SOW_Rev1-_Augmentor_Fuel_Pump_Test_Stand_Upgrade_23_May_2016.pdf

STATEMENT OF WORK

For

Augmentor Fuel Pump Test Stand Upgrade Rev 1

FSC: 4920

NAICS: 334419

Air Driven Accessories Tinker A.F.B., OK 73145

Dated 23 May 2016

Prepared by:

76 CMXG/ENA

1.0 SCOPE: The Contractor shall provide all labor, tools, equipment, test equipment, material, parts, quality control, transportation, inspection manuals, personal protective equipment and clothing including reflective clothing, hearing and eye protection including prescription safety glasses, safety harnesses, fall protection equipment, lifting equipment and any incidentals necessary for design, installation, and activation of one (1) Augmentor Fuel Pump Test Stand Upgrade to be installed on the current Augmentor Fuel Pump Test Stand Test Stand, Pratt and Whitney part number PWA 56214-3, currently in operation in Building 200, Tinker Air Force Base (TAFB), OK 73145-5990. See Appendix A.

2.0 STATEMENT OF REQUIREMENTS

2.1. General

2.1.1. The test stand upgrade is required to perform final acceptance testing on two military aircraft end item Augmentor Fuel Pumps. The test stand upgrade shall be capable of testing the end items listed in Appendix D in accordance with the required end item Air Force (AF) Technical Orders (T.O.) listed in Appendix D.

2.1.2. The Contractor shall use the current test stand (Pratt and Whitney P/N PWA 56214-3 operation and maintenance instructions, electrical, compressed air, and fuel schematics from T.O. 33D4-6-744-1 dated 26 September 2011 and the illustrated parts breakdown (IPB) from T.O. 33D4-6-744-4 dated 15 September 1996 as reference for the required test stand operation in the design of the upgrade. The test stand technical orders are listed in Appendix E.

2.1.3. The Contractor may request the Contracting Officer (CO) provide a copy of the test sections of the end items and test stand technical orders listed in Appendices D and E. The request shall be by e-mail. The Contractor shall not disclose the data provided for any purpose or in any manner not specifically authorized or required by this SOW or the contract.

2.2. Design

2.2.1. The Contractor shall utilize Commercial Off-the-Shelf (COTS) equipment in the design of the test stand upgrade The current Augmentor Fuel Pump Test Stand utilizes compressed air at four hundred fifty (450) Pounds per Square Inch Gauge (PSIG) at eight hundred fifty (850) degrees Fahrenheit (F) and Calibration Fluid (MIL-C-7024, Type II). These systems, combined with low pressure pneumatic and electrical systems, are required in order to provide performance testing of the end items.

2.2.2. The current Augmentor Fuel Pump Test Stand consists of three (3) main components, the Service Module, the Control Module, and the Power Cabinet.

The Contractor may utilize and modify the existing components or provide new components. The Service Module is located in a Class I Division I environment.

The Control Module and Power Cabinet are located in a non-hazardous environment. Any changes to the Service Module shall comply with all National Electric Code (NEC) and all National Fire Protection Association (NFPA) regulations governing Class I Division I environments. Any changes to the Service Module shall ensure that a minimum of four (4) feet clear distance around the perimeter is maintained. The maximum size of any new Control Module shall be seventy two (72) inches wide, thirty (30) inches deep and eighty four (84) inches high. Any new Control Module shall be designed for standard nineteen (19) inch rack mount equipment and shall provide a front work surface for an operator. The maximum size of any new Power Cabinet shall be forty (40) inches wide, twenty (20) inches deep and eighty four (84) inches high. Any new consoles or modules shall be powder coated white on the interior and powder coated light gray or tan on the exterior. The Contractor shall provide color samples and the color will be approved by the Government prior to purchase and application. The surfaces to be powder coated shall be sand blasted and thoroughly cleaned prior to powder coating. All painting shall be performed at the contractor’s facility.

2.2.3. The test stand upgrade shall provide a minimum of three (3) emergency stop buttons. One (1) shall be located at the middle left on the front panel of the Control Module, one (1) shall be located at the middle right on the front panel of the Control Module, and one (1) shall be located on the Service Module near the connection location of the unit under test. All buttons shall remove power from the compressed air system, the fuel system, the chilled water system, and the four hundred eighty (480) and one hundred twenty (120) Volt Alternating Current (VAC) electrical system. All emergency stops shall be hard wire controlled.

