Attachment 1 Statement of Work.docx

Statement of Work Computed Tomography (CT) Inspection System Fleet Readiness Center Southeast (FRCSE) Jacksonville, FL

1. SCOPE: Fleet Readiness Center South East (FRCSE) requires a Computed Tomography (CT) system. This new capability is necessary to support the inspection of flight components and future additive manufacturing (AM) fabricated aircraft parts and components at the FRCSE maintenance facility onboard Naval Air Station (NAS) Jacksonville in Florida. The required system shall be a complete, installed turnkey CT system as a shielded cabinet X-ray with ionizing radiation of 225 kV (kilovolt) and 450 kV potentials and have capabilities of advanced 2-D radiographic inspection, 2-D CT slice reconstruction, CT volume reconstruction for complete 3-D inspection, 3-D internal and external surface scanning, and complete tools for precision measurement and analysis. Upon completion of the upgrade, the contractor shall provide on-site training and phone support for Government Nondestructive Inspection (NDI) engineers.

2. APPLICABLE DOCUMENTS: All work performed by the contractor shall be accomplished in accordance with applicable original equipment manufacturer (OEM) of the provided equipment publications, technical directives, instructions, standards and procedures contained in pertinent manuals, utilizing blueprints, drawings or schematics.

2.1. “Attachment 1” – CT System Area Layout

2.2. “FRCSE Work Restrictions” – Base Restrictions and Contractor Access information

2.3. Code of Federal Regulations (CFR) Title 21-1020.40

2.4. ASTM E2737

3. REQUIREMENTS: The contractor shall provide and install the CT system complete in the designated space as shown on Attachment 1. It is the responsibility of the contractor to get the entire unit or assembled components to the prescribed space and meet all requirements as set below as a complete system.

3.1. System Capabilities: System shall be capable of all functions described below

3.1.1. Advanced 2-D X-ray inspection

3.1.2. 2-D CT slice reconstruction

3.1.3. CT volume reconstruction for 3-D inspection

3.1.4. 3-D internal and external surface scanning

3.1.5. Measurement and analysis tools

3.2. Designated Location: Designated location is in NAS-Jacksonville, B793, Materials Lab in the southeast corner of the NDI area as illustrated in Attachment 1.

3.3. Radiation Shielded Cabinet: Enclosure shall meet or exceed 21CFR 1020.40

3.3.1. Shielding Location and Performance

3.3.1.1. Radiation leakage shall not exceed 0.5 mr/hr (milliroentgen per hour) at any point 2 inches away from the outer surface of the enclosure. This applies to all enclosure outer surfaces.

3.3.1.2. Primary radiation shielding shall be capable of reducing energy of maximum kVp (Kilovolt Potential) constant potential attainable by system to leakage requirement in Section 3.3.1.1 or below for all surfaces capable of being exposed to the primary beam.

3.3.1.3. Secondary shielding for all other surfaces shall be capable of reducing back scatter and stray radiation to the leakage requirement in Section 3.3.1.1 under any operating conditions.

3.3.2. The supplied equipment and all ancillary items required to meet the requirements set in this document shall fit in the space prescribed in Attachment 1 and meet the following requirements:

3.3.2.1. Equipment shall be fully operational with all capability unimpeded.

3.3.2.2. Equipment shall be fully functional including:

3.3.2.2.1. All operations/functions shall be accessible and within reach of equipment operator without shifting from an initial position or having to bend or twist awkwardly.

3.3.2.2.2. Access shall not be restricted to any point below operational envelope/capability.

3.3.2.3. Equipment shall be fully maintainable. All maintenance points specified in the OEM Maintenance Manual as specified in Section 3.12.1.2 below shall be accessible without safety hazards including, but not limited to pinch points, sharp edges, falls from height (greater than 4 feet), or clearances that create interference for the hand and/or tools/equipment required to perform the maintenance.

