Attachment 1 PWS_FSAR.docx

ARS Lab Winch and Track Performance Work Statement

Scope:

The Fuel Systems & Aerial Refueling lab located at Naval Air Station (NAS) Patuxent River utilizes a hydraulic winch in combination with a test track system in order to test and operate the Aerial Refueling Store (ARS) used by the F/A-18. The ARS is a refueling system that is used to provide fuel to receiver aircraft in flight. The ARS has an integrated hose reel system that will extend/rewind the hose. In flight, aero drag forces will provide the required force to pull the hose into the extended position, while the ARS hydraulics will provide the power required to retract the hose. At the Fuels lab, the ARS winch and test track are used to interface directly with the ARS hose reel system and allow the hose to extend and retract by increasing or decreasing tension force applied to the ARS hose. A track system, utilizing a trolley which supports the ARS/winch interface, facilitates movement of the ARS hose as it travels in and out.

Figure 1

The objective of this contract is to design, fabricate, and deliver a new ARS winch and track system according to the specified requirements located in section 3.1.8 of this document. The current winch system used at the fuels lab is no longer sufficient to evaluate new technologies being integrated into aerial refueling (AR) systems. The winch lacks controllability, and the winch design creates a response lag to user input that prevents consistent and repeatable application of tension. In short, the new winch system delivered under this effort will respond to small user-input incremental changes, respond rapidly to user input, supports programmable tension profiles, and contains an integrated load cell to verify input and output loads match and automatically correct as necessary.

In addition, it is highly desired for the ARS track system delivered under this effort to provide the capability of fuel recirculation while the ARS hose is in a dynamic state. The current ARS test track is only capable of evaluating hose reel performance or fuel flow individually rather than simultaneously. The ability to evaluate both of these capabilities simultaneously would allow for more accurate characterization of ARS hydraulic power draw.

Applicable documents: The documents listed below are presented only as representative sources of the technological interface details that may be required during Contract performance. Likewise, the documentation listed is not all-inclusive but is representative of the type of information that may be necessary to perform the work. The applicable document version is the latest version at time of award. Documents may be added and/or updated to the latest applicable revision as required during the execution of this Contract.

2.1 Department of Defense specifications

2.1.1 DoDI 5200.48, Controlled Unclassified Information (CUI), 6 Mar 2020.

2.1.2 DoDI 5230.24, Distribution Statements on Technical Documents, Change 3, 15 Oct 2018

2.1.3 NIST SP 800-171 – Special Publication: Protecting Controlled Unclassified Information in Nonfederal Systems and Organizations, February 2020

Requirements

3.1 General Requirements

3.1.1 Work Location: Approximately 5 percent of work will be performed at Government site and 95 percent of work to be performed at Contractor site. Government site(s) include (Fuel Systems & Aerial Refueling Lab, NAS Patuxent River). Contractors performing on-site support will be provided access to workspaces. necessary to carry out assigned tasks.

3.1.2 Contract Status reporting. The Contractor shall provide the following documentation.

3.1.2.1 Monthly Progress and Financial Status Report: The Contractor shall provide a progress and financial status report in accordance with the Contract Data Requirement List (CDRL A001). The report shall include work accomplished since submittal of the last report, both monthly and cumulative man-hour labor costs expended by labor category and material and travel costs.

3.1.2.1.1 Holidays: The Government observes the Federal holidays identified on the Office of Personnel Management (OPM) website: https://www.opm.gov/policy-data-oversight/pay-leave/federal-holidays/#url=Overview.

The Contractor is permitted to observe these Federal Holidays in accordance with its corporate policy.

3.1.2.1.2 Installation closure: When Federal facilities are closed by the Government, or when Federal employees are officially excused from work due to a holiday or a special event, severe weather, a security threat, or any other Government facility related problem that prevents Federal personnel from working at the Government facility, contractor personnel assigned to work at that facility in support of such Federal employees shall follow their parent company’s policies.

While generally contractor personnel may not perform work on-site at a Government facility without oversight from Federal personnel, in very limited circumstances, work being performed by contractor personnel may be deemed mission essential and performance of such mission essential work may be authorized to continue at the Government facility despite the facility being otherwise closed for normal operations. The circumstances permitting work being performed by contractor personnel to be deemed mission essential are extremely limited and generally only apply to performance of efforts related to public health, safety, or matters related to national security. The cognizant Contracting Officer must concur with any determination that work being performed by contractor personnel is mission essential.

3.1.3 Other Direct Costs:

3.1.3.1 Travel: Travel may include general and administrative expenses, but shall not include profit. Temporary travel to other locations in support of program tasking is required. Temporary travel locations include NAS Patuxent River. This list is not all inclusive as locations may change over the life of the contract.

