Attachment 01 - Statement of Work.pdf

STATEMENT OF WORK

Summary

Technical Requirements:

This procurement is for a turnkey, state-of-the-art, 7-axis, digital radiography computed tomography system. The system must be able to scan parts up to 27” in diameter and 48” in length. The system must be fully shielded and interlocked cabinet-style unit. It must comply with all applicable industry regulations. The system must also be modular in nature, to allow for all parts to be maneuvered into the building/laboratory through a standard double door.

The system must be assembled in place with no forklift support other than unloading from the delivery truck. The system must include a flat panel detector, 225Kv Microfocus Tube, 450kV Mesofocus Tube, DR Image processing acquisition workstation and software, and a separate CT reconstruction workstation including software and meet the Technical Requirements listed below.

System Capabilities

· Advanced 2D X-ray inspection

· 2D CT Slice reconstruction

· CT volume reconstruction for 3D inspection

· 3D internal and external surface scanning

· Measurement and Analysis tools

System Specifics

X-ray tube: The X-ray tube shall have the following characteristics at a minimum (or better):

Microfocus 225kV Directional

· Tube Voltage …25 - 225kV

· mA Range …0 -3 mA

· Power …320 W max

· Focal Spot Size < 6 microns

· Detail Recognition …< 2 microns

· High Tension Cable of appropriate length for assembly setup

· Closed Loop Water Cooler X-ray Control Software

· Windows based

· Automatic and manual tube warm-up capabilities

· Automatic and manual filament current adjustment capabilities

· Automatic and manual focusing capabilities

· Automatic target loading control

· Intensity control

· Spare parts and customer service kit

450Kv Mesofocus Xray Source

• X-ray tube MXR-451MF

• Generator iVario 450Kv/1.0Kw

• Voltage Range 100 - 450Kv

• iVario Cable Package as necessary for installation

• I/O power distribution panel

• Oil-to-air cooler with flow and temperature interlocks

• All associated cables, cooling lines, and documentation

Mesofocus Source Mount and X-ray Tube Shutter

• Four-leaf, four-axis tube shutter shielded for 450kV

• Independent axis control

• Laser alignment system

• Source Mount

Spare Pack of 225kV Filaments Spare Pack of 225kV Filaments

Spare 225kV Target Spare 225kV Target

X-ray detector: The X-ray detector shall have the following characteristics:

4343N DRZ +

• 17” x 17” (432mm x 432mm) active area

• DRZ+ (Gadox) Scintillator

• 150-micron pixel pitch

• 2880x2880 pixel matrix

• 16-bit A/D Conversion

• 15 fps (1x1); 30fps (2x2 pixel binning)

• Premium CT Grade

• Tungsten shielded to 450kV (increased lifetime)

• Power & Ethernet cables

Manipulator: The manipulator shall have the following characteristics:

Movement of the inspection object is capable of x, z, tilt, and rotation, along with detector and tube vertical movement.

All drives are motorized with variable speed multi-directional joystick operation. Each axis control is independent allowing simultaneous movement of the axis.

7 Axis Manipulator

· All drives are motorized with variable-speed joystick operation

· Desktop control console

· Detector Manipulator:

· Focal Distance: 0” to 48" (0cm to 122cm) or better

· Detector and Tube Vertical Axis – 48” (122cm) or better

Part Manipulator:

· X Axis/front-to-back translation: 33” (84cm) or better

· Z Axis / focal distance tube to detector translation: 48" (122cm) or better

· Tilt: +20 /-20 Degrees or better

· CT precision nickel plated 9" (22cm) rotational stage - 360 Degrees Continuous. Resolution

0.001 degree or better

· 250lb static capacity (not including tilt) or better

· Integrated electronics

· Heavy duty welded and precision machined frame construction

· Precision linear bearing rail

Cabinet

• Radiation shielding to energies of 450kV constant potential.

• Approximate dimensions: 80" deep, 98” tall, 115" wide (2032mm deep, 2489mm tall, 2921mm wide).

• Steel/lead/steel construction. Modular construction assembled in place.

• Cable access port with cover.

• Large, motorized sliding access door.

• Primary and secondary x-ray safety interlocks.

• Interior lighting.

• X-ray on warning light.

• Designed to meet all state and federal X-ray safety regulations.

Motion Control Module The Motion Control Module provides an operator-friendly teach-and-learn interface to create complex motion control programs easily and quickly. Shall include an additional 31" (787mm) 4k monitor.

4 Camera Color Surveillance System Internal Camera surveillance system w/split screen monitor and 4 cameras.

Computer hardware and Software:

The system shall include a computer(s) workstation to operate the system. The workstations shall include:

DR Workstation (Minimum Requirements)

• Windows® 10 Operating System

• Eight-Core Intel® Xeon® Processor

• 8 GB RAM

• 512 GB Operating System Drive

• 3TB of Data Storage in RAID 0 Configuration

• DVD+/-RW Drive

• 10/100/1000 Network Interface

• NVidia High-Performance Display Adaptor

• 31.5” (800mm) 4K Color Display

• Wired or wireless Keyboard and Mouse

DR software High-performance image analysis system with a comprehensive set of image analysis tools.