2.2.4. The Contractor shall provide new labeling of all the operator interface bulkhead connections. The Contractor shall use 0.63 thick Garolite or equivalent sheets with a black background and white lettering. The lettering shall be 0.25 inch to

0.37 inches in height.

2.2.5. The test stand shall be equipped with labels on the front test panel which identify every calibration fluid, air, and electrical connection point, valves, switches, site glasses, gauges, indicators and instrumentation. The identifying numbers/letters shall be the same numbers/letters as is currently on the test stand. The labels and mounting shall be resistant to the test fluid and not degrade as a result of exposure to the test fluid. The labels shall be fabricated in accordance with Paragraph 2.2.4

2.2.6. The test stand shall have a new nameplate affixed to the front upper right. The nameplate shall be corrosion resistant and securely affixed to the test stand.

The words and numbers shall be engraved, etched, embossed or stamped in boldface print on a contrasting background. The words shall be a minimum of

0.25 inches in height and maximum of 0.5 inches in height. The nameplate shall contain the following information: nomenclature, manufacturer’s name, manufacturer’s model designation, manufacturer’s serial number, date of upgrade and contract number.

2.2.7. Chilled Water Control System

2.2.7.1. The Contractor shall provide one (1) each new chilled water control system.

The control system shall have the capability to control the current chilled water system components as required to maintain the control parameters necessary for testing the end items listed in Appendix D. The control system shall include all programming and the data acquisition system hardware required in Section 2.2.16 and any additional components needed to work in conjunction with current or new SOW required system components to control the chilled water circuits. All required modifications to the chilled water system for the test stand upgrade shall be rated for a fifty/fifty (50/50) water/glycol mix. The chilled water system and all components shall comply with the latest version of ASME 31.1 Power Piping and ASME 31.3 Process Piping.

2.2.7.2. The Contractor shall provide new chilled water control valves and actuators.

The valves shall replace the current valves 518A and 559A. All electrical actuators shall be rated for operation in a Class I Division I environment. The Contractor shall provide all hardware required to ensure replacement valves work in conjunction with current chilled water system components as required to maintain the control parameters necessary for testing the end items listed in Appendix D.

2.2.8. Shop Air Pneumatic Control System

2.2.8.1. The Contractor shall provide a new shop air pneumatic control system for the test stand. The control system shall have the capability to control the current shop air pneumatic system components as required to maintain the control parameters necessary for testing the end items listed in Appendix D. The control system shall include all programming and the data acquisition system hardware required in Section 2.2.16 and any additional components needed to work in conjunction with current or new SOW required system components to control the shop air pneumatic circuits. All required modifications shall be rated for a minimum of one hundred fifty (150) PSIG working pressure at two hundred (200) degrees F unless otherwise noted. The pneumatic system and all components shall comply with the latest version of ASME 31.1 Power Piping and ASME 31.3 Process Piping.

2.2.9. Calibration Fluid Control System

2.2.9.1. The Contractor shall provide a new calibration fluid control system. The control system shall have the capability to control the current calibration fluid system components as required to maintain the control parameters necessary for testing the end items listed in Appendix D. The control system shall include all programming and the data acquisition system hardware required in Section 2.2.16 and any additional components needed to work in conjunction with current or new SOW required system components to control the calibration fluid circuits. All required modifications to the calibration fluid system and all components shall comply with the latest version of NEC, NFPA, ASME 31.1 Power Piping and ASME 31.3 Process Piping.

2.2.10. Calibration Fluid System

2.2.10.1. The Contractor shall provide one (1) each new boost pump capable of delivering 200 gallons per minute against a total dynamic head of 400 feet.

The pump shall be designed to pump MIL-C-7024, Type II calibration fluid at temperatures between 70 and 110 degrees Fahrenheit. The pump shall be designed for operation in a Class I Division I environment. The pump design shall ensure cavitation free operation. The pump shall be rated for continuous operation. The pump shall be a PACO model 16-30955140115- 3891 or equivalent. The pump vibration levels shall comply with ISO 10816-

1. Alignment of the pump and motor shall be performed.

2.2.10.2. The Contractor shall provide one (1) each new motor to drive the boost pump. The motor shall be a minimum 40 horsepower designed for 460 VAC, 60 HZ, 3 phase power. The rpm shall be 3550 to 3600. The motor shall be rated for continuous duty operation. The motor shall have a minimum NEMA efficiency of 91.0 and service factor of 1.15. The motor shall be equipped with an over-heat protective device. The motor shall be designed for operation in a Class I Division I environment and comply with all NEC requirements.