3.3.3. Equipment provided shall include interlocked baffles for cable access to working envelope/radiation space.

3.3.3.1. Equipment shall include as many baffles as necessary for full function without swapping cables.

3.3.3.2. Supplied baffles shall have minimum dimensions of 6” x 12”.

3.3.4. Equipment provided shall be equipped with an automated door to work space

3.3.4.1. Portal shall be fully accessible with and capable of handling a part the full size and weight of the work envelope/table/space provided.

3.3.4.2. Doors shall be equipped with primary and secondary safety interlocks with all supplied X-ray generation equipment.

3.3.5. Equipment shall be supplied with a warning lamp indicating x-rays are being generated.

3.3.5.1. Warning lamp shall illuminate when X-ray generation is initiated and remain on until X-rays have stopped.

3.3.5.2. Warning lamp shall include backlit lettering ‘X-RAY ON’.

3.3.5.3. Warning lamp shall be ‘fail-safe’ and not allow X-ray generation if the bulb is not illuminated for any reason.

3.3.6. Equipment shall include surveillance cameras.

3.3.6.1. Cameras shall be provided in sufficient number at field of view and resolution to observe process and diagnose any issues with operation of the unit.

3.4. Object Placement and Control

3.4.1. A flat, level surface shall be provided for placement of object to be inspected. Surface shall be provided with sufficient details to hold part fixtures securely in place during inspection – some examples would be tee slots or holes. These details shall be sub-flush to flat, level surface provided – no permanent or semi-permanent detail shall be proud of the surface.

3.4.2. For purposes of describing motion control, components in this section shall be referred to as the ‘Part’ in the remainder of this document.

3.5. Motion Control

3.5.1. All motion control axes shall be independent and capable of variable speed.

3.5.1.1. The inspection envelope is defined as the volume required to physically fit a part for 2-D inspection. The inspection envelope of the supplied equipment shall have the following MINIMUM dimensions:

3.5.1.1.3. 30 inches diameter.

3.5.1.1.4. 30 inches in height.

3.5.1.1.5. 100 pounds weight.

3.5.1.2. The scan envelope is defined as the volume required to perform a complete CT scan. The scan envelope of the supplied equipment shall have the following MINIMUM dimensions:

3.5.1.2.6. 20 inches diameter.

3.5.1.2.7. 26 inches in height.

3.5.1.2.8. 100 pounds weight.

3.5.1.3. All motion axes shall have resolution as described below:

3.5.1.3.9. 0.001 inches for translational axes.

3.5.1.3.10. 0.001 degrees for rotational axes.

3.5.2. Devices Included in Motion Control

3.5.2.1. For purposes of describing motion control, components listed in this section shall be referred to as ‘Device’ or ‘Devices’ in the remainder of this document.

3.5.2.1.11. Digital Detector Array (DDA) as described in Section 3.7 below.

3.5.2.1.12. 225 kV open microfocus ionizing tube as described in Section 4.6.1 below.

3.5.2.1.13. 450 kV X-ray ionizing tube as described in Section 3.6.2 below.

3.5.3. Part Views

3.5.3.1. The base view shall be with the surface provided as described in Section 3.4 above parallel to the ground/floor. The part shall be capable of being viewed continuously through revolutions of 360 degrees about a vertical axis through the center of the part envelope.

3.5.3.2. The base view shall be able to be tilted on an axis transverse to the X-ray/detection path a minimum of 20 degrees in either direction. This view shall not inhibit the function in the base view in any way.