· Windows® based

· Non-proprietary image storage format.

· Multiple Windows interface

· High-performance image processing and measurement functions utilizing GPU technology

· Automatic parallelization for systems with multiple CPU’s and GPU’s

· Live Imaging up to 30 frames per second

· Live Averaging

· Live Histogram

· Live line Profile

· Live Rotation between portrait and landscape modes

· Live Measurements with 1-pixel resolution

· Live image gain/offset calibration and defective pixel correction

· Automatic creation of Technique sheet for operator record

· Capture video into AVI files.

· Supports digital flat panel detectors, LDAs, and digital/analog cameras at 8, 10, 12, and 16 bits.

· Read and store images in TIFF 32-bit / 16-bit / 8-bit, BMP, JPEG, RAW

DR CT Acquisition Module The CT acquisition module provides automated CT acquisition capabilities for:

• Capable of CT acquisition up to 10,000 angle steps

• Automatic creation of Technique sheet

• Monitors x-ray performance and will pause the CT scan if x-ray interruption is detected

• Acquisition of Spiral CT scans

• Ring Reduction acquisition capabilities

Fast CT Acquisition Module The module allows continuous fast CT acquisition of projections for fast CT scans from 5 seconds to minutes for thousands of projections.

Reconstruction Workstation (Minimum Requirements)

• Windows® 10 Operating System

• Dual 10-Core Processors (Total 20 Cores)

• 1 TB RAM

• 1 TB SSD Operating System Drive

• 24 TB Hard Drive with High-Speed Raid 5 capabilities

• 4 NVidia High-Performance Display Adaptors for Display and Reconstruction

• 15,360 total processing cores

• 96 GB of GPU Memory

• 3D Rendering capabilities

• 31.5” 4K Color Display

• Wired Keyboard & Mouse

CT Computed Tomography Software CT software shall include:

⋅ CT calibration, Cone-Beam reconstruction, 3D real-time visualization, and analysis tools in the same interface.

⋅ The software shall not limit the size of the reconstruction ⋅ The software shall be capable of the following:

o Combining 2 or more datasets taken at different settings o Significantly improving CT quality of widely varying densities.

o Increasing the dynamic range of the CT dataset.

o Reducing noise and photon starvation in the CT reconstruction o The software shall be able to perform local CT reconstructions of a small area of interest inside a larger object.

Simplified processing - The software shall include a simplified, user-friendly mode that lets the user quickly navigate through the full CT scanning process, from the creation of the project to the final results. The simplified interface shall include features to guide the user through the calibration and reconstruction process.

Automatic Calibration - This tool has been developed to optimize cone-beam CT reconstruction process and to simplify CT and μCT equipment.

· Cone Beam Reconstruction –Reconstruction performed on GPU hardware.

· 3D Volume Rendering –

• Real-time volume rendering

• Export slices at any angle

• Create movie animations

• Perform localized reconstruction.

• Ring Reduction - Uses a combination of hardware and software to virtually eliminate ring artifacts caused by nonuniform pixel responses. *

· 3D Surface Rendering - Surface extraction to CAD compatible format:

• Export to STL (Stereolithography), cloud points, OBJ, DXF, WRL, PLY. Visualization in wireframe mode. Map textures with reflection.

• Export an executable viewer module with a dataset to allow others to view, slice, rotate, window, and manipulate the dataset on a traditional laptop or desktop computer without the need for licensed software. Ideally, the viewer module is fully capable and equivalent to the post-processing capabilities of the CT Workstation.

High-Accuracy Geometry Tools High-accuracy geometry tools for use with metrology applications

· Serialized small, medium & large tools

· Certificate of Conformance

· High-accuracy CMM inspection

· Precision-engineered mounting fixtures

· Heavy duty carrying case

⋅ Spiral Acquisition CT ⋅ The system shall be capable of performing automated spiral acquisition with a digital flat-panel detector for the scanning of elongated objects that traditionally cannot fit into a single exposure. The scan does not require volume stitching and the object length is only limited by the system scanning area. This reduces or eliminates the cone angle artifacts caused by flat, planar features common in non-spiral CT techniques. Software is provided by the vendor, not a 3rd party software company.

⋅ Image stitching CT ⋅ Larger parts may require multiple scans to completely scan the part when it is larger than the detector panel. The software shall be able to stitch multiple images into one seamless image of the part or assembly. Software is provided by the vendor, not a 3rd party software company.