2.2.10.3. The contractor shall provide all new hardware as required to interface the boost pump with the boost pump motor and the boost pump to the test stand and calibration fluid supply system.

2.2.10.4. The contractor shall provide one (1) each new scavenge pump capable of delivering 8 gallons per minute against a total dynamic head of 60 feet. The pump shall be designed to pump MIL-C-7024, Type II calibration fluid at temperatures between 70 and 110 degrees Fahrenheit. The pump shall be designed for operation in a Class I Division I environment and comply with all NEC requirements. The pump design shall ensure cavitation free operation. The pump shall be rated for continuous operation.

2.2.10.5. The contractor shall provide one (1) each motor to drive the scavenge pump. The motor shall be a minimum 1 horsepower designed for 230/460 VAC, 60 HZ, 3 phase power. The motor shall be rated for continuous duty operation. The motor shall have a minimum and service factor of 1.15.

The motor shall be equipped with an over-heat protective device. The motor shall be designed for operation in a Class I Division I environment and comply with all NEC requirements.

2.2.10.6. The contractor shall provide all new hardware as required to interface the scavenge pump with the scavenge pump motor and the scavenge pump to the test stand and calibration fluid supply system.

2.2.10.7. The Contractor shall provide new calibration fluid control valves and actuators. The valves shall replace the current valves 551A, 562A, and 563A. All electrical actuators shall be rated for operation in a Class I Division I environment. The Contractor shall provide all hardware required to ensure replacement valves work in conjunction with current chilled water system components as required to maintain the control parameters necessary for testing the end items listed in Appendix D.

2.2.11. High Pressure Pneumatic System

2.2.11.1. Ambient Temperature System

2.2.11.1.1. The Contractor shall provide one (1) each new high pressure ambient temperature control system. The control system shall have the capability to control the current system components as required to maintain the control parameters necessary for testing the end items listed in Appendix D. The control system shall include all programming and the data acquisition system hardware required in Section 2.2.16 and any additional components needed to work in conjunction with current or new SOW required system components to control the high pressure ambient temperature circuits. All required modifications to the ambient temperature pneumatic system and all components shall comply with the latest version of ASME 31.1 Power Piping and ASME 31.3 Process Piping.

All components shall be rated for eight hundred (800) PSIG working pressure.

2.2.11.2. High Temperature System

2.2.11.2.1. The Contractor shall provide one (1) each new high pressure high temperature control system. The control system shall have the capability to control the current system components as required to maintain the control parameters necessary for testing the end items listed in Appendix D. The control system shall include all programming and the data acquisition system hardware required in Section 2.2.16 and any additional components needed to work in conjunction with current or new SOW required system components to control the high pressure high temperature circuits. All required modifications to the high temperature pneumatic system and all components shall comply with the latest version of ASME 31.1 Power Piping and ASME 31.3 Process Piping. All components shall be rated for eight hundred (800) PSIG at one thousand (1000) degrees Fahrenheit working pressure and temperature.

2.2.11.2.2. The Contractor shall repair or replace the Hot Air Bypass Valve control circuit components that control valve 564A and remove the current temporary manual regulator and instrument air lines connected between valves 560A and 564A. The repair or replacement of the required components shall return system control of valves 560A and 564A to original configuration operation.

2.2.12. Carbon Dioxide Fire Suppression System

2.2.12.1. The test stand is equipped with a carbon dioxide fire suppression system.

The Contractor shall ensure the upgrade does not interfere or compromise the system.

2.2.13. Tubing and Fittings

2.2.13.1. All tubing shall be seamless stainless steel. All bulkhead fittings on the operator front panel shall be stainless steel with stainless steel caps and lanyard cables connected to caps and test stand front panel. All bulkhead fittings sizes on the operator front panel shall match the existing test stand. All other fittings shall be stainless steel or cadmium or zinc plated steel. All tubing and fittings shall be rated for the required maximum working pressure of the required highest end item test pressures and temperatures in a required circuit. All tubing and fittings shall comply with the latest version of ASME 31.1 Power Piping and ASME 31.3 Process Piping.

