2024 Appendix C -Test Support Oct 24 Update.pdf

APPENDIX C – Test Support

1.0 Purpose

The purpose of this appendix is to define the requirements for Hardness Maintenance Hardness Surveillance (HM/HS) Test Support.

1.1 Test Support Scope of Services

Cooperating with the Air Force HM/HS Test Team, the Contractor shall support Low-Level Continuous Wave (LLCW) tests at Palmdale, CA Air Force Plant 42 using the Portable Hardness Surveillance Test System (PHSTS), Remote Test Point Entry System (RTPES), and all other necessary support equipment.

Refer to Appendix D for estimated workload data.

Test Support activities include the following:

1.1.1 Technical Engineering Support

The Contractor shall perform technical engineering support for LLCW test execution of PDM HM/HS tests.

The Contractor shall provide a Senior Engineer and support personnel proficient in use of the PHSTS with necessary ability, knowledge, and skill sufficient to execute all activities described herein.

1.1.2 Test Planning

The Contractor shall participate in pre-test and post-test planning sessions and shall review test planning documentation and provide comments as requested by the COR. Meetings include:

• Pre-Test planning meetings via telecom or in person.

• Pre-Test organization meetings at the Test Site.

• Post-Test lessons-learned meetings at the Test Site.

• Post-Test results and analysis meetings via telecom or in person.

1.1.3 System Operation

The Contractor shall operate the LLCW test system and equipment. This shall include system power up procedures, equipment preparation, database preparation, equipment inventory management, pre-test field mapping, post-test field mapping, equipment preparation, system checkouts, test data collection/verification, troubleshooting, system security, and general site coordination with the Test Director.

1.1.4 LLCW Equipment Preparation

The Contractor shall prepare the PHSTS and LLCW equipment to conduct test activity.

Equipment preparation shall include the preparation of hardware and software.

Examples of LLCW equipment preparation performed by the Contractor includes moving the LLCW equipment to the test site, routine maintenance, equipment inventory checkout, troubleshooting instrumentation, unspooling fiber-optic cables, hardware inspection and configuration, and software and database updates and configuration on the PHSTS and RTPES.

1.1.5 LLCW Equipment Database Preparation

The Contractor shall perform database setup for the software in the PHSTS and RTPES prior to the start of the Operational Test Period (including the AV instrumentation phase). The Contractor shall submit required database setup reports to the COR upon completion of database preparation.

1.1.6 Pre-test Field Mapping

The Contractor shall prepare and operate the PHSTS LLCW equipment and antenna for pre-test field mapping. Field mapping shall be completed before the AV arrives to the test site. The Contractor shall map the electromagnetic fields of the test antenna as a pre-test diagnostic procedure.

The Contractor shall compare the acquired pre-test data to historical data from the same test site to verify consistent performance of the test system including the antenna.

Any defects found in the test system during pre-test field mapping must be reported and repaired or mitigated before proceeding with AV Test Conduct. During test activity, The Contractor shall make available electronic copies of the currently updated Logs to be reviewed at any time requested.

This effort shall include any necessary equipment check out, software and database configuration, deployment of instrumentation, and movement of sensor stands across test point locations.

1.1.7 AV Test Conduct

The Contractor shall provide twenty-four (24) hour per day support during the operational test period to run the test data acquisition cycles of the PHSTS. The Contractor shall prepare and operate the PHSTS LLCW equipment during the AV test. This includes the AV instrumentation phase, operation of the RTPES, and transfer of test point data to PHSTS.

The Contractor shall provide operational testing support including PHSTS LLCW equipment setup and configuration, troubleshooting, database and software configuration, and test data acquisition. The Contractor shall support software and data acquisition bug fixes during the operational test period to avoid work stoppage.

The Contractor shall support instrumentation of aircraft and test-system troubleshooting using correct instrumentation techniques, document instrument configurations by recording in database, and report any problems encountered in Logs.

The Contractor shall follow the test plan provided by the COR. The Contractor shall ensure acquired data is accurate for phase and magnitude. The Contractor shall ensure all data points are collected IAW test plan and shall report to the COR progress and any deficiencies of data acquisition IAW with the test plan.

During test activity, The Contractor shall make available electronic copies of the currently updated Logs to be reviewed at any time requested.

