EC2000 STATEMENT OF WORK (SOW).pdf

Statement of Work Upgrade Four (4) EC2000 Eddy System Machines

Fleet Readiness Center Southeast (FRCSE) Jacksonville, FL

1. SCOPE

Fleet Readiness Center South East (FRCSE) requires an upgrade to four (4) existing EC2000 Eddy Current Inspection System Machines, FRCSE Asset Numbers 65886050980 (0980), 65886057934 (7934), 65886051492 (1492), 65885225142 (5142), necessary to support the repair of rotating engine components on General Electric (GE) TF34, F404, and F414 engines at the FRCSE maintenance facility onboard Naval Air Station (NAS) Jacksonville in Florida. This upgrade will encompass the machine’s motions control system, Industrial PC, and eddy current instrumentation required to monitor and manage motion control, to include cables, software and associated hardware. Upon completion of the upgrade, on-site training and phone support is required for Government artisans and Government Nondestructive Inspection (NDI) engineers.

2. APPLICABLE DOCUMENTS

All work performed by the contractor shall be accomplished in accordance with applicable OEM publications, technical directives, instructions, standards and procedures contained in pertinent manuals, utilizing blueprints, drawings or schematics. The contractor must have or have access to all required documents and approvals to use UniWest and General Electric technical data and obtain an equivalent of the current manufacturer certification to upgrade equipment that is part of GE Aviation Data for OrderingDFO-P3TF21. The Government will not be providing any OEM or GE specifications to the contractor.

3. REQUIREMENTS

The contractor shall upgrade the motion control system on each machine from the current configuration to the required configuration to include the Central Processing Unit (CPU), servo amplifiers, brushless direct current (DC) servo motors, all cables, all adapters, software, and tuning.

3.1 Servo Motors/Industrial Brakes: The current motion control is driven via Aerotek 3200 driving standard DC servo motors for seven (7) independent axes on each machine.

3.1.1 Each motor shall be replaced with a brushless DC equivalent that performs at a minimum of torque and power delivery of the existing motors.

3.1.2 Each motor shall fit in the same space as existing motors without affecting function or deteriorating performance. If new motors by design do not fit current couplings/end-effectors, it is the responsibility of the contractor to adapt them without affecting function or deteriorating performance of the machine.

3.1.3 Industrial Brakes: There is currently one industrial brake on each machine.

3.1.4 The brake shall be re-used or replaced. Whether re-using the existing brake or replacing it, the brake shall be capable of being actuated and shall function as it exists.

3.2 Servo Drives: The existing eight (8) servo amplifiers on each machine shall be replaced with new drives that are recommended by the OEM of the motors to maximize performance and efficiency and shall not have a negative impact on reliability.

3.2.1 Servo amplifiers shall fit in the same space as the current (8) amplifiers per machine. If this is not feasible or is impractical, the Contractor shall create space for them to fit within the current workstation without affecting the footprint of the workstation or negatively impacting the function of the workstation.

3.2.2 If the existing cables from the amplifier to the motors do not support power delivery or input signal, or feedback signal to the new motors, then the Contractor shall install new cable compatible with both the number and size of conductors and appropriate connectors for operation as recommended and intended by the OEM of the motors.

3.3 Central Processing Unit (CPU): The existing motion control system has a CPU that buffers information to and from the PC and directly controls the operation of the drives/motors.

3.3.1 A new, appropriate CPU designed to work with the type and number of drives on the system shall be provided unless the individual drives are designed to connect directly to the PC.

3.3.2 Parameters of the CPU shall be programmable as an entity and for each individual drive from the Industrial PC provided. No additional equipment shall be required to tune the parameters of the CPU or the individual drives.

3.3.2.1 The program function may be password protected beyond the security provided with the machine for normal operation.

3.3.2.2 Any additional passwords or security measures shall be provided to the TPOC (CDRL A001) and shall be separate from any operation and/or maintenance manuals that are supplied with the upgrade.

3.3.3 All software for the monitoring, tuning, and diagnostics of the CPU and the individual drives shall be included on the Industrial PC and shall be accessible in its entirety to the government.