2.2.14. Hoses

2.2.14.1. All hoses shall be rated for the required maximum working pressure of the required highest end item test pressures and temperatures in a required circuit and utilize swivel Joint Industrial Council (JIC) 37 degree flare or Swagelok compression end connections. All hoses shall be labeled on each end with a metal band which indicates the maximum working pressure, size, material, material manufacturer, material manufacturer’s part number and length. All hose internal and external material shall be compatible with MIL-C-7024, Type II calibration fluid. All hoses shall comply with the latest version of the National Fluid Power Association, ASME 31.1 Power Piping and ASME 31.3 Process Piping.

2.2.15. Valves

2.2.15.1. All valves shall be rated for the required maximum working pressure of the required highest end item test pressures and temperatures in a required circuit. All valves shall comply with the latest version of the National Fluid Power Association, ASME 31.1 Power Piping and ASME 31.3 Process Piping.

2.2.16. Data Acquisition

2.2.16.1. The Contractor shall provide a new data acquisition system.

2.2.16.2. The Contractor shall use a computer with data acquisition cards and/or a programmable logic controller (PLC) for data acquisition system. The analog to digital converter shall be sixteen (16) bit or better. The data acquired shall be for automatically and manually controlling test parameters, calculating if the test results are pass/fail, displaying the data on the LCDs, and printing the test results to printer. The data acquisition system shall be capable of displaying all transducer inputs. The data acquisition system shall be capable of capturing the required maximum or minimum functional test parameters and displaying them on the LCD.

2.2.16.3. All computer components and computer data acquisition cards shall be mounted in a standard 19 inch rack mount enclosure with a minimum 4U height.

2.2.16.4. The Contractor shall ensure adequate ventilation of all computer components and PLC equipment.

2.2.16.5. The test stand shall use only a PLC or computer controller for all hydraulic, chilled water, pneumatic, calibration fluid, and electrical control loops.

2.2.16.6. The Contractor shall provide one (1) each spare computer system with duplicate hardware, software, and programming.

2.2.16.7. The Contractor shall provide three (3) USB connections on the Control Module and three (3) USB connections of the service Module.

2.2.16.8. The Contractor shall provide two (2) each computer keyboards and two (2) each computer mice.

2.2.17. Transducers

2.2.17.1. Test Pressure Transducers

2.2.17.1.1. The Contractor shall provide new pressure transducers for each test stand upgrade.

2.2.17.1.2. The test stand upgrade shall be equipped with new gauge and differential pressure transducers as required to perform all functional end item tests for the end items listed in Appendix F. The transducers shall include, but not be limited to the pressure transducers listed in Appendix F. The transducers shall be rated for industrial conditions with built-in overload protection and utilize stainless steel construction for wetted parts.

2.2.17.1.3. Each pressure transducer shall be Highway Addressable Remote

Transducer (HART) capable or otherwise be capable of communicating with the host computer or Human-Machine Interface (HMI) utilizing a digital readout on the pressure transmitter.

2.2.17.1.4. Each pressure transducer shall be capable of setup and adjustment without additional equipment or tools. The setup and adjustment buttons or controls shall be located on the pressure transducer.

2.2.17.1.5. Each pressure transducer shall incorporate a display to enable setup and maintenance activities with the transmitter.

2.2.17.1.6. Each pressure transducer shall be rated for ten percent (10%) over pressurization from maximum designed working pressure of the system.

2.2.17.1.7. The contractor shall provide shutoff valves for calibration that isolate the test pressure transducers from the system.

2.2.17.1.8. All new pressure transducers shall be located inside a NEMA 4 enclosed cabinet. The cabinet shall be equipped with a hinged front cover.

2.2.17.2. Test Temperature Transducers

2.2.17.2.1. The contractor shall provide new Resistance Temperature Detector (RTD) temperature transducers as required to perform all functional end item tests for the end items listed in Appendix F. The transducers shall include, but not be limited to the temperature transducers listed in Appendix F.

2.2.17.2.2. The contractor shall provide panel mount connections for calibration of the test temperature transducers.

2.2.17.3. Test Calibration Fluid Flow Meters

2.2.17.3.1. The Contractor shall provide two (2) new calibration fluid flow meters for each of the two (2) calibration fluid flow meters (E511A and E559A) on the current test stand. The flow meters shall match the current transducers size and shall meet the accuracy, ranges and resolutions specifications as the current flow meters.

2.2.17.3.2. The transducers shall include, but not be limited to the flow meter transducers listed in Appendix F.

2.2.17.3.3. The contractor shall redesign and reconfigure the flow meter section containing flow meter E511A. The flow meter section shall be designed to minimize the risk of leaks as a result of frequency removal and installation of the flow meter and minimize the personnel effort in the flow meter change outs. The flow meter section shall ensure stable and accurate flow readings.