3.5.4. Motion Limits

3.5.4.1. Motion shall be provided to the devices, the part, or both meet the following requirements at a minimum:

3.5.4.1.14. Acquire an image of the edge/limit/boundary of a part that maximizes the envelope as described in Section 3.5.1.1 above. The system shall be capable of displaying the image of the edge/limit/boundary of the part with at least 1 inch visible outside/beyond the edge/limit/boundary in the field of view at all possible settings and combinations of settings as described below:

3.5.4.1.14.1. Tube settings

3.5.4.1.14.2. Distance from source to part

3.5.4.1.14.3. Distance from source to detector

3.5.4.1.14.3.1. In addition to axis/axes required to adjust distance from source to detector, system shall have capability of translating the detector transverse to the source-to-detector path in both horizontal and vertical directions with sufficient range to adjust effective pixel-pitch during image acquisition (Sub-Pixel).X-Ray Generation

3.5.5. 225 kV Open microfocus ionizing tube

3.5.5.1. Tube voltage 225 kV min

3.5.5.1.15. Max Power 350 W

3.5.5.5. Oil-free vacuum system

3.5.5.6. High Tension Cable Length to support safety/100% motion

3.5.5.7. Complete Control Unit

3.5.5.7.16. Automatic tube warm-up routine including high voltage, filament current

3.5.5.7.17. Automatic focus, electron beam alignment, and target loading control

3.5.5.8. High Energy Copper Filter Kit

3.5.5.8.18. 0.125 inch

3.5.5.8.19. 0.250 inch

3.5.5.8.20. 0.500 inch

3.5.6. 450 kV x-ray ionizing tube

3.5.6.1. Tube voltage 450 kV min

3.5.6.1.21. 1800 W high stability generator

3.5.6.1.22. 5mm Be window

3.5.6.1.23. Target angle 11 degrees

3.5.6.1.24. Radiation coverage 40 degrees x 30 degrees

3.5.6.2. Multi focal spots

3.5.6.2.25. 50 microns – 50 W

3.5.6.2.26. 100 microns – 100 W

3.5.6.2.27. 250 microns – 250 W

3.5.6.2.28. 350 microns – 350 W

3.5.6.2.29. 450 microns – 450 W

3.5.6.3. Digital Controller with the following modes:

3.5.6.3.30. Warm up

3.5.6.3.31. Radiographic

3.5.6.3.32. Fluoroscopic or ‘Live-Mode’

3.5.6.3.33. Auto Watt

3.5.6.3.34. Manual

3.5.6.4. High tension cables of sufficient length to support full function safely

3.5.6.5. Oil-to-air cooling system to include the following interlocks:

3.5.6.5.35. Fluid flow

3.5.6.5.36. Working Fluid Temperature

3.5.7. Automated collimator

3.5.8. Automated shutter

3.5.8.1. 4-leaf

3.5.8.2. 2-axis

3.6. Digital Detector Array (DDA)

3.6.1. DDA shall be delivered with objective evidence that it meets or exceeds all qualifications for ASTM E2597 with the following specifications:

3.6.1.1. Pixel Pitch 139 micron

3.6.1.2. Array size 3072 x 3072 pixel

3.6.1.3. Dynamic range 16-bit (65,536 level grey scale)

3.6.1.4. Acquisition speed of 6 frames per second (fps) at full resolution

3.6.1.5. Detector size 16.8 inches x 16.8 inches

3.6.1.6. Shielded housing capable of protecting the DDA from energy when the unit is run to full power

3.7. Workstation – A workstation shall be provided that fits in the prescribed area as indicated in Attachment 1. It shall fit conveniently in the space complete with all peripheral hardware described below as a minimum:

3.7.1. Ergonomic control console

3.7.1.1. Human-Machine Interface (HMI)

3.7.1.2. Display

3.7.1.2.37. Monitor or monitors sufficient size to perform all operations equipment is capable of

3.7.1.2.37.4. Minimum nominal size 32 inches

3.7.1.2.37.5. Minimum contrast ratio 1300:1

3.7.1.2.37.6. Maximum pixel pitch shall be 0.1845mm

3.7.1.2.37.7. Display minimum of 256 shades of grey

3.7.1.2.38. Reconstruction system including any additional hardware that is required to acquire, view, and process images created by the system.

