20155109_Attachment 05 - Testing Requirements.docx

Large-Scale Fixed Systems

ATTACHMENT 05 – TESTING REQUIREMENTS

U.S. Department of Homeland Security U.S. Customs and Border Protection

Attachment 05 – Testing Requirements

For:

U.S. CUSTOMS AND BORDER PROTECTION

NON-INTRUSIVE INSPECTION SYSTEMS

Large-Scale Fixed Systems

PREPARED BY:

OFFICE OF FIELD OPERATIONS

INNOVATION AND STRATEGY DIRECTORATE

NON-INTRUSIVE INSPECTION DIVISION

LOGISTICS/DEPLOYMENT BRANCH

Table of Contents

Testing

1. Quality Control and Testing The Contractor shall perform inspections and tests necessary to ensure that LS- NII Systems conform to CBP approved technical documentation and configuration.

Quality Control The Contractor shall provide for Government review a Quality Control Plan prepared in accordance with the Statement of Work and Attachment 07, Deliverables as it pertains to measuring performance of the system production and manufacturing.

Contractor Testing The Contractor shall develop separate Test Plans for, as a minimum, those tests which are designated as being witnessed or performed by the Government. The Test Plans shall detail the required tests that the Contractor shall perform to successfully complete the testing of the production and quality assurance phases of production and installation.

The Contractor shall utilize the following standard, ANSI N42.46-2008 American National Standard for Determination of the Imaging Performance of X-Ray and Gamma-Ray Systems for Cargo and Vehicle Security Screening for the testing and evaluation of image quality. The Contractor shall provide the test articles as defined in ANSI N42.46-2008 to affect this level of testing. In addition, the Contractor's tests shall include a 40-hour "burn-in" period of the entire integrated system to ensure component(s) failures are discovered and corrected prior to any CBP tests.

Acceptance Test Plan (ATP)(TE001) The Contractor shall be responsible for the preparation of and submission to the Government for approval, an Acceptance Test Plan (ATP). Using the approved ATP, the Contractor shall perform the tests necessary to ensure that the system meets the performance requirements of Attachment 1a, Functional Requirements Document (FRD) – MEP and 1b, Functional Requirements Document (FRD) – LEP and that the system can be operated as specified in the system's User Manual. The ATP details the required tests that the Contractor shall perform to successfully complete the testing of the production and quality assurance phases of development and production. It shall be written in sufficient detail so that the Government can be assured that when the system is ready for Government acceptance testing, it has in fact tested and met all SOW and contract delivery requirements.

The ATP shall be utilized to establish testing guidelines and support the requirements needed to conduct the test program. The ATP shall be submitted in an editable format, such as word.

The ATP shall include the following.

· Personal and materials needed to successfully complete the Contractor's final Factory/Site Acceptance Test.

· An inventory of all FT/SAT required documents and major components including software. This is to include the serial numbers of hardware items, and the software version numbers

· The results of supporting test standards such as the ANSI N 42.46 Performance Test, Material Discrimination Test and Radiation Survey; this includes test fixtures.

· All normal and emergency system operations of a fully integrated system. This shall include start up, safety checks, scanning, image analysis, image and Image Data Set operations (printing, exporting, copying, and deleting), and shut down.

First Article Testing For this contract, the “First Article” means the initial production unit from the first lot. The first article testing shall include testing and evaluating the first article for conformance with specified contract requirements in the initial stage of production, prior to full system deployment. The Government will conduct the first article testing of the performance and other characteristics that the first article must meet for approval according to the ATP and conduct further system characterization testing for a period of 180 days of operation at the deployment location. The Government reserves the right to conduct Factory Testing on additional system components.

The Government will inform the contracting office whether to approve, conditionally approve, or disapprove the first article. The contracting officer shall then notify the contractor of the action taken and furnish a copy of the notice to the contract administration office. The notice shall include the first article shipment number, when available, and the applicable contract line-item number. Any changes in the drawings, designs, or specifications determined by the contracting officer to be necessary will be made under the Changes clause, and not by the notice of approval, conditional approval, or disapproval furnished by the contractor.

The Contractor shall not proceed with production of additional units beyond the first article unless otherwise directed by the contracting office.

CBP Factory Testing A CBP Factory Test (FT) of all units shall be conducted at the Contractor's facility to verify that the unit is suitable for shipment to its intended Port of Entry (POE). The FT shall be conducted in accordance with a CBP FT Plan for that system. The Contractor shall provide the appropriate test articles for the CBP team to test the technical performance in accordance with the ANSI N42.46-2008 standards.