2.2.17.4. Speed Sensor Transducer

2.2.17.4.1. The Contractor shall provide new speed sensor transducer for the test stand upgrade as required to perform all functional end item tests for the end items listed in Appendix F.

2.2.17.5. Specific Gravity Transducer

2.2.17.5.1. The Contractor shall provide new specific gravity transducers for the test

2.2.17.6. Leak Detector Transducer

2.2.17.6.1. The Contractor shall provide a new leak detector transducer for the test

2.2.17.7. Power Supply

2.2.17.7.1. The Contractor shall provide a new power supply to replace E547A. The power supply shall be capable of providing the required power to perform all functional end item tests for the end items listed in Appendix D.

2.2.17.8. Power Controls

2.2.17.8.1. The Contractor shall replace the Boost Pump Power Button (E2A) and the Boost Pump Button (E2B). The Contractor shall use computer or PLC controlled buttons that are operated from the Control Module LCD touchscreen. The display shall indicate ‘ON’ and ‘OFF’ positons of the buttons

2.2.17.9. Service Pressure Transducers

2.2.17.9.1. The Contractor shall provide new service pressure transducers for the test stand upgrade. As a minimum, the service transducers shall include those listed in Appendix G. The pressure transducer accuracies shall be a minimum of ±1.0% of full scale and the range shall be as required monitor the test stand and to performance test the end items listed in Appendix D. The transducers shall be rated for industrial conditions with built-in overload protection and utilize stainless steel construction for wetted parts.

2.2.17.9.2. The contractor shall provide shutoff valves for calibration that isolate the test pressure transducers from the system.

2.2.17.9.3. All new pressure transducers shall be located inside a NEMA 4 enclosed cabinet. The cabinet shall be equipped with a hinged front cover.

2.2.17.10. Service Temperature Transducers

2.2.17.10.1. The temperature transducer accuracies shall be ±3.0 degrees F and the range shall be as required to monitor the test stand and to performance test the end items listed in Appendix G. The temperature transducers shall be RTD, J-type, or K-type thermocouples.

2.2.17.10.2. The contractor shall provide panel mount connections for calibration of the test temperature transducers.

2.2.18. LCD Touch Screen Displays

2.2.18.1. The Contractor shall provide three (3) new LCD touch screen displays for the test stand upgrade.

2.2.18.2. Each LCD displays shall be touch screen, nineteen (19) inch minimum and capable of plus or minus eighty-five (85) degree wide side to side viewing angles with a minimum of one thousand twenty four by seven hundred sixty eight (1024 x 768) resolution. The displays shall have a seven hundred fifty to one (750:1) contrast ratio, seven hundred fifty (750) Nits brightness and lifetime of forty thousand (40,000) hours. Each LCD display shall be rack mountable for a standard nineteen (19) inch electronics cabinet.

2.2.18.3. One (1) nineteen (19) inch LCD display shall be mounted in the Control

Module. The LCD display shall be rack mountable for a standard nineteen

(19) inch electronics cabinet and shall be capable of displaying the end item test screens and calibration screens.

2.2.18.4. One (1) LCD display shall be mounted in the Control Module. The LCD display shall be rack mountable for a standard nineteen (19) inch electronics cabinet and be capable of displaying the annunciator (E4A and E4B) conditions, the I/O Module (E7A) states, the alarm screens, and the service transducers. The LCD shall allow an operator or service technician to toggle between the alarm, annunciator, I/O Module status, and service transducer screens.

2.2.18.5. One (1) LCD display shall be mounted in the Service Module. The LCD display shall be capable of displaying the end item test screens and calibration screens. The display shall be rated for a Class I Division I hazardous area.

2.2.18.6. The test stand upgrade shall be capable of displaying the end item test screens or calibration screens on one Control Module LCD display, the service screens, annunciator, I/O Module, or the alarm screens on the other Control Module LCD display, and the end item test screens or calibration screens on the Service Module LCD display simultaneously.

2.2.19. Timer

2.2.19.1. The Contractor shall provide one (1) timer for the test stand upgrade as required to perform all functional end item tests for the end items listed in Appendix D.

