monitored remotely. At most this would be real time monitoring of performance on a computer screen.

Q: What is the operating duty cycle of the system? (Minimum to Maximum) A: The system will be operated from 4 to 12 hours over a single day.

Q: Does the system need to operate for any period of time in a low pressure or "stand-by" mode?

A: During the transition from one test set-up to another the HPU could run on lower pressure or “stand-by”

Q: Is there a specific hydraulic oil required to be used for the system? Mil-Spec?

A: Oil is DTE25.

Q: Are there any specific material requirements for construction of the system? (ie: stainless steel, aluminum, etc.)

A: No material specific requirements.

Q: Is there a paint specification to be followed for protection of the system?

A: Painted for indoor conditions.

Q: Is there a hydraulic schematic available for the existing system we can use as reference in designing the new one?

A: A drawing is provided.

Q: Are there any other mil specs or design standards applicable to these systems?

A: Some of the connectors are mil spec. Actual connectors would have to be confirmed. No other Mill-spec standards are required.

A 63GPM pump is close to the maximum pump size that can be supported by a 200A service because it draws 147A when running at full output. 63 GPM is adequate for the existing actuators and may be adequate for additional actuators as well, depending on the requirements. See Questions/Notes for Section B part b.i.1.

According to documents the hydraulics are run off 280 Amps @ 460V 3 Phase, 60 Hz.

The servovalve flow of the three existing actuators appears to be:

Yates #1 – 16.5 GPM Yates #2 -- 16.5 GPM Satec – 15 GPM Total of 48 GPM

Notes: Accumulation provides additional flow so the velocity limiting component is the servovalve, not the hydraulic supply. The maximum servovalve size is recommended at 1.5 times the pump flow. For example, a 10 GPM pump with accumulation can support up to a 15 GPM servovalve.

This vendor recommends our 63GPM pump for the 48GPM of servovalve flow volume at ERDC-CERL. The pump and distribution manifold for the actuators would have accumulation, which supports servovalve flows of up to 63 GPM x 1.5 = 95 GPM, which is more than enough supply for the existing actuators.

2) Will the additional actuators have flow requirements similar to the existing three actuators?

3) Which option to “easily upgrade” is of greatest interest?

a) Use just the base 63GPM pump to power the existing 3 actuators now plus the additional 4 actuators later

b) Install more than 63GPM of hydraulic supply now

c) add hydraulic supply capacity when the additional actuators are added

Notes:

a) If the three additional actuators for the enhanced system have servovalves no larger than existing actuators, then the combined total flow would be about 96GPM and just the 63 GPM pump (with accumulation) would run them.

Note: This option doesn’t allow for more/larger servovalves on the additional actuators or leave room for future expansion.

b) a 63GPM pump draws 147A when running at full output. This is about the maximum that can be supported by the 200A service as described in Section A, part e.

1) The Servovalves for the yates actuators are Moog G761-3005B the servovalve on the Satec actuator is a Moog 760F-103A. The rated flow for the Moog G761-3005B is 16.5 GPM at a 1000 psi valve pressure drop and for the Moog 760F-103A is 15 GPM at a 1000 psi valve pressure drop. The total of the rated flows is 48 GPM.

2) The servovalve requirements for the additional actuators has yet to be determined. The enhanced system is still in the planning. Please assume that the three additional actuators will have flow requirements similar to the Moog G761-3005B with a rated flow of 16.5 GPM at 1000 psi pressure drop. The sum of the rated flows would be 49.5 GPM. The sum of all actuator rated flows would be 97.5 GPM.

3) Option c) is preferred, Install the base system to power the existing 3 actuators, then add hydraulic supply capacity when the additional actuators are added.

· Oil level warning

· Oil level shutoff

· High motor temperature

· High oil temperature

· Filter blocked

Is this satisfactory?

The intent was to connect to one or more gages on the unit (e.g. temp, pressure, flow meters) to remotely monitor if the system running close to limits, in order to minimize system wear. If there are visible gages on the unit, at minimum temperature and oil level, that can be monitored via a camera, and there are warning and fault indicators that would be satisfactory.

Approximate Lengths:

HPU to manifold:

Manifold to Yates actuator #1:

Manifold to Yates actuator #2:

Manifold to Satec actuator:

Maximum Lengths:

HPU to manifold (At Ground Floor): 25 ft (If a hose is used for basement option add additional length based on height from HPU to Manifold) Manifold to Yates actuator #1: 30ft Manifold to Yates actuator #2: 40 ft Manifold to Satec actuator: 30 ft

2) Does any of the below NOT meet your expectations?

Site Services provided by ERDC-CERL

· Three-Phase Power, located in close proximity to the hydraulic power unit (HPU) and with access to adequate earthing terminations

· Supply of 3-wire plus Protective Earth (PE) cable from three phase power supply to HPU via a suitable fused isolator

· Cooling water supply to the HPU, including supply and connection of water hoses

· Provision of lifting equipment

· Off-loading from delivery vehicle and unpacking

· Moving equipment to final operation location

· Placing Instron-supplied rubber feet under HPU

· Making 3-phase electrical connections to HPU

· Provision of a keyed padlock for the HPU mains isolator to prevent unauthorized access to the electrical cabinet if required

· Routing of cables and hoses through building spaces (e.g. conduits)

HPU Site Services provided by This vendor

· Making all hydraulic connections to the HPU, service manifold, and actuators

· Filling HPU with hydraulic oil

· Supply of new cable(s) and making electrical connections to service manifold

· Flushing hydraulic lines

· Installation checks

· Customer demonstration using the existing actuators and Instron 8800 controller

· Customer training as defined in contract

1) Yes, but actuators have been calibrated since last use. This will be confirmed prior to installation and training.

2) The below are reasonable.