The Contractor shall operate the LLCW equipment to process acquired data. The Contractor shall perform preliminary data analysis as test data is acquired and make written recommendations in the test log to the Government, per each work shift, to ensure quality data is being acquired. The Contractor shall perform a complete LLCW computer and data backup following each test.

All information generated as a result of performing these services shall become Government Property. Unless otherwise specified by the COR, CO or Test Director, all data acquired during testing and stored in the PHSTS is designated as Controlled Unclassified (CUI) and shall remain Government Property. The PHSTS computer systems and operations procedures are not certified for storage of Classified material.

The Contractor shall control and account for all instruments used for pre-test, test conduct on AV, and post-test activities. If any instrumentation is unaccounted for, the Contractor shall record deficiencies in the Operations Report Log and report verbally to the COR to prevent instrumentation from being left on the AV.

1.1.8 Post-test Field Mapping

The Contractor shall prepare and operate the PHSTS LLCW equipment and antenna for post-test field mapping. Field mapping shall be completed after the AV is removed from the test site.

The Contractor shall map the electromagnetic fields of the test antenna as a post-test diagnostic procedure.

The Contractor shall compare the acquired post-test data to the pre-test and other historical data from the same test site to verify consistent performance of the test system including the antenna.

Any defects found in the test system during post-test field mapping must be reported and repaired or scheduled for repair before leaving the test site. During test activity, The

Contractor shall make available electronic copies of the currently updated Logs to be reviewed at any time requested.

This effort shall include any necessary equipment check out, software and database configuration, deployment of instrumentation, and movement of sensor stands across test point locations.

1.1.9 Activity Logs

During Pre-test Field Mapping, AV Test Conduct, and Post-test Field Mapping, the Contractor shall maintain a continuously updated Operations Report Log and a continuously updated Test Log.

The Operations Report Log maintains a record of noteworthy events such as equipment malfunctions, software problems, and any other issues with the PHSTS LLCW test system needing corrective actions.

The Field Map Test Log maintains a record of the progression of Field Map Test data acquisition, test points per-run lists, test points acquired, and any noteworthy events related to test activities. Written recommendations must be annotated in the Field Map Test Log concerning any irregularities in data.

1.1.10 Post-Test Restoration

The Contractor shall, upon completion of LLCW test activity, restore the PHSTS LLCW equipment and test site to a condition commensurate with non-test periods in preparation for a period of inactivity awaiting the following test. This shall include, and is not limited to, lowering the antenna, if necessary, and properly storing instruments and supplies, recovering and storing fiber-optic cables, accounting for all equipment in instrument inventory, database inventory check, database and computer system backups, and system shutdown.

The contractor shall prepare, package, and ship equipment requiring repair and/or maintenance.

If required, the Contractor shall prepare and package the PHSTS for shipment.

1.2 Equipment Inspections

The Contractor shall perform inspections and tests on the PHSTS HVAC, fire suppression system, instrumentation, mechanical components, LLCW antenna system, computer systems, and software used during testing periods and document any discrepancies found. The Contractor shall maintain procedures for verifying system or component state-of-health and perform system and component performance tests on the components indicated herein and on the intervals indicated the maintenance actions tables in Appendix D. Items found to be discrepant shall be identified for maintenance. This documentation shall be available for viewing by the

COR either in hard-copy or electronic format at any time. Equipment inspection documentation shall remain Government Property.

1.2.1 PHSTS Trailer

The PHSTS Trailer is a 50-foot long, 10-foot wide transportation trailer containing all the PHSTS instrumentation. The trailer has eight (8) wheels and two (2) spares and an air-ride suspension system. The Contractor shall complete inspections, preventative maintenance, and repairs for the PHSTS Trailer as follows.

1.2.1.1 Heating, Ventilating and Air-Condition (HVAC) System for PHSTS

The PHSTS trailer has two (2) separate, redundant, hot-gas-bypass HVAC systems used to cool the electronics inside the PHSTS. The HVAC systems maintain appropriate temperature and humidity inside the PHSTS during equipment operation, under a wide variety of outside environmental conditions. The Contractor shall provide preventative maintenance activities for the HVAC systems and the Electronic Control Unit (ECU) on the intervals indicated.