3.7.1.2.38.8. Processing System Requirements. Industrial Controller. The contractor shall provide an industrial Controller or Personnel Computer (PC). If a PC is provided,. its sole purpose must be to control the machine and display system output and meet all of the requirements set forth in this document. The case shall be of a size that is capable of containing all of the hardware necessary to support the complete function of the machine. In addition, the case shall have adequate ventilation with filtered intake. Intake filter shall be replaceable by operating personnel with either no tools or basic hand tools. An electronic rack mounted PC is acceptable as long as the Controller and the rack have adequate ventilation capable of supporting running of the unit at full power for 100% duty cycle. Controller and all components including any processors supplied shall be of current manufacture and supported by the OEM with no known date of obsolescence published at the time of contract award. The Controller shall be equipped with the latest operating system (OS) provided by the developer of the Controller or third party that develops operating systems. The Controller shall be provided with the equipment and ready to run with all required software loaded onto it. All applications and/or software required for the use of the machine shall be provided loaded and tested on the Controller and provided separately on appropriate media complete with instructions to be loaded by DoD IT personnel in the event that the unit should fail or need to be updated. All testing of the performance of the software shall be performed during the Required Testing portion of the installation as prescribed in Section 4 below.

3.7.1.2.38.9. Operating System shall be Microsoft Windows 11 capable of running all operation, reconstruction, measurement, and reporting software for complete function of the system

3.7.1.2.38.9.2. Software Support. All proprietary software required for the complete functioning of the machine shall be provided. Software shall be provided with a license for the government to install and delete on at least the number of machines covered by this contract. The contractor shall disclose a price at the time of proposal for additional copies/licenses for the software in the event it would be to the advantage of the government to utilize the software on PC’s other than the ones that are dedicated to running the machine. Support shall include updates and troubleshooting support. Updates shall be provided at any time that they are made available. The government shall be supplied with any updates by the time they are offered on the open market at the latest. If no software updates are issued within a calendar year, the contractor shall issue a letter on its company letter head addressed to the TPOC to serve as proof that the software is up to date. Support can include online support and/or telephone support during normal working hours. Support shall be sufficient for government IT professionals to troubleshoot and resolve any issues that may arise due to software performance or conflicts. Other services that are not covered in this section shall be made available as an option to the government. Prices for these additional services shall be disclosed at the time of proposal.

3.7.1.2.38.10. Processor shall be of manufacture by the company that was originally founded and formerly known as Advanced Micro Devices and now called only AMD. It shall be the model of nomenclature Threadripper 64 Core/128 Threads or unit of equivalent processing capability compatible with system.

3.7.1.2.38.11. Random Access Memory (RAM) supplied with unit shall be minimum of 1 Terabyte (TB) and system shall be capable of recognizing and utilizing all of it.

3.7.1.2.38.12. Operating System storage shall be 2 TB minimum and connected via non-volatile memory express (NVMe) or equivalent.

3.7.1.2.38.13. Internal data storage shall consist of a solid state drive (SSD) with a minimum of 16 TB capacity.

3.7.1.2.38.14. Graphics processing unit (GPU) or units as required shall be supplied in sufficient number to be capable of driving all graphics capabilities of the system seamlessly and shall be provided with a combined 96 GB (Gigabyte) memory at a minimum.

3.7.1.2.39. External Data Storage Hardware

3.7.1.2.39.15. Unit shall be supplied with a networked attached storage device with 8 diskless bays as a minimum.

3.7.1.2.39.16. Networked attached storage shall be supplied with a minimum of (8) x 8 TB SSD. Any additional hardware required for the system to recognize the full capacity of this external storage device shall be supplied and operating with the unit.

3.7.1.3. Office/Lab Standard Ergonomic Chair

3.7.1.3.40. Shall be of rolling type with at least (5) legs/castors

3.7.1.3.41. Ergonomically adjustable with minimum adjustments

3.7.1.3.41.17. Height

3.7.1.3.41.18. Tilt (entire chair)

3.7.1.3.41.19. Backrest angle

3.7.1.3.41.20.