3.3.4 The CPU shall fit in the same space as the existing unit without affecting function or deteriorating performance. If this is not feasible or impractical, it is the responsibility of the contractor to create space for them within the current workstation without affecting the footprint of the workstation or negatively impacting the function of the workstation.

3.3.5 The Contractor shall provide all cables required for complete operation, tuning, and diagnostics of the CPU and drives from the PC.

3.4 Eddy Current Instrumentation (Single Channel): The existing scheme on the equipment uses a

UniWest 450Z eddy current instrument on each machine for single channel inspections.

3.4.1 The Contractor shall install new single-channel eddy current instrumentation, cables, software, and tuning to ensure performance of the functions listed below:

3.4.1.1 Operation from PC

3.4.1.1.1 Tuning frequency amplitude response

3.4.1.1.2 Start/Stop

3.4.1.2 Output to PC

3.4.1.2.1 Standard virtual oscilloscope sweep

3.4.1.2.2 Any output required for reports on inspections of GE TF34, F404, and F414 engines

3.4.2 The new instrumentations shall fit in the same space as existing unit without affecting function or deteriorating performance. If this is not feasible or impractical, the Contractor shall create space for them to fit within the current workstation without affecting the footprint of the workstation or negatively impacting the function of the workstation.

3.4.3 The Contractor shall install new cables to connect the new instrumentation to existing probes, PC, and to provide power to the unit.

3.5 Multi-Channel Eddy Current Array: The existing Arrayed inspections are currently executed by a MicroDesigns four (4) channel multiplexed instrument on two (2) of the machines (0980, 1492) and the UniWest (24) channel US-454-MC-24 instrument on the other two (2) machines (7934, 5142).

3.5.1 The Contractor shall install new multi-channel array instrumentation, cables, software, and tuning that meets or exceeds the minimum capability (listed below) of the existing instruments:

3.5.1.1 Operation from PC

3.5.1.1.1 Tuning frequency and amplitude response

3.5.1.1.2 Start/Stop

3.5.2 Output to PC

3.5.2.1 Standard virtual oscilloscope sweep

3.5.2.2 At least (4) channels on one monitor simultaneously

3.5.2.3 An output required for reports on inspections of GE TF34, F404, and F414 engines

3.5.3 The new instrumentation shall fit in the same space as existing units without affecting function or deteriorating performance. If this is not feasible or impractical, the Contractor shall create space for them to fit within the current workstation without affecting the footprint of the workstation or negatively impacting the function of the workstation.

3.5.3.1 It is acceptable for the single-channel and multi-channel array functions to be performed by a single eddy current instrument unit. In that case, the instrumentation shall fit into one of the areas of the existing eddy current instrument only. If this is not feasible or impractical, the Contractor shall create space for both eddy current instruments within the current workstation without affecting the footprint of the workstation or negatively impacting the function of the workstation.

3.5.4 The Contractor shall install new cables to connect new instrumentation to existing probes, the PC, and to provide power to the unit.

3.6 Industrial PCs: The existing system on each machine is controlled and feedback displayed by an Industrial Personal Computer (PC) that is run via Microsoft Windows XP operating system.

3.6.1 The contractor shall install a new Industrial PC on each machine capable of managing and monitoring both the new motion control and the new eddy current instrument (or instruments), as well as networking for all four (4) machines, and a printer.

3.6.1.1 The new Industrial PC shall network all four (4) machines with the Government-owned printer model in place at the time work begins on the upgrade. The printer model currently connected to the existing machines is a Hewlett-Packard Color LaserJet Pro MFP M281fdw.

3.6.2 The new Industrial PC processing capability, memory, architecture, and case shall be of a size and capacity that is capable of containing and operating any and all peripheral hardware necessary to support the complete function of the machine.

3.6.3 The new Industrial PC for each machine shall fit in the same space as the existing unit without affecting function or deteriorating performance. If this is not feasible or is impractical, the contractor shall create space for each unit within the current workstation without affecting the footprint of the workstation or negatively impacting the function of the workstation. An electronic rack mounted PC is acceptable as long as the PC and the rack meet space requirements and have adequate ventilation.