1.2.1.2 PHSTS Safety Lighting

The Contractor shall inspect the PHSTS Safety Lighting daily during operational periods to ensure it is functioning and repair as needed.

1.2.1.3 Fire Suppression System

The Contractor shall maintain certified inspections of all fire suppression system components every year of contract in accordance with OEM specifications for each unit and schedule repairs as needed. Fire suppression system components including fire extinguishers, CO2 fire suppression system, and all fire and smoke detection components. Written indications of these inspections shall be attached to each component.

1.2.1.4 Uninterruptible Power Supplies

The Contractor shall perform an inspection of uninterruptible power supply units in the PHSTS prior to test execution and repair as needed.

1.2.1.5 Software Verification and Configuration Management

The PHSTS is comprised of the LLCW capabilities, PHSTS data acquisition system and the RTPES software systems. The Contractor shall inspect and verify the functionality of the PHSTS acquisition and RTPES software. The Contractor shall manage the maintenance and configuration of all Executable and Source Code bases, Databases, and Database Interface environments.

1.2.1.6 Software

The Contractor shall notify the COR when software updates/modifications are available for the LLCW and RTPES systems. Upon approval of the COR, the Contractor shall install LLCW and RTPES system updates/modifications and test the systems to verify performance. The Contractor shall provide configuration management support for the LLCW and RTPES software systems.

1.2.1.7 Software Modifications & Verification

The Contractor shall provide support for software maintenance for the LLCW systems and RTPES software systems. This software support shall include modifications to resolve problems encountered during previous test periods or to improve the efficiency of system operations.

The Contractor shall provide written recommendations to the COR, for the purchase and installation of additional commercial software components and for modifications to improve efficiency. This shall include upgrades, updates and service packages for software currently installed in equipment. Upon approval from the CO, the Contractor shall provide the technical personnel and support to accomplish these modifications or updates, test the system after the new software is installed, and verify that the new software updates do not adversely affect system operation and performance.

1.2.1.7.1 PXIe Analyzer Acquisition Software Upgrade

The contractor shall upgrade the Data Acquisition Controller with Transient software to add functionality of Keysight Technologies 48-port PXIe M980xA series Vector Network Analyzer (VNA) for data acquisition. The purpose of this upgrade is to significantly increase the speed of test data acquisition by acquiring data on 48 ports simultaneously.

The existing PHSTS data acquisition system and software currently use a Keysight Technologies E5061B 2-port analyzer. The upgrade to Keysight Technologies 48-port PXIe M980xA series analyzer shall support data acquisition on all ports simultaneously.

The contractor shall provide four (4) rack-mount computers as part of the deliverables. These computers shall be compatible with the existing PXIe chassis and associated components, including the Keysight Technologies M980xA series VNA. The computers shall meet the required specifications for running the upgraded Data Acquisition Controller software and handling data acquisition from the PXIe system.

The contractor shall set up and configure the computers, ensuring full integration with the existing PXIe chassis and analyzer blades already owned by the Government. The contractor shall install the upgraded acquisition software on these computers and ensure seamless communication between the software, PXIe components, hardware, and existing PHSTS system.

The contractor shall integrate the computers, software, and PXIe hardware into the existing PHSTS system ensuring that the entire system is operational. The contractor shall test the system and verify it is fully functional for simultaneous data acquisition on all PXIe chassis analyzer ports.

The upgraded software shall include a Probe Verification System (PVS). The existing acquisition system and software use a National Instruments USB-5133 oscilloscope for PVS. The upgraded software shall support PVS using the 48-port PXIe M980xA series analyzer.

All other functionalities and interfaces of the PHSTS and Data Acquisition Controller with Transient software shall be preserved.

The contractor shall deliver a fully functional, releasable version of the software ready for deployment and use. The contractor shall ensure that the software is free from defects and fully compatible with existing systems as specified. The Government retains irrevocable ownership of all source code developed and technical data generated during this project. The contractor shall deliver all source code, associated documentation, and technical data to the Government. The Government will have the rights to use, modify, reproduce, release, perform, display, and/or disclose the software, source code, and technical data for any purpose.

The contractor shall deliver a comprehensive user manual and provide training sessions designed to enable effective use of the upgraded software. The user manual shall include detailed instructions on software functionalities and troubleshooting tips. Training shall be conducted by qualified personnel and shall cover all new features and operational procedures introduced in the upgrade. The contractor shall schedule and complete these training sessions within one month of software deployment.

