Attachment_1_-_Purchase_Description.pdf

FA2263-18-Q-A004

Attachment 1

18M-243A-FO

April 12, 2018

Revision 3

PURCHASE DESCRIPTION

FOR

102,000 lbf and 30,000 lbf DEADWEIGHT CALIBRATORS

1.0 SCOPE: This purchase description is for 102,000 and 30,000 lbf Deadweight Calibrators. They will be used to calibrate force transducers such as load cells, crane scales, and other force measuring instruments. The deadweights provided will be directly traceable to the SI through National Institute of Standards and Technology (NIST). Specifications apply to both system unless individually specified. The requirements listed shall be provided such that both systems can operate independently.

2.0 PERFORMANCE REQUIREMENTS:

2.1 Measuring Range: The 102,000 lbf Deadweight Calibrator shall have a measuring range of at least 3000 to a minimum of 102,000 lbf in both tension and compression. The 30,000 lbf Deadweight Calibrator shall have a measuring range of at least 500 to a minimum of 30,000 lbf in both tension and compression.

2.2 Uncertainty: The Expanded Uncertainty of the Deadweight Calibrator shall be U= ± 0.0016% of applied force or better over the entire measuring range.

2.3 Weight Calibration: The yoke and the weights supplied shall be adjusted to produce a nominal lbf at the AFPSL by National Institute of Standards and Technology (NIST). The weights have to be machined light, but not too light that the weight cannot be brought up to the nominal value at NIST. The gravity value and average air density at the Deadweight Calibrator site will be provided by AFMETCAL.

3.0 FUNCTIONAL REQUIREMENTS:

3.1 Operating Modes: The Deadweight Calibrator shall be capable of operating in manual and automatic mode. Manual mode shall allow the operator to apply any weight(s) individually or in combination while reading the Test Instrument manually/visually. Automatic mode shall allow the operator to input a loading sequence and read the Test Instrument automatically through the software.

3.1.1 The Deadweight Calibrator shall incorporate digital communication connections which consist of at least RS232, USB, and Ethernet to communicate at a minimum the Tovey 9150 and HBM DMP40 indicators.

3.2 Weight Loading: The Deadweight Calibrator shall be capable of loading and unloading the weights automatically.

3.2.1 Shock Loading: The weights shall be applied and removed at a rate to minimize the effects of shock loading.

3.2.2 The weight support cones shall be designed to eliminate any sticking of the weights to the conical seats on the central shaft when weights are removed.

3.2.3 Sensors shall be used on the machine to inform the user which weights are loaded and which are not.

3.3 Test Section: The test section of the force application yoke shall be adjustable to accept test instruments of varying heights and allow for tension as well as compression calibration.

3.3.1 102,000 lbf Deadweight Calibrator Test Section Specification: At a minimum, the test section shall be as stated in the table below:

Minimum Requirement Compression Tension Test Section Height 36 inches 36 inches Test Section Width 18 inches 18 inches

30,000 lbf Deadweight Calibrator Test Section Specification: At a minimum, the test section shall be as stated in the table below:

Minimum Requirement Compression Tension Test Section Height 29 inches 29 inches Test Section Width 14 inches 14 inches

3.3.2 Crosshead: The crosshead shall remain parallel throughout the force range of the machine such that it shall not exceed the uncertainty stated in paragraph 2.2.

3.3.2.1 Crosshead Movement: The crosshead shall be motorized to control vertical height adjustment.

3.3.2.2 Crosshead Leveling: The crosshead shall be adjustable to maintain level.

3.3.2.3 Testing Surfaces for Compression: The testing surfaces shall be designed to mount load cells for measurement in compression. It will be capable of calibrating load cells with a ball cup/flat adapter on top and pinned on the bottom to ensure proper alignment.

3.3.2.4 Testing Surfaces for Tension: The testing surfaces shall be designed to mount tension rods for load cells, crane scales, and dynamometers for measurement in tension.

3.3.3 Adapters: All provided adapters shall be clearly marked with load ratings.

3.3.3.1 Compression Adapters: 5/8 to 1 ¼ inch Ball cup Adapters and Flat Adapters required for compression testing shall be provided.

3.3.3.2 Tension Adapters: Tension rods and shackles required for tension testing shall be provided.

3.4 Safety: Safety features shall be designed into the Deadweight Calibrator that will not allow the entire system to collapse in case of mechanical failure of the Deadweight Calibrator or the item under test.

Provisions to limit the travel of the load frame and weights in case of failure shall be made. In addition, there shall be a statement in the manual stating a schedule of periodic visual inspection or NDI of critical components.