3.6.4 The PC case shall have adequate ventilation to be used in the designated space. If space filtration is not in line with the filtration recommended by the original equipment manufacturer (OEM) of the PC, then the contractor shall provide a properly filtered intake.

The Intake filter shall be replaceable by operating personnel with either no tools or basic hand tools that are readily available in the shop.

3.6.5 The PC and all components, including any processors supplied, shall be of current manufacture and supported by the OEM of the PC with no known date of obsolescence published at the time of contract award.

3.6.6 The industrial PC supplied shall be shipped to the technical point of contact (TPOC) to have software loaded onto it.

3.6.7 Software:

3.6.7.1 Any proprietary software shall be capable of running in the Windows 10 environment and shall not conflict with the Microsoft Office Suite currently in use by the Government.

3.6.7.2 Proprietary software required for the use of the machine shall be developed securely (e.g.

– using Systems Development Lifecycle (SDLC) process, automated code review, others as appropriate) and provided on appropriate media complete with instructions to be loaded by Department of Defense (DoD) Information Technology (IT) personnel. Verification of secure development shall be submitted with the Industrial PC when it is shipped to the

TPOC (CDRL A002).

3.6.7.3 If there is any testing that the contractor would like performed after the software is loaded, the procedures for those tests shall be included with the software. These tests shall only include basic diagnostics to determine that the software was properly loaded with no faults or issues due to installation. Any testing of the performance of the software shall be performed during the Testing and Acceptance portion of the installation.

3.6.7.4 Software supplied by the government and loaded onto the machine shall include:

3.6.7.4.1 MS Windows 10 OS

3.6.7.4.2 Current version of Microsoft Office Suite used by DoD if it is required for rendering reports.

3.6.7.4.3 Shall be provided with a license for the government to install and delete on at least the number of machines covered by this contract.

3.6.7.4.3.1 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.

3.6.8 Proprietary software Support:

3.6.8.1 The contractor shall provide a document stating support shall be provided for 10 years post-Acceptance (CDRL A003). Support shall be sufficient for government IT professionals to troubleshoot and resolve any issues that may arise due to software performance or conflicts.

3.6.8.2 Support shall include updates and troubleshooting support for 10 years from the date the equipment is accepted.

3.6.8.3 Updates shall be provided at any time that they are made available during the 10 year support coverage. Updates that are fully tested may be supplied to the government before they are offered on the open market; however, the government shall be supplied with any updates by the time they are offered on the open market at the latest. Updates shall be provided to the TPOC, 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 (CDRL A004).

3.6.8.4 Support can include online support and/or telephone support during normal working hours of 0800 to 1600 Eastern Standard Time (EST) Monday through Friday.

3.7 Operation Timer/Meter: As machine maintenance has evolved, Facilities & Plant Maintenance (F&PM) is transitioning to Reliability Centered Maintenance (RCM). For these machines, that includes the alternative to apply preventive maintenance based on use instead of time. The contractor shall provide a means of determining the time in total hours that the machine has been used performing inspections. The current method is a vibration sensor on the C-axis to a dedicated device. While the current system has allowed us to make some advances, it has some serious drawbacks. The preferred method would be to count the time that the machine is in motion and display it on the monitor when requested. Other means are acceptable as long as it provides a time that the machine was actually moving and/or performing an inspection – not just turned on.

3.8 Handling of Data: All data acquired by the machine in operation – regardless of the process in which it was acquired, shall remain the property of the government. No data shall be uploaded to or downloaded from the machine without express consent from a government representative.

The direction to a contractor to upload or download in a Statement of Work or Contract shall constitute express consent. Other activity with data shall be performed by government personnel unless under the direct supervision of IT/Cyber Security.