3.7.1.4. The workstation shall not negatively affect or impede the operation, function, or maintainability of the unit.

3.8. Sufficient hardware to manage all machine functions continuously for CT scans that could run up to 8 hours in duration. Image Acquisition/Processing – The system shall include all software necessary to acquire images created by the system and process them completely to meet or exceed all capabilities listed in Section 3.1 of this document. The software should be capable at a minimum of the following functions:

3.8.1. Image Averaging

3.8.1.1. System shall include the below two modes of image averaging. Both shall be capable of averaging up to 256 image frames in either of two these two modes:

3.8.1.1.42. Weighted Summation Method

3.8.1.1.43. Rolling Average Method

3.8.2. Image Resolution

3.8.2.1. System shall be capable of mosaic imaging stitching capability

3.8.3. Image Storage

3.8.3.1. Storage in raw mode is adequate for data as acquired in real time.

3.8.3.2. Video shall be stored in the form of .avi files

3.8.3.3. Images shall be capable of being read and stored in all of the following formats:

3.8.3.3.44. TIFF 32-bit/16-bit/8-bit

3.8.3.3.45. .bmp

3.8.3.3.46. .jpg

3.8.3.3.47. DICONDE

3.8.4. Image Measurement and Analysis

3.8.4.1. The system shall be equipped with VGSTUDIO MAX image measurement and analysis software or equivalent.

3.9. Automatic Scan Geometry Corrections – System shall be capable of performing scan geometry corrections automatically.

3.10. Process Control Software – The system shall include Process Control Software and routines that are capable of verifying/validating the system checks prescribed in ASTM E2737.

3.11. Installation – Installation shall be performed and completed by personnel qualified for installation by the OEM of the equipment installed.

3.11.1. Installation shall be accomplished in the space prescribed in Attachment 1.

3.11.2. Installation shall be complete including:

3.11.2.1. Transportation

3.11.2.2. Supervision

3.11.2.3. Preparation

3.11.2.4. Assembly

3.11.2.5. Testing

3.12. Tech Data – Placeholder for CDRL’s at this time

3.12.1. Operation & Maintenance (O&M) Manual

3.12.1.1. Operation Manual (CDRL A001). This manual or portion of a single O&M manual shall contain, at a minimum, instructions and procedures for proper operation of the equipment provided. This manual shall contain all resources necessary for a trained engineer, engineering technician, or production artisan to start up the machine from a cold start after being down for an extended period of time, operate the machine at capacity meeting all performance parameters as set forth in this document, properly shut down operations for short periods (e.g. – 15-60 minute periods.), starting up after short periods as described above, continuing operations, and shutting equipment down for extended periods of time (e.g. – up to an extended period beyond 7 days). Instructions and procedures set forth shall allow continued operations as necessary and keep the equipment operating at capacity and meeting the performance prescribed in this document.

3.12.1.2. Maintenance Manual (CDRL A002). This manual or portion of a single O&M manual shall contain, at a minimum, the theory of operation, detailed preventive/periodic maintenance procedure, list of required expendables, list of recommended spare parts, a section that covers corrective maintenance, and original equipment manufacturer literature. Theory of Operation shall include the basis of design including, but not limited to, the concepts from physics and chemistry that make the machine work properly. The contractor shall provide a single compiled section for Preventive Maintenance (PM). This portion of the manual shall include all recommended PM prescribed in parameters of both usage in units of displacement covered or hours of use and by absolute time as measured by a clock or calendar. PM tasks shall be listed in an orderly format that is intuitive with the sequence necessary to keep the equipment operating at capacity and meeting the performance prescribed in this document. The lists of expendable items and spare parts shall include manufacturer and specific identification (model number/part number/etc.) of each item sufficient to procure the exact item required at a later time from an authorized dealer. In addition, the contractor shall use this manual to identify any suitable substitutes should the original item be unavailable at the time it is required. It is understood that not all items will have a substitute, but every effort shall be made to locate alternative items that could be used to repair the machine. A section of Corrective Maintenance shall include a listing of the most severe and the most likely modes of failure along with the most likely causes of each failure (there may be more than one likely cause for each failure). Likely causes shall also be linked to alternative solutions to the failure. This portion of the guide shall be formatted so that it can be used by an operator of the system as a resource in the field when diagnosing issues on the machine.