1.2.1.7.2 Database Manager Software Update

The contractor shall update the Database Manager software to a recent and supported version of database management system software. The existing Database Manager was created using Microsoft Access 2010. The purpose of this update is to have a recent and supported version of database management system software which allows the users to interact with a SQL database through a graphical user interface.

The updated Database Manager software shall work with the existing SQL Server database and shall have all functionalities of the existing Database Manager.

The contractor shall deliver a fully functional, releasable version of the software ready for deployment and use. The contractor shall ensure that the software is free from defects and fully compatible with existing systems as specified. The Government retains irrevocable ownership of all source code developed and technical data generated during this project. The contractor shall deliver all source code, associated documentation, and technical data to the Government. The Government will have the rights to use, modify, reproduce, release, perform, display, and/or disclose the software, source code, and technical data for any purpose.

The contractor shall deliver a comprehensive user manual and provide training sessions designed to enable effective use of the upgraded software. The user manual shall include detailed instructions on software functionalities and troubleshooting tips. Training shall be conducted by qualified personnel and shall cover all new features and operational procedures introduced in the upgrade. The contractor shall schedule and complete these training sessions within one month of software deployment.

1.2.1.8 Antenna System

The contractor shall inspect and repair the antenna LLCW System that will be used for this test located at site three (3), AF Plant 42, Palmdale, CA. LLCW Ellipticus Antenna Systems and support structures are listed in Appendix A.

1.3 General PHSTS Housekeeping

The Contractor shall keep the PHSTS Trailer internal spaces clean both during the Operational Test Period and during routine maintenance periods. This includes the requirement to complete carpet vacuuming, storage of cabling, power cords, and tools, and disposal of consumables and non-recyclable trash.

1.4 Interruption of Test Support

The Contractor shall make every effort to make repairs and correct malfunctions that are required to prevent cancellation or interruption of a scheduled test.

1.5 Hours of Operation

During LLCW test support: Working hours will be conducted on a twenty four (24) hours per day/ seven (7) calendar days per week schedule. The Government will provide the test schedule to the Contractor one (1) week prior to start of test. The shift work normally lasts between four

(4) and six (6) calendar days during the instrumentation and data acquisition period. Each shift operation will include Contractor support and government personnel support.

1.6 Special Qualification

The Contractor shall provide a Senior Engineer (SE) and additional technical support personnel during test activities. Contractor personnel must be able to operate the PHSTS through all test activities including instrumentation checkout/inventory, database preparation, pre-test field map, extrapolation construction, instrumentation installation, data acquisition, data quality control, post-test field mapping, data analysis/processing and instrumentation inventory.

The SE shall have the following qualifications, certifications, and functions:

Education: A Bachelor of Science degree in a physical science or relevant engineering discipline such as physics, electrical engineering, computer engineering.

Experience: Knowledge and experience of engineering sufficient to apply new concepts, developments, and experienced judgment to solve a variety of complex technical problems.

This experience must include at least ten (10) years of engineering experience in the foregoing engineering functions for a BS degree, or eight (8) years of experience in the foregoing engineering functions for a MS degree, or six (6) years of experience in the foregoing engineering functions with a PhD degree, and minimum of three (3) years of specific experience in the operation and maintenance of hardware and software identified in this solicitation. SE also shall possess six (6) years of specific experience processing and analyzing Hardness Maintenance/Hardness Surveillance and EMI/EMC data associated with the LLCW test systems used during test acquisition.

Functions: The SE provides technical engineering advice and expertise for the design, development and testing of Specialized Electromagnetic Transient (EMT), Electro Optical equipment, similar electromagnetic or other physical phenomena, data acquisition on the PHSTS and large-scale instrumentation systems. The SE may also be responsible for leading a technical engineering group involved with the development of hardware and software systems and component-level designs for the support of testing capabilities. Provides system engineering designs and recommendations to resolve technical problems and supports documentation of technical efforts and reports.

1.7 Mission Essential Contractor Services

The Contractor shall provide access to Subject Matter Expert (SME) to accommodate the continuation of data collection during mission essential test periods for both software and hardware failures. Test period will begin with aircraft instrumentation and end with the removal of aircraft from test pad.