3.1.4 Subcontractors: Provisions stated herein shall be clearly and effectively communicated to all subcontractors providing support under this contract. All provisions of this PWS shall flow down to subcontractors providing support under this contract.

3.1.5 Management of Contractor Personnel: The Government will neither supervise contractor employees nor control the method by which the Contractor performs the required tasks. Under no circumstances will the Government assign tasks to, or prepare work schedules for, individual contractor employees. The Contractor shall manage its employees and guard against any actions that are of the nature of personal services, or give the perception of personal services.

3.1.6 Program Unique Requirements:

There are two major components that are being procured under this contract: (1) A winch with a digital control system and, (2) a test track that interfaces with the winch. Unique design requirements for each component are listed below. At the completion of this contract, the contractor shall submit to the TPOC the deliverable A002 Operating Procedures Manual as well as deliverable A003 Maintenance Procedures that details all standard operating procedures and maintenance actions and procedures respectively for all equipment developed under this contract.

3.1.6.1 Winch

3.1.6.1.1 Winch Requirements:

· 100 ft minimum dispensable cable length

· Loads up to 2000 lbs (with a Safety Factor of 1.5)

· Tension adjustment increment resolution: 10 lbs (objective), 20 lbs (threshold)

· Be capable of dispensing cable/rope at 18 ft/s under no load

· Be capable of maintaining constant input tensions between 200-600lbs with a line speed of 15 ft/s (objective), 10 ft/s (threshold)

· Powered by 240 VAC or 480 VAC 3 phase 60Hz

· Integrated dispensed cable distance measurements (objective)

· Input change response time >1 second (objective), >2 seconds (threshold)

· Cable Output height between 37 and 45”

· Cable Diameter shall not exceed ½"

· Cable end fitting shall be capable of linking to a ½" shackle

· Winch base shall not exceed 6 ft in length (in-line with the cable), 8 feet wide, or 8 feet tall

· No winch components shall extend outside of winch base dimensions

· Maximum allowable winch assembly height is 8 feet

· Winch base shall have pass-throughs to pick up with a forklift from all sides

· Forklift pass-throughs shall be of 8-10” wide and 3-4” tall, and not more than 36” inches apart (outside to outside)

· Winch base shall have 6-8 provisions to secure winch into test pad concrete utilizing bolts of diameters between ½” and ¾"

· Environmental protection cover (removable)

· Operational temperature between 0F – 120F

· Winch shall be capable of being powered for a standard 9 hr workday with winch providing tension control for 30 minutes on, 30 minutes off.

· Storage temperature between –30F - 150F

· Exposed components shall be resistant to rain, humidity, and corrosion

· Electrical components and wiring shall be isolated from rain/moisture through waterproof enclosures/sheathing.

· Winch shall support incorporation of physical emergency brake buttons to stop all winch motion. Buttons shall be separate from digital control system.

3.1.6.1.2 Control System Requirements:

· Wiring distance between winch and control is 145ft outside and 10 ft inside

· Tension adjustment increments: 10 lbs (objective), 20 lbs (threshold)

· Windows based touchscreen input (18-30" screen)

· Touchscreen GUI layout shall be adjustable by user

· Computer fit into 19” rack, 4U maximum

· Additional outputs for load cell and dispensed cable measurements to user computer

· Powered by single phase 120VAC, 60 Hz

· Programmable loading patterns, see Figure 2 below for example

Figure 2

3.1.6.1.3 Winch/Control Station interface:

· Communication between the controller (touchscreen computer) and the local / low level winch controls shall be RS-485

· The low level / local winch controls shall have the following (RS485) inputs: desired / commanded tension (in lbs)

· The low level / local winch controls shall have the following (RS485) outputs: measured tension, dispensed cable distance (threshold)

· Additional outputs (objective): hydraulic pressures and / or system health status indication(s).

3.1.6.2 Track System

The track system is used to support an aerial refueling drogue while the aerial refueling store is tested in the lab environment. The system is divided into 3 subsystems: Refueling Store Stand, Traveling Track, and Fluid Transport System.

3.1.6.2.1 Refueling Store Stand (RSS) Requirements:

· RSS shall interface with the refueling store rack 66-70” off the ground

· RSS Structure shall not exceed the dimensions notated in Figure 3 below.

· RSS shall interface with the refueling store utilizing the bolt pattern denoted in Figure 4 below.

· RSS structure shall be capable of supporting 4000 lbs (with a Safety Factor of 1.5) subjected to a 1000lb tension load and 400lb side load.