3.13. Training – Training shall be performed at FRCSE utilizing the equipment and O&M manuals provided. Onsite training by the supplier of the equipment shall be for up to six (6) Engineers and Engineering Technicians. It is understood that some training – notably for image analysis – may be beneficial to the government and convenient for the supplier to be performed by the company that developed the software supplied with the unit. Such arrangements shall be disclosed at the proposal stage of the project with a clear statement that at least two (2) seats shall be provided for that training will be provided at no additional cost to the government. Onsite training by the supplier shall include two parts:

3.13.1. Onsite Training

3.13.1.1. Definitions

3.13.1.2. Theory of Operation

3.13.1.3. Typical qualitative and quantitative values under normal conditions

3.13.1.4. Image analysis training

3.13.2. Hands-on Training

3.13.2.1. Start up after an extended period of non-use

3.13.2.2. Start up of system for normal/daily operation

3.13.2.3. Process Control monitoring and checks

3.13.2.4. Set up of part to be inspected

3.13.2.5. Inspection of part including all functions

3.13.2.6. Shut down of system for normal/daily operation

3.13.2.7. Shut down of system of an extended period of time

4. Required Testing: Required testing in this section shall be performed after final placement and/or assembly of equipment provided at FRCSE. All prescribed testing in this section shall be performed and passed or waived at the discretion of the government before equipment can be accepted.

1.1. Radiation Safety Testing

1.1.1. Each X-ray tube will be tested at max power. If tube can be moved, it will be moved to its limits while monitoring radiation leakage with a radiac monitor. Performance shall meet all parameters of CFR 21 1020.40 as prescribe in Section 3.3.1 of this document.

1.2. Motion Control Testing

1.2.1. Motion will be initiated and measured for accuracy for each axis provided. Motion limits shall meet or exceed the parameters prescribed in Section 3.4.1 of this document.

1.2.1.1. Each axis will be run to its limits and measured

1.2.1.2. Axes will be run independently to determine any conflicts

1.3. Operations Testing

1.3.1. Operation of the unit will be tested by running test parts provided by the Government

1.3.2. The parts provided will measure 20 inches diameter, 26 inches in height, 100 pounds weight.

1.3.2.1. At the discretion of the government, a part that matches the inspection envelope as indicated in Section 3.5.1.1 or multiple parts that represent the inspection envelope will be loaded into the system. System will demonstrate that all part views prescribed in Section 3.5.3 above are visible as described in the sub-sections. These points will be verified in the neutral part position as well as the maximum ‘tilted’ views as described in Section 3.5.3.2.

1.3.2.1.1. Upper left corner

1.3.2.1.2. Center at top

1.3.2.1.3. Upper right corner

1.3.2.1.4. Lower right corner

1.3.2.1.5. Center at bottom

1.3.2.1.6. Lower left corner

1.3.2.2. At the discretion of the government, an ASTM-E2737 Duplex Phantom will be loaded and tested for the following:

1.3.2.2.1. Achieve a minimum SNR of 250 over the 0.250” – 0.750” material thickness of the Duplex Phantom

1.3.2.2.2. Achieve a minimum CNR of 2.5 on using the 2T-hole of both plaque type penetrameters on the Duplex Phantom

1.3.2.2.3. Resolve 4 out of 4 sides and the 1T-hole of both plaque type penetrameters on the Duplex Phantom

1.3.2.3. At the discretion of the government, up to three parts will be loaded and compared to a previous scan of the same part. The frequency and level of false indications shall be the same or less than the original scan and the known discrepancies shall be present and at a level of intensity of the original scan or greater.