⋅ Sub-pixel resolution CT

The designed motion of the manipulator and the software shall be capable of displaying and analyzing scan data utilizing sub-pixel analysis routines that are typically double what the detector alone is capable of achieving. Software is provided by the vendor, not a 3rd party software company.

⋅ Time and motion analysis (4D Computed Tomography Module)

The system shall be capable of creating and analyzing moving or changing parts as dynamic, time-based data sets. The system shall be able to acquire time-based data in either a continuous or stepped mode. Continuous scan mode refers to repeatedly scanning the part while motion or change is occurring at a speed that is slow relative to the time it takes to complete a full scan. Stepped scanning refers to re-scanning the part multiple times after the part is removed from the CT unit, subjected to some condition that will cause motion or change in the part. The system shall be able to generate time-sequenced images (videos) showing the motion or change in the part resulting from the continuous or stepped scans.

Software is provided by the vendor, not a 3rd party software company.

SIMULATION Software Simulation Software is a powerful software platform that creates a digital twin of your x-ray/CT system in a virtual environment. Software is provided by the vendor, not a 3rd party software company.

• Some of the key features include:

• Windows® based (Compatible with Windows 10 or higher)

• Offline Technique Development o Import/Export configurations directly from an NSI system o Optimize system settings & positions offline o Import CAD models of parts/fixtures/etc o Configure part alloy with alloy mixing o Simulated machine environment o Visualize system crash protection

• Offline Motion Programming o Program motion routines without tying up a system o Controls look/feel/act the same as the real system

• Imaging Simulation o Simulate different results based on changing settings o Change beam hardening parameters o Realistic polychromatic beam results

• Training o Remotely learn system operation o Train new employees o Reduce system damage by training in a virtual environment

⋅ Programmable CNC Motion Control ⋅ The system shall utilize programmable CNC motion control.

⋅ Detector Lateral Shift o Detector Lateral Shift of at least 30”

⋅ Continuous CT scan mode is included for faster CT scans in seconds or minutes.

⋅ Local CT reconstruction capabilities (reconstruct just a small area of interest inside a larger object).

⋅ No limitation of reconstruction size – Successful tests have been made with

10000x10000x10000 voxels reconstruction

Detector Qualification Package The Process Control Software is an interface that allows the user to routinely monitor digital detectors.

Specifically, this module allows for the qualification of pixel mapping and the verification of the detector quality, spatial resolution, and contrast sensitivity. Also included in this module is an SMPTE test pattern used for checking the quality of the display monitor. Software is provided by the vendor, not a 3rd party software company.

To include the following:

· Pixel Mapping Qualification

· Detector Quality Check

· Spatial Resolution

· Contrast Sensitivity Check

· SMPTE Display Test Pattern

Also includes:

· EN-462 D13 Duplex Wire Gauge

· Photo Light Meter

Secondary Hard Drive Set - DR & CT Hot-swappable hard drives in both the DR and CT workstations to quickly and easily separate sensitive and non-sensitive scan data. A protective storage/carrying case.

Additional Components

Copper Filter Kit Set of copper filters for use with microfocus tubes

· Selection of 0.005", 0.010", 0.020", 0.040", 0.060", 0.080" thick filters

High Energy Copper Filter Kit Set of copper filters for use with minifocus tubes

· Selection of 0.093", 0.250", 0.375" thick filters

Fixture Kit

All the basics:

• T-slot table & tools

• Vices

• Clamps

• Chucks

• Geo Tool handling

• Tape

Turn Table Riser

Installation and Training

System Installation

DR / CT System Training:

7 Days of On-Site DR/CT system operation training. The offeror shall provide 4 Days of On-Site training for system operators covering: digital radiography, computed tomography, and operation/maintenance/safety of the delivered CT system operation. This training shall be provided as part of the system delivery and acceptance.

2 Seats to Digital Radiography & Intro to CT Training (40-hour course) 40-hour ASTM/ASNT Certified DR/CT training course, held at vendor’s site.

This course follows the recommended curriculum of FWG-IDR, MAI, ASTM, and ASME in a format for compliance with the NAS 410 Qualification/Certification program.

1 Seats to Advanced CT Training The Advanced CT Training is a 40-hour class at the vendors’ site that dives into the advanced capabilities of the Industrial CT technology. The course shall include CT Technique Development training and CT Reconstruction, The class shall focus on the advanced capabilities of the delivered system and Industrial CT technology. The course shall include CT Technique Development training and CT Reconstruction

Maintenance

• 12 Month Hardware Warranty and one preventative maintenance visit

• Local support time zone support by the main manufacturing facility

• Software and systems made by the same company

• First-year DR & CT Software Maintenance/Updates

• First-year Preventative Maintenance

Technical Manual: The system shall include a user’s guide technical manual that covers system operation, routine maintenance, and basic troubleshooting information. The standard commercial user/technical manual(s) for the hardware and software should meet this requirement.