· All metallic RSS components shall be made of a corrosion resistant material (Aluminum or Stainless Steel), or have a corrosion resistant coating such as plating, powder coating, or paint. All paints shall be designed for usage in outdoor areas.

Figure 3

Figure 4

3.1.6.2.2 Traveling Track Requirements:

· Track shall be a total of 80 feet long and have between 8-10 supports equally spaced.

· Track shall have a traveling trolley that shall interface with the refueling assembly at the hose end fitting via standard clamshell clamp.

· All track structure at or below the height of the trolley shall be within 20 and 45 inches from trolley centerline. (See Figure 5 below)

· All metallic track and trolley components shall be made of a corrosion resistant material (Aluminum or Stainless Steel), or have a corrosion resistant coating such as plating, powder coating, or paint. All paints shall be designed for usage in outdoor areas.

· The travelling trolley shall have an interface compatible with the fluid transport system to recirculate fluid pumped out of the refueling store hose.

· The trolley/track interface shall not allow lateral or vertical movements of the trolley during system operation.

· Trolley movement shall not degrade finished surfaces on track such as to expose bare metals to environmentally induced corrosion.

· Track segments shall be capable of being aligned to enable smooth travel of trolley.

· Track shall be provisioned with ends that prevent trolley from coming off the track.

· Track/trolley interface shall not allow for trolley to be removed from track without direct user manipulation/part removal.

· Track supports shall have provisions for bolting into concrete using 4 bolts ½” bolts. Max bolt depth in concrete is 2”.

· All rollers and bearings shall be commercial off the shelf (COTS) items.

Figure 5

3.1.6.3 Option - Fluid Transport System (FTS) Requirements:

Description: The fluid transport system is intended to recirculate fluid pumped out of the refueling store back into the store. The system must be dynamic, and capable of recirculating fluid during hose movement via the winch and trolley system. This system is not required, but highly desired.

· The FTS shall be compatible with 1010 oil (MIL-PRF-6081E), JP-5, and JP-8.

· All metallic FTS components shall be made of a corrosion resistant material (Aluminum or Stainless Steel), or have a corrosion resistant coating such as plating, powder coating, or paint. All paints shall be designed for usage in outdoor areas.

· The FTS plumbing shall interface with the travelling trolley to capture fluid pumped from the refueling store hose.

· The FTS shall be dynamic in its design such that the fluid recirculation is uninterrupted by hose/trolley movement.

· All FTS plumbing shall be positioned and installed such that it does not interfere with refueling store hose/trolley movement, and does not hinder movement of personnel on the test pad.

· All FTS plumbing will be designed to accommodate flow rates of at least 400 GPM.

· All FTS plumbing will be capable of withstanding operating pressures of 60psi, and proof pressures of 120psi.

· The FTS shall integrate a fluid collection tank capable of storing at least 300 gallons of fluid volume, and 2,500 lbs of fluid weight

· The collection tank shall incorporate a shut off valve that will isolate it from the rest of the FTS plumbing.

· The collection tank shall incorporate provisions to pump fluid out of the collection tank back into the FTS. The system shall incorporate the means to prevent fluid flow back upstream into the refueling store when the hose is connected to the FTS.

· The collection tank pump shall be capable of emptying the collection tank from full volume in less than 15 minutes.

· The FTS shall interface with the top of the refueling store via a –24AN (1.8750 x 12 UNJ) Male fitting with a swiveling 90 degree fitting to allow fluid recirculation back into the store. Fittings may be aluminum, zinc plated steel or stainless steel. -24AN male end may be either the 37 degree flared or SAE O-ring boss style. An example is using Aeroquip parts: 202702-24-24S and 2250-24-24S.

3.1.6.4 Additional Requirements

The contractor shall be responsible for the installation and execution of acceptance testing at the Fuel Systems & Aerial Refueling Lab facility at NAS Patuxent River. The contractor shall be responsible for generating CDRL A004 Acceptance Test procedure, which will be provided to the TPOC for review and approval. After execution of the approved acceptance test procedures, the contractor shall generate and provide CDRL A005 Acceptance Test Report to the TPOC for review and approval.

3.2 Security

3.2.1 Citizenship Requirements: Only U.S. citizens may perform under this contract, unless waived by the Government. If the Contractor cannot find qualified U.S. citizens to perform the work, the Contractor shall submit a citizenship waiver request with justification to the Government Security Office. The waiver request should include:

a. The individual's name, date and place of birth, position title, and current citizenship.

b. A statement that a qualified U.S. citizen cannot be hired in sufficient time to meet the contractual requirements.

c. A statement of the unusual expertise possessed by the applicant.

d. A statement that access will be limited to a specific government contract (specify contract number).

e. A statement that the Contractor has obtained an export license for the information required to perform the contract.

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