Atch 01 Statement of Work.pdf

Flip Tower Requirements Document

For 704th Test Group/Det 1

16 Sep 2022

1.0 PURPOSE

The 704th Test Group (704 TG) mission is to be the premier provider of unique test and evaluation capabilities relevant to tomorrow’s warfighter through world-class people improving technical excellence, cost-effectiveness, and agility. The 704 Test Group/ Detachment 1 (Det. 1) is assigned to the 704 TG and conducts Static Radar Cross Sectioning for both military and civilian customers. The 704 TG/Det. 1 manages the National Radar Cross Section Test Facility (NRTF), which consists of the Department of Defense’s (DoD) only outdoor, static radar signature measurement range known as the RCS Advanced Measurement System (RAMS).

RAMS test range offers one-of-a-kind, unique resources and test capabilities. These capabilities often require the use of large target that must be moved and oriented in different positions by utilizing the flip tower. The flip tower system is a combination of structures and equipment utilized to reorient a target by lifting it to a specified height, rotating it about a single axis, then lowering it back to the ground. The main system components consist of two structural steel towers which support two lifting systems connected by an axle which uses two rotational units to rotate the axle and the connected target. The 704 TG requires a flip tower system to be built and installed at the RAMS test range.

2.0 SCOPE

The contractor shall deliver flip tower components that meet the following:

2.1 Rotator Requirements:

2.1.1 Capacity: Up to 30,000 lbs.

2.1.2 The Center of Gravity (CG) shall be offset from the centerline of the rotator by as much as 6’00”

2.1.3 The rotator shall be designed to generate a rotational torque of approximately 180,000 ft/lb’s

2.1.4 Length (span): 75’0” center to center of the track wheels that resist the rotation torque

2.1.5 Rotation speed: 1 Revolution per Minute (RPM) maximum

2.1.6 Rotation range: 180 degrees +/- 10 degrees

2.1.7 ASME BTH-1 Category B, Service Class 1 (up to 100,000 load cycles in its operation life)

2.2 Load Pipe Requirements

2.2.1 The load pipe shall be constructed in five sections, with no section being longer than

27’0”. The pipe diameter shall be 36”

2.2.2 Pipe sections will bolt together through welded flanges using grade 8 bolts

2.2.3 The center section shall support the adaptors that bolt to the model

2.2.4 Intermediate pipe sections shall attach to the center pipe with bolted flange plates. At the outside ends are flange plates that connect to the offset adaptor plates

2.2.5 the end pipes shall have the offset adaptor plates that connect to the intermediate pipes.

The outside ends shall attach to the driven half of a slewing gear

2.2.6 Each pipe section shall have lifting eyes or swivel hoist rings to facilitate safe handling during manufacturing and field assembly. The end pipes will have welded on support stands.

2.2.7 Provide four portable adjustable height support stands that can support the load pipes as the pieces are mated together on site.

2.2.8 Maximum allowable deflection produced by the dead load of the load pipe, plus the weight of the heaviest model attached directly below the Load Pipe is 1/600 of the span.

2.3 Load Pipe Drive System Requirements

2.3.1 Load pipe shall be power rotated by two motors with brakes and two gear reducer assemblies at both ends.

2.3.2 Drive system shall be capable of producing torque of 90,000 ft/lbs. at each end

2.3.3 Each motor shall drive a fully enclosed gear drive. The gearbox output shaft shall drive an open gear set to achieve the required torque output

2.3.4 Each motor will have one motor mounted spring sent electric release holding brake.

2.4 Drive System Housing and Wheels

2.4.1 Two drive housings shall be constructed of welded steel plates and structural members

2.4.2 Internal diaphragms and gussets shall be applied so the housing can withstand all forces applied from rotating the model

2.4.3 Access covers shall be provided for inspection, lubrication and repair of the drive components.

2.4.4 Open gearing shall be guarded with sheet metal covers and lubricant patch cans shall be provided

2.4.5 Grease fittings shall be piped to an accessible external manifold.

2.4.6 The housings shall attach to the lifting carriages provided

2.5 Electrical Requirements

2.5.1 The system shall have one large National Electrical Manufacturers Association (NEMA)

12 control panel that must be covered to protect from the environment

2.5.2 Power supply: 460/3/60

2.5.3 An air conditioner shall be provided to protect control panel components

2.5.4 Rotator motor and brake requirements:

2.5.4.1 15 Horsepower x 4 motors

2.5.4.2 Inverter duty

2.5.4.3 Totally Enclosed Non-ventilated (TENV) or Totally Enclosed Fan Cooled (TEFC)

2.5.4.4 IP 66 motor enclosure

2.5.4.5 Terminal box sealed with resin

2.5.4.6 Class H insulation

2.5.4.7 Epoxy dipped windings

2.5.4.8 Potted rectifier

2.5.4.9 Corrosion protected brake

2.5.5 Two end of travel proximity sensors shall be provided, one to be a final stop near the zero degree position and the other near the 180 degree position. The sensors shall be mounted at one end of the load pipe. The sensors or the targets shall have 5 degrees of adjustability.

2.5.6 Allowance for four absolute encoders, ethernet/IP shall be included

2.5.7 Control of the system shall be from the control buttons on the main control panel. This shall include Human Machine Interface (HMI) with diagnostics.

2.5.8 An additional handheld remote with up/down, rotate, and full speed/jog shall be included

2.6 Paint

2.6.1 SSPC-6 commercial blast

2.6.2 Prime coat shall be Sherwin Williams Macropoxy 846 or equivalent

2.6.3 Mid coat and top coat shall be Sherwin Williams Fast Clad Urethane or equivalent

2.6.4 External surface of load pipe only

2.7 Testing

2.7.1 Full load factor acceptance testing shall be performed at manufacturing site with reduced height lifting columns (approximately 10-15 ft. of vertical travel). Testing shall demonstrate the capability of the system to raise, lower and rotate a 30,000 lb. payload at an eccentricity of 6 ft. from axis of rotation as well as to demonstrate functionality of drive motors, brakes, rotation speed, and limit switches.

2.7.2 Initial acceptance testing shall be performed at RAMS after installation is complete.

Personnel shall be provided to oversee testing. The NRTF shall provide a test load and mount/unmount the test load to the rotator as required.

2.8 UL Listing

2.8.1 All control panels and enclosures shall be UL listed.

3.0 MILESTONES

The Contractor shall deliver and install the flip tower components no later than 40 weeks

ARO.

4.0 DELIVERABLES

The contractor shall deliver all hardware and operating documents to 704 Test Group/Det. 1 Attn: Major Gabrielle Llanos and Michael McGuire 575-572-1034. The delivery driver will be provided access to Holloman Air Force Base by 704 TG/Det. 1 personnel In Accordance With (IAW) local base guidelines and escorted approximately 50 miles to RAMS on White Sands Missile Range. Prior coordination for delivery will be required for access.