3.9 All oil holes, grease fittings, and filler caps shall be accessible.

3.10 Hour Meter. Machine shall be equipped with the means to display accumulated hours. If an analog hour meter is used, it shall be mounted on the main electrical panel visible from the outside unless some other arrangement was agreed to prior to the start of the upgrade. The hour meter shall be installed to display accumulated operating time of the C-axis and/or A-axis drive motor(s). The meter shall be of the non-resetting type and shall have a range of 0 to 99,999 hours in increments of 1 tenth of 1 hour. The meter shall be sealed to prevent the entrance of dust and moisture and shall be mounted to withstand shock and vibration generated by the machine to which it is attached. As an alternative, it is acceptable to display accumulated hours of the prescribed motor(s) by the PC. In this case, detailed instructions on how to retrieve the hours shall be included in the Maintenance Manual.

3.11 Special Tools. Any specialized tooling NOT available in normal Production or Maintenance shops required for the operation or maintenance of the equipment shall be provided by the contractor. This shall include consumable items needed for start-up of the equipment.

3.12 Marking on Instruments, Control Panels, and Plates. All words on plates shall be in the English language. Characters shall be engraved, etched, embossed, or stamped in boldface on a contrasting background. All plates shall be corrosion resistant.

3.13 Lubrication Plate. A lubrication plate shall be permanently and securely attached to each machine. The plate shall contain the following information:

3.13.1 Points of lubricant application

3.13.2 Servicing interval

3.13.3 Type of lubricant

3.13.4 Viscosity

3.13.5 Military or Federal Specification for each lubricant (If applicable)

3.13.6 Size and type of each lubricant filter

4. Installation and Acceptance Testing: The upgrade shall be installed and tested/inspected prior to acceptance, in accordance with (IAW) the following criteria:

1.1. Machine upgrade installations shall be conducted in a systemic order so that one (1) EC machine is always working and available to the Government for operational use.

1.2. On-site support: A technician shall be on-site for the duration of the execution of the upgrade and until all training is complete. It is not required for the same technician to be present the entire time.

1.3. Testing at the Contractor Site.

1.3.1. Windows-10 based EC-2000 system Capability Demonstration. The Contractor shall perform a Sub-set of tests from the original Engine OEM EC-2000 system qualification criteria.

1.3.2. Utilizing Engine OEM Low Cycle Fatigue (LCF) Cracked Specimens, the Contractor shall generate Probability of Detection Demonstrations in all required inspection features (holes, surfaces and complex features) of one Material. The resulting Probability of Detection

(PODs) shall be compared to the Original OEM EC-2000 system baseline to assure that flaw detection capability has not changed.

1.3.3. Windows-10 based EC-2000 full Capability Demonstration. The Contractor shall perform a Sub-set of tests from the original Engine OEM EC-2000 system qualification criteria:

1.3.3.1. Utilizing Engine OEM Verification Standards (Notched engine components), the contractor shall successfully inspect selected Verification Standards to cover all inspection modes (conventional, imaging) and applicable features (holes, surfaces and Complex features). The results shall be compared to the Original OEM EC-2000 system baseline to assure that all appropriate notches are detected.

1.4. Post-Installation Testing at FRCSE.

1.4.1. Functional Testing

1.4.1.1. Each axis shall be run manually with the pendent individually from a neutral ‘home’ position

1.4.1.2. Cover range of motion without faults at all speeds

1.4.1.3. Reaches set limits before mechanical limits/stops

1.4.1.4. Stops at set limits without requiring to be recovered or reset

1.4.1.5. While one axis is run, other axes shall not drift or move from their set position

1.4.2. Accuracy Testing

1.4.2.1. Each axis shall pass calibration procedure as supplied with unit – see Technical

Data section below.

1.4.3. Operational Testing

1.4.3.1. Up to three (3) different parts that have been previously inspected will be provided to the contractor by the Government for testing operation of the upgraded machines. The contractor shall load the parts to the machine and the scan plan from the database, and inspect the parts in accordance with GE specifications for the individual part by Type/Model/Series (TMS).

1.4.3.2. Each inspection shall complete with no motion faults.

1.4.3.3. Each inspection result shall meet or exceed the performance of a machine that has not been upgraded based on previous inspection report results.