4.0 MECHANICAL & PHYSICAL REQUIREMENTS:

4.1 Corrosion Resistant: All weights, yoke assembly and force generated components shall be corrosion resistant. All weights, yoke assembly and force generated components shall be made of non-magnetic stainless steel or nickel plated steel. The load frame shall be painted or coated and free from rust. Support equipment shall be rust resistant.

4.2 Weights:

4.2.1 Weight Markings: All weights shall be permanently marked with a unique serial number and its nominal weight value, which is visible when assembled.

4.2.2 Weight Material: The weights shall be forged from the same lot of material and homogeneous throughout the entire weight. A material sample of the same lot shall be measured for material density and retained by the owner.

4.2.3 Weight Construction: Each weight shall be new and constructed as axi-symmetrical discs. They shall be constructed with a minimum of two adjustment cavities with removable seals equally separated along the same concentric axis. Surface finish of the weights shall not exceed 120 µin for average roughness (Ra).

4.2.3.1 Adjustment Cavities: Cavities have to be large enough to allow NIST to adjust weights to nominal value using cavity pellets.

4.2.3.2 Adjustment Cavity Pellets: Adjustment Cavity Pellets shall be constructed with the same material and lot of the weights.

4.2.4 Weight Orientation: Weights shall be arranged with largest weights on top to reduce the pendulum effect through the loading cycle.

4.2.5 Weight Compliments: The weight compliments for the Deadweight Calibrators shall be the following:

102,000 lbf Deadweight Calibrator:

Yoke – 1000 lb, 1 – 1000 lb, 2 – 2000 lb, 7 – 4,000 lb, 2 – 5,000 lb, 7 – 6,000 lb, 2 – 8,000 lb weights

30,000 lbf Deadweight Calibrator:

Yoke – 500 lb, 1 – 500 lb, 9 – 1000 lb, 10 – 2000 lb weights

4.3 Weight Leveling: A leveling adjustment shall be capable of leveling each weight support. The weights shall be capable of being leveled within 0.1 inch.

4.4 Power Requirements: The Deadweight Calibrator shall operate on a 110 volt, 60 Hz, 20 amp power outlet.

4.5 Pneumatics: Pneumatics will be used to position weights, the Deadweight Calibrator shall require no more than 120 psi of shop air supply.

4.6 Components: Commercial parts and materials that are used shall have properties consistent with a precision laboratory instrument.

4.7 Use of Best Commercial Practices: The equipment shall be designed and constructed of materials that meet the requirements of this specification and in accordance with the best commercial practices for industry approved equipment. It shall be designed and manufactured to maximize reliability, maintainability, accuracy of operation, and ease of operation All parts (which include, but are not limited to, shafts, bearings, regulators, switches, controls) shall have proper clearance and adjustments. They shall work together so that the equipment will supply the rated requirements without unnecessary strains, vibrations or overheating. They shall be able to withstand the conditions met in shipping, storage, installation and service. All materials and parts of this equipment shall be capable of withstanding the environmental requirements of this specification. The Deadweight Calibrator shall be constructed in accordance with ASTM E74, applying a deadweight force directly without the use of intervening mechanisms.

4.8 Matched and Selected Components: These shall be kept to an absolute minimum. Use of specially built, nonstandard components shall be avoided.

4.9 Model and Serial Number Identification: Item’s Part Number, Manufacturer, and Serial Number shall be identified clearly on the item in a location visible to the operator. Unique item identification shall follow the Item Identification and Valuation clause as stated in the contract.

4.10 Operating Environment/Storage:

4.10.1 Operating Temperature: Electrical, electronic, and electromechanical items shall be capable of operating in an ambient temperature of 73 ± 5 °F without loss of required performance. Note: The room will be stable to 2 °F over any eight hour period.

4.10.2 Operating Humidity: The equipment shall maintain specified performance in an atmosphere from 20% to 50% relative humidity without loss of required performance.

4.11 Working Height: The working height of the machine shall begin at or within two inches above the height of the second floor.

4.12 Second floor opening: Both Deadweight Calibrators shall fit through a 9’6” by 19’6” hole, which will be concentric to the 12’ x 21’ concrete pad on the first floor. This is at the working height stated in the paragraph 4.11.

4.12.1 The opening in the second floor will be 9’6” by 19’6” for the protrusion of the yoke assembly of both a 102,000 and a 30,000 lbf Deadweight Calibrator. Removable platforms shall be provided to fill the opening between the second floor and up to one inch but not in contact with the yoke of the Deadweight Calibrator. These platforms shall be capable of supporting personnel working around the Deadweight Calibrator.