The Contractor is responsible for conducting Factory Tests. CBP Technical Team Members reserve the right to observe, augment and evaluate the Contractor's Factory Test program on an "as required" basis. Contractors shall submit Test Result Reports to the NIID and the COR upon completion of tests, regardless of whether the unit passed or failed.

CBP Site Acceptance Testing A CBP Site Acceptance Test (SAT) shall be conducted in accordance with a CBP SAT Plan (SATP) for that system for each unit at its designated location. The CBP SAT shall consist of a review of the Contractor's pre-SAT documentation and Radiation Survey/Leak Test Report (Attachment 7, Deliverables), plus an inventory and physical inspection of the system, system component operations and tests of the total integrated system against actual targets. The Contractor may be required to provide test articles for the (SAT) as determined by the SAT Plan or the Test Manager. This allows CBP to verify that the system performance has not degraded during transit. The CBP SAT shall not occur until OTD has approved the training package.

Material Discrimination Testing In the absence of an ANSI for Material Discrimination the following characteristics shall be tested, using the following or similar test fixtures, and shall be required to meet the following success rates. The two following characteristics shall be demonstrated:

The first characteristic is the system's ability to differentiate and identify the three or four categories of material (organic, intermediate, metallic (Threshold), and heavy metal (Objective)) from each other as a function of color when they are placed in close proximity to one another. The materials suggested are High Density Polyethylene (HDPE), Aluminum (Al), Steel, and Lead (Pb). The materials used shall all have the same attenuation, which can be between 20X and 50X. The test fixture used shall be able to hold at least two plates of each material. Success shall be based on the number of plates where at least 50% of the surface is the correct color. Twelve scans shall be required and 90% of the plates must display the proper color.

The second characteristic to be demonstrated is the system's attenuation range for two of the materials. For a three-material category system, the material used shall be HDPE and Steel. For a four-material category system, the material used can be either HDPE Steel or Al & Pb. There shall be at least 7 different thickness (steps) of each material. One step shall be so thin that the system cannot properly identify the material and therefore it appears gray. The other step shall be so thick that the system cannot properly identify the material and therefore it appears black. All the other steps shall vary in color intensity as a function of their thickness (the thicker the step, the more intense the color). Success shall be based on the number of steps where at least 75% of the surface is the correct color intensity. Twelve scans shall be required and 90% of the steps must display the proper color intensity.

Radiation Safety The Contractor shall maintain a system safety program that continually identifies all hazards and provides a methodology to either eliminate or control these identified hazards.

All products, designs, and specifications provided, and all construction and installation activities conducted shall comply with all OSHA and NRC regulations, as well as any other appropriate laws, regulations, standards, codes and health and safety guidelines. (See SOW Section 6, Applicable Documents for further details.)

Radiation Safety Design Review The Contractor shall demonstrate the construction techniques, practices and design of the protective shielding/cabinet interfaces (corner joints, collimator joints, imaging source housing, etc.) and shall be in compliance with ANSI N43.3- 2008 and N43. 14-2011 standards for their system. (See Section 6, Applicable Documents for further details.)

The Contractor shall ensure that any movement or shifting that may be associated with a system shall not produce or lead to emission leaks from cracks, stress or misalignment of the structures and shielding devices that are either associated with the primary beam containment or scatter containment scheme.

Radiological Survey and Report (TE002) The Contractor shall be required to conduct a radiological survey to ensure that radiation emissions are within specified limits. A radiological survey carried out on the LS-NII unit, signed by the Radiation Safety Officer, shall accompany each system delivered by the company. This survey shall address both the radiation levels that LS-NII Inspection System operators shall be exposed to while at their workstations and the level of radiation that is transmitted to the environment as a result of system leakage. The report shall show that by means of an outline drawing the levels of emission/scatter radiation measured, the operating conditions (worst case) and the measurement equipment used. The Contractor shall provide a radiological survey report and a Radiation Survey/Leak Test Report in accordance with Attachment 7, Deliverables for each system delivered.

Radiation Survey and Report The Contractor shall perform Radiation Surveys prior to site acceptance and annually thereafter for the systems that contain radiation emitting devices (X-Ray systems). The X-ray systems shall be in compliance with CFR 21 Part 1020.31 of U.S. Food and Drug Administration: Performance Standards for Ionizing Radiation Emitting Products - Cabinet X-ray Systems. The Contractor shall provide a radiation survey report to the ILD Operations Center within 48 hours of completion. A Radiation Survey Report shall be submitted with the proposal and each Site Acceptance Test.

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