2.2.20. Printer

2.2.20.1. The Contractor shall provide one (1) each printer for the test stand upgrade.

The printer shall be located at the location of the current test stand. Should the Contractor provide a new Control Module, the printer shall be rack mounted and on slide rails such that the printer can be stored inside the test stand and slide out of the test stand for access and shall be located on the front of the console.

2.2.20.2. The printer shall be capable of color printing with a minimum input paper tray size of 250 pages of 8-1/2 X 11 inch paper. The minimum ISO print speed for black and white shall be 8 pages per minute. The minimum ISO print speed for color shall be 6 pages per minute. The minimum print resolution shall be 600 x 600 dpi for both color and black and white. The manufacturer recommended monthly printed page volume shall be a minimum of 1500 pages. The printer shall have a Hi Speed USB minimum

2.0 compatible connection.

2.2.20.3. The Contractor shall provide two (2) sets of spare printer ink cartridges for the printer.

2.2.21. Protection Circuits

2.2.21.1. The test stand shall be equipped with the required hardware and software for protection circuits in the test stand. The circuits shall automatically reset upon determination of a safe or in limits conditions. The protection circuits shall include but not be limited to those listed in Appendix H and shall also include all requirements determined by the Safety System Analysis. The Contractor shall develop alarm screens on the LCD that display the protection circuits and current states. The screens shall include as a minimum annunciator (E4A and E4B) conditions/states. The screens shall be capable of password protection.

2.2.22. Facility Utilities/Connections

2.2.22.1. The test stand upgrade shall operate on the four hundred eighty (480) VAC, sixty (60) Hertz (Hz), three (3) phase and one hundred twenty (120) VAC, sixty (60) Hz, single phase electrical power of the current test stands. The test stand upgrade shall operate on the compressed air systems and chilled water supply and return of the current test stand.

2.2.23. Electrical

2.2.23.1. The label or listing of the Underwriters Laboratories, Inc. (UL), shall be accepted as evidence that the materials or equipment conform to the applicable standards of that agency. In lieu of this label or listing, a statement from a nationally recognized, adequately equipped testing agency indicating that the items have been tested IAW required procedures and that the materials and equipment comply with all contract requirements will be accepted. Materials and equipment shall be approved based on the manufacturer's published data.

2.2.23.2. For other than equipment and materials specified to conform to UL publications, a manufacturer's statement indicating complete compliance with the applicable Federal Specification, or standard of the American Society for Testing and Materials, National Electrical Manufacturers Association (NEMA), or other commercial standard, is acceptable.

2.2.23.3. Any new Alternating Current (AC electric motors shall be NEMA premium efficient severe duty design. All AC motors shall be manufactured in the United States of America (USA) and meet all requirements in NEMA MG-1.

Motor design shall be Baldor Super E, ECP or equivalent.

2.2.23.4. The Contractor shall use multiple colored wires for the different types of wiring circuits for all new wiring required for the test stand upgrade.

2.2.23.5. All wire shall be UL listed. Machine Tool Wire (MTW) shall be used for control panel wiring and Thermoplastic High Heat Resistant Nylon Coated (THHN) shall be used for general power wiring.

2.2.23.6. The Contractor shall label both ends of all wires/cables with plastic sleeves or similar material describing wire list reference. Wire/cable identifiers shall be installed within two (2) inches of each connector or terminal.

2.2.23.7. The Contractor shall ensure all new wire, components, equipment, and installation are in compliance with the latest versions of the NEC, NEMA standards and National Fire Protection Agency (NFPA) 70.

2.2.23.8. The test stand shall have all electrical circuits equipped with ground fault interruption.

2.2.23.9. The Contractor shall not use splice connections for connection to existing terminals or hardware. All wiring shall be continuous from end to end.

2.2.23.10. All new control, signal, and power wires and cables shall be enclosed in metal conduit of an enclosed metal cable tray.

2.2.24. Software

2.2.24.1. The Computer and/or Programmable Logic Controller (PLC) programming software shall be COTS type. All software versions shall be the latest available. No custom proprietary software shall be used. Both PLC and computer shall have a hardware method to ensure a backup program can be copied and installed from a removable media source.

2.2.24.2. The programming shall be developed such that the upgraded end item testing is performed identical to the current test stand.

2.2.24.3. The programming shall allow for manual control of the end item test parameters in addition to automatic control.

2.2.24.4. The programming shall allow for capturing of the required end item test output data based on required input test parameters.