4.13 Installation: The Deadweight Calibrator shall be shipped to the site and installed by the OEM.

4.14 Loading Device

4.14.1 Loading of Test Instrument: There shall be loading device located near the Test Section of the Calibrator to assist in the lifting process. This device shall be capable of transferring load cells or crane scales near the floor and raising it up to the appropriate height of the Test Section of the Calibrator. Then it shall be capable of placing the load cell or crane scale in the Test Section of the Calibrator.

4.14.2 Assist Capability: The loading device shall lift 200lbs. The operator shall be able to maneuver the loading device appropriately to place the load cell or crane scale into the test section.

4.14.3 Loading duration: The process of lifting the Test Instrument into the Test Section shall not exceed 30 seconds with minimal effort from the operator.

5.0 Software and Controller:

5.1 Controller: A controller is required that can efficiently operate under Microsoft Windows 10 Professional 64 bit operating system. All major components of the system shall be commercially available and fully supportable by commercial sources. Where specific brands are identified in this specification, no substitutes are allowed without prior approval from the AFMETCAL. The Controller shall meet or exceed Microsoft Windows 10 Professional hardware requirements.

5.2 Processor:

5.2.1 CPU PassMark Score: 4,000 or higher

5.2.2 Supports Credential Guard: Virtualization Extensions (Intel VT-x or AMD-V)

5.2.3 Supports Device Guard: VT-d or AMD-Vi; IOMMU (Input/output Memory Management units)

5.2.4 Supports Extended Page Tables (Second Level Address Translation)

5.2.5 Supports Direct Memory Access (DMA)

5.2.6 UEIF Firmware V. 2.4 (or higher)

5.3 Memory: Minimum 8 GB system Memory.

5.4 Input Output (I/O) External Ports, Slots and Connectors (At minimum, the following types of I/O interface connections shall be available on the controller or via port replication):

5.4.1 USB: Minimum of three integrated USB 3.1, Thunderbolt Type 3/USB-C

5.4.2 USB-C to USBA Adapter w/USB-C port

5.4.3 Ethernet: One 10/100/1000 BaseT Ethernet port.

5.4.4 Video: G3D Video PassMark Score: 500 or higher

5.4.4.1 External video support

5.4.4.2 Adapter to DVI connection

5.5 Display Panel: 20-inch (diagonal) or larger viewable display.

5.6 Hard Drive:

5.6.1 120 GB (Minimum) Hard Disk Drive

5.6.2 FIPS 140-2 certified SED

5.7 DVD-ROM: Internal or External DVD +/- RW dual layer or Blue-Ray

5.8 Operating System and Software: All software shall run under Microsoft Windows 10 (Professional operating system or greater 64bit, latest version release). All software shall run Windows 10 as a non-elevated user. Shall be supplied with Microsoft Word and Excel, latest release with a non-renewable license.

5.9 Additional Hardware: Additional hardware required to make this system function as identified by this purchase description shall be required.

5.10 Interchangeability:

5.10.1 When firmware or software upgrade is anticipated by a manufacturer during the life of this contract, the contractor shall contact AFMETCAL for concurrence. If AFMETCAL concurs with the proposed upgrade all previous units shall be updated to this upgrade.

5.10.2 All firmware or software provided under this contract shall be at the same version, revision and revision date at the completion of the contract.

5.11 Software Identification: Software version shall automatically display upon startup.

5.12 Software shall have a minimum of the following sections, which can be selected from the opening screen.

5.12.1 Calibration Files: The user shall be able to select Create a New Test File or select an Existing Test File. It is also where the calibration file information is shown and filled in by the user. The user shall have the option to save the calibration data without finishing, but program shall prompt user to save upon exiting.

5.12.2 Calibration Data: Once the Test File has been created, the computer shall be used to store all calibration data. The software shall perform all necessary calculations and analysis in accordance with ASTM E74. See instruction to offerors for content of Calibration Data.

5.12.2.1 The software shall allow user to transfer appropriate data into the Tovey 9150 and HBM DMP40 digital indicators.

5.12.3 Manual Mode: The user shall be capable of manually selecting the desired weight to be applied to the Test Instrument by using the computer.

5.12.4 Semi-Automated Calibration: The user shall be capable of creating and running a sequence of weights in ascending and/or descending order, stopping after each load until prompted to continue. Once the Deadweight Calibrator has stabilized, it shall prompt the user to record a reading.

5.12.5 Automated Calibration: The software shall be capable of calibrating a load cell or test item automatically in ascending and/or descending order once the calibration file has been created by the user.

Automated calibration shall be in accordance with Sections 3.1 and 3.2.

5.12.5.1 Automated calibration shall include user inputs for command read prompts of Test Instruments.

5.12.6 Calibration Reports: System shall be capable of exporting data into Microsoft Excel formats, at a minimum, as well as print them in any of the saved formats. Data shall include all information included in previous sections. See instruction to offerors for content of Calibration Reports.