5. Technical Data Deliverables

5.1. Operations Manual (CDRL A005). Shall include detailed steps for all of the following events at a minimum:

5.1.1. Recommended daily inspections to be performed before startup (if required)

5.1.2. Startup instructions from an extended shutdown

5.1.3. Startup instructions for daily/shift operations

5.1.4. Moving the machine manually

5.1.4.1. By pendant

5.1.4.2. By PC using the display and inputs

5.1.5. Setting up and inspecting a part

5.1.6. Interpreting the display during operation

5.1.7. Interpreting inspection results

5.1.8. Preparing and documenting reports (electronic and/or hardcopy as required)

5.1.9. Diagnosis, repair, and recovery of common faults/errors – operational level

5.1.10. Shutdown instructions for daily/shift operations

5.1.11. Shutdown instructions for an extended period of time

5.2. Maintenance Manual (CDRL A006). Shall include the following at a minimum:

5.2.1. Theory of operation

5.2.2. Detailed periodic maintenance procedure

5.2.3. List of required expendable materials and supplies

5.2.4. List of recommended spare parts

5.2.5. Trouble-shooting section

5.2.6. Original equipment manufacturer OEM literature

5.2.7. Preventive Maintenance (PM) Manual

5.2.8. Single, compiled document

5.2.9. Comprehensive list of all tasks required to keep equipment operating reliably at capacity

5.2.10. Events listed in chronological order including, but not limited to:

5.2.10.1.1. Daily

5.2.10.1.2. Weekly

5.2.10.1.3. Monthly

5.2.10.1.4. Semi-annual

5.2.10.1.5. Annual

5.2.10.1.6. And by hours of run time

5.3. Calibration Procedures (CDRL A007). Detailed procedures shall be provided for the Motion Control calibration.

5.4. Scan Plan Development Manual (CDRL A008). Detailed procedures on the development and use of scan plans including:

5.4.1. Development strategies

5.4.2. Composing/compiling machine instructions

5.4.3. Saving developed scan plans to the database

5.4.4. Retrieving and using developed scan plans during operations

5.4.5. Diagnosing typical issues that occur during scan plan development

6 TRAINING.

6.1 After satisfactory completion of acceptance testing of at least one upgrade install, but prior to the time that the last system is taken down for the upgrade, the contractor shall provide a qualified representative(s) to provide specialized training to familiarize receiving activity personnel with the upgraded equipment and to help ensure reliable performance and maximum service life during normal usage. The training shall be provided for (6) Production artisans and (10) Plant Services artisans, (4) Calibration Technicians and Engineers, and (6) NDI Engineers. Training shall be performed at location of the equipment. Training that requires more than one day shall be performed over consecutive days. Training shall be performed during the normal 8 hour workdays, between 6:00 am and 2:30 pm excluding any Federal holidays. The courses shall utilize the manuals provided under this contract in the Technical Data section above, and shall include both classroom and hands on portions. All printed training aids shall be supplied at no additional cost to the government, and be in the English language. All materials and references used in training shall be provided as part of this contract. A portion of the training shall be dedicated to demonstration and/or hands on of the operations required to start up the equipment from a cold shutdown, all tasks in sequence to perform a complete operation, and a complete shutdown that would be desirable or required for an extended period of non-use. Training shall begin as described at the beginning of this paragraph. Training classes shall be broken down as described:

6.2 Operations Training

6.2.1 Up to (6) Production Artisans and Supervisors

6.2.2 Primarily utilize the Operations Manual.

6.3 Maintenance Training

6.3.1 Up to (10) Maintenance Artisans, Technicians, Engineers

6.3.2 Primarily utilize Maintenance Manual

6.4 Calibration Training

6.4.1 Up to (4) Calibration Technicians/Metrology Engineers

6.4.2 Primarily utilize Calibration Procedures

6.5 Scan Plan Development Familiarization Training

6.5.1 Up to (4) NDI Engineers and Technicians

6.5.2 Primarily utilize Scan Plan Development Manual