2.2.24.5. The Contractor shall provide all programming source code.

2.2.24.6. The Contractor shall provide a backup hard drive copy of the computer hard drive.

2.2.24.7. The Contractor shall provide a backup copy of the PLC programming.

2.2.24.8. The programming shall automatically generate test reports in a format similar to the current test stands as shown in Appendix I. The test reports shall allow for operator input of the end item part number and serial number.

2.2.24.9. The Contractor shall provide legal licensed copies of all software utilized in the test stand. The Contractor shall provide two (2) electronic backup copies of all programmed software. The Contractor shall provide all licensed software one (1) business day prior to Data Acquisition computer and PLC components’ arrival at TAFB. The Contractor shall provide copies of all programmed software NLT five (5) business days after successful completion of acceptance testing. The Contractor shall provide two (2) each any special items or cables required to interface between a computer and the Data Acquisition and/or PLC.

2.2.24.10. The Contractor shall provide the Government all software codes, password codes and technical data delivered with the system.

2.2.24.11. The Contractor shall provide development versions of the software utilized for the upgrade and a laptop computer capable of running the software.

2.2.24.12. A copy of the current test stand programming source code will be provided to the Contractor by the Government.

2.2.25. Test Screens

2.2.25.1. The test stand shall be capable of displaying all required end item test parameters based on the end item under test on the LCD display. The test screens shall be configurable for a minimum of five hundred (500) different screens. The LCD screen shall have a blank screen saver after fifteen (15) minutes of inactivity.

2.2.25.2. The Contractor shall provide test screens for each of end item part numbers listed in Appendix D. The Contractor shall provide, as a minimum, a separate test screen for each test paragraph in the test section of the T.O.

for each end item.

2.2.25.3. The test screens shall be capable of displaying the upper and lower limits of the test parameters and the actual value in different colors.

2.2.25.4. The test screens shall allow operator input of required test conditions by utilizing the touch screen LCD display.

2.2.25.5. The test screens shall be capable of displaying a minimum of sixteen (16) colors.

2.2.25.6. The display software shall be capable of test screen modifications including changes to test parameter limits and addition and deletion of transducer outputs limits without going into the main programming level.

2.2.25.7. The test screens shall be capable of three (3) levels of password protection.

The minimum password protection levels required shall be for the operator, the technician and the engineer.

2.2.25.8. The test screens shall, as a minimum, provide on screen indication of all test functions and parameters shown on the current test screens of the existing test stand.

2.2.25.9. The Contractor shall provide to the Government all software codes, password codes and technical data delivered with the system.

2.2.25.10. The Government will approve all test screens prior to the installation of the test stand upgrade.

2.2.26. Calibration Screens

2.2.26.1. The Contractor shall develop and program calibration screens which will be displayed on the LCD display.

2.2.26.2. The calibration screens shall be capable of recording as found, as left, and calibration summary data as a minimum and displaying the data on the LCD display.

2.2.26.3. The calibration screens shall have user input multi-point alignment tables for the required transducers.

2.2.26.4. The Government will approve all calibration screens prior to the installation of

2.2.27. Service Screens

2.2.27.1. The test stand shall be capable of displaying all readouts for the service transducers on one of the LCD’s to be mounted in the Control Module. The Contractor shall develop the screens required to display the service transducers.

2.2.27.2. The Government will approve all service screens prior to the installation of

2.2.28. Standard Products / Service Availability

2.2.28.1. Materials and equipment furnished by the Contractor shall be new and standard products of a manufacturer regularly engaged in the manufacture of such products. The standard products shall have been in satisfactory commercial and/or industrial use for two (2) years prior to bid opening and still be in production at the time of this contract.

2.2.28.2. The Contractor shall use, when possible, test measurement diagnostic equipment (TMDE) currently in use by the AF and normally found in a Class II precision measurement equipment laboratory. If the TMDE equipment is not in the inventory, the Contractor shall provide required calibration equipment as part of the contract.

3.0 BUILD SCHEDULE

3.1. The Contractor shall provide a Preliminary Design Review. The design review shall be completed at the zero to five percent (0-5%) test stand upgrade design stage. The Contractor shall be required to conduct a meeting at Tinker Air Force Base (TAFB) for the Preliminary Design Review. The date and time will be coordinated by the Government POC. The Contractor shall submit four (4) complete hard copy data packages and one (1) electronic data package. The submittal shall be sent to the Government POC NLT seven (7) calendar days prior to the on-site meeting. The Government POC will coordinate the on-site meeting. The Contractor shall be responsible for taking minutes during the on-site meeting and shall provide one (1) electronic copy to the Government POC NLT seven (7) calendar days after the meeting date.

3.2. The Contractor shall provide an Intermediate Design Review. The design review shall be completed approximately fifty percent (50%) into the test stand upgrade design stage. The Contractor shall be required to conduct a meeting at TAFB for the Intermediate Design Review. The date and time shall be coordinated by the Government. The Contractor shall submit four (4) complete hard copy data packages and one (1) electronic data package. The submittal shall be sent to the Government POC NLT seven (7) calendar days prior to the on-site meeting.

The Government will coordinate the on-site meeting. The Contractor shall be responsible for taking minutes during the on-site meeting and shall provide one

(1) electronic copy to the Government POC NLT seven (7) calendar days after the meeting date.

3.3. The Contractor shall provide a Critical Design Review. The design review shall be completed approximately one hundred percent (100%) into the test stand upgrade design stage. The Contractor shall be required to conduct a meeting at TAFB for the Critical Design Review. The Government will coordinate the on-site meeting. The Contractor shall submit four (4) complete hard copy data packages and one (1) electronic data package including engineering data, specifications, certificates, reports, and final products including catalog excerpts and salient characteristics to the Government POC. The submittal shall be sent to the Government POC NLT seven (7) calendar days prior to the on-site meeting.

The Government POC will coordinate the on-site meeting. The Contractor shall be responsible for taking minutes during the on-site meeting and shall provide one (1) electronic copy to the Government POC NLT seven (7) calendar days after the meeting date.

3.4. The Critical Design shall be approved by the Government POC in writing prior to purchase of any materials or fabrication.

3.5. Installation

3.5.1. The Contractor shall provide a build schedule which shall include as minimum the following phases; design, material procurement, pre-fabrication, upgrade installation, operational check out, calibration, and acceptance testing.

3.5.2. The Contractor shall provide the upgrade installation start date one-hundred eighty (180) calendar days in advance in writing to the Government POC.

3.5.3. The Contractor shall begin installation of the test stand upgrade only after approval of the Critical Design Review. The installation shall comply with the latest edition of the NEC and NFPA codes as required for the Class I Division I environment and non-hazardous environment. The Contractor shall perform the initial startup and inspection of the test stand after installation. The startup and inspection shall be performed with the Government present. The date will be coordinated by the Government. The Contractor shall be responsible for correct operation of the test stand.

4.0 CALIBRATION

4.1. The Contractor shall provide calibration of all TMDE using transfer standards traceable to the National Institute of Standards and Technology (NIST).

4.2. The Contractor shall provide the required training of calibration support technicians per Paragraph 6.1. The Government will calibrate the test stand after Contractor provided training is completed. The Contractor shall assist Government calibration personnel during initial calibration of the test stand.

4.3. The Contractor shall perform acceptance testing IAW the approved Acceptance Test Procedure after the Government calibration is completed.

5.0 ACCEPTANCE TESTING

5.1. Acceptance Test Procedure

5.1.1. Utilizing two (2) different Government furnished end items, the Contractor shall develop an Acceptance Test Procedure designed for acceptance testing the test stand after installation of the upgrade at TAFB. The end item part numbers are 749091, 773220, or 759057 and 792840. The Acceptance Plan shall include on-site tests of each of the two (2) end items on the current test stand. Each end item will be tested three (3) times on the current stand. The Contractor shall witness the testing of the two (2) end items on the existing test stand at Tinker to verify the test results. The Contractor shall provide all required personnel at the time of acceptance testing to ensure a thorough knowledge of the end item testing requirements and test stand operation is acquired. No other test stand is available to verify a test or service parameter after the installation of the upgrade has begun. The on-site tests of the end items shall serve as the correlation reference by which the test stand upgrade will be verified. The Government will package and store the two (2) end items after testing on the existing test stand. The Contractor shall be responsible for correction of any deficiencies in the test stands upgrade design to ensure successful testing of each of the two (2) end items. Should testing result in data which cannot be correlated, additional test runs of the end items shall be required to determine the problem. The Acceptance Test Procedure shall include providing an Acceptance Test Report upon successful testing of the end items. The Contractor shall provide three (3) hard copies and one (1) electronic copy of the Acceptance Test Procedures to the Government POC at the Critical Design Review meeting. The Government will have fourteen (14) calendar days after the on-site