5.12.7 Operations Files: All data / files mentioned in section 5.12 shall be savable, editable and retrievable.

5.12.8 Active Visual Schematic: A visual schematic of the machine shall be available to show what weights are being applied.

5.13 Software Warranty: The contractor shall warrant that the software product meets this purchase description and is free from defects in design and operation and will perform to stated specifications from the date of shipment through warranty expiration date of the equipment. The contractor's Commercial Warranty or Addendum shall include verbiage to assure the following minimum requirements are satisfied. All other clauses of the contractor's warranty shall remain in effect unless they contradict the requirements stated below.

5.13.1 The contractor shall (at no additional cost) update, or replace the software product as necessary to correct any deficiencies identified in the software. Replacement software shall meet or exceed the requirements in this purchase description, shall not require additional training to operate and be warranted for the remainder of the original warranty.

5.13.2 The contractor shall bear transportation costs for all replacement products.

6.0 TRAINING: Training encompassing the operation and maintenance of the Deadweight Calibrator shall be provided and not exceed one week.

7.0 TESTING: This item will be inspected and accepted at destination as stated in the contract. The item will be checked with test equipment with parameters equal to or better than those required to assure that specified performance parameters are met. Test equipment used shall have first echelon certification directly traceable to the National Institute of Standards Technology (NIST) or other AFMETCAL-approved equivalent international laboratory. Tests will be performed to assure that the item meets the requirements of this purchase description. Such testing at destination does not relieve the contractor of performing all inspections and quality checks at the point of manufacture as necessary to assure performance as specified herein.

Attachment:

Data Requirements

Attachment to Purchase Description

18M-243A-FO

102,000 lbf Dead Weight Calibrator and 30,000 lbf Dead Weight Calibrator

DATA REQUIREMENTS

MANUALS: A set of operational and maintenance manuals shall be provided. As a minimum, the manuals shall include an explanation of features, performance specifications, operational instructions, theory of operation, calibration procedures, and an illustrated parts breakdown. Wherever possible, use of pictures, diagrams, schematics and mathematical formulas shall be included such that any text material may be better understood. Specifically, the calibration procedure shall include a list of required calibration equipment, by part number, connection diagrams and step-by-step instructions to follow for completing this task. In addition, a system- level manual explaining the system operation and software shall also be provided. Manuals shall be on CD/DVD-ROM in Indexed Portable Document Format (iPDF).

A validation and verification of the manuals will be required. The manual shall be in accordance with the Air Force Technical Manual Contract Requirements (TMCR) TM86-01Q and Contract Data Requirements List (DD Form 1423).

CALIBRATION CERTIFICATE: A calibration certificate, traceable to the National Institute of Standards and Technology (NIST) or other national metrology institutes (NMIs) shall be provided with each instrument. This calibration certificate must comply with Data Item Description (DID) DI-QCIC-80798C and the Contract Data Requirements List (DD Form 1423).

PRODUCT DRAWINGS AND ASSOCIATED LISTS: The product drawings shall be delivered to the Government with delivery of the evaluation unit. The drawings shall be in contractor format and document the information specified and in accordance with Data Item Description DI-SESS-81000E and Contract Data Requirements List (DD Form 1423). When possible, product drawings and associated lists shall be delivered on CD-ROM in Indexed Portable Document Format (iPDF).

SOFTWARE USER MANUAL: The software user manual shall contain instructions to execute one or more related computer software configuration items. The software user manual shall be on CD/DVD- ROM in Indexed Portable Document Format (iPDF) and prepared in accordance with Data Item Description DI-IPSC-81443A and Contract Data Requirements List (DD Form 1423).

SOFTWARE TEST PLAN (STP): The Software Test Plan (STP) describes plans for qualification testing of Computer Software Configuration Items (CSCIs) and software systems. It describes the software test environment to be used for the testing, identifies the tests to be performed, and provides schedules for test activities. There is usually a single STP for a project. The STP enables the acquirer to assess the adequacy of planning for CSCI and, if applicable, software system qualification testing. The STP must comply with Data Item Description DI-IPSC-81438 and Contract Data Requirements List (DD Form 1423).

SOFTWARE TEST REPORT (STR): The Software Test Report (STR) is a record of the qualification testing performed on a Computer Software Configuration Item (CSCI), a software system or subsystem, or other software-related item. The STR enables the acquirer to assess the testing and its results. This DID is used when the developer is tasked to analyze and record the results of CSCI qualification testing, system qualification testing of a software system, or other testing identified in the contract. The STR must comply with Data Item Description DI-IPSC-81440A and Contract Data Requirements List (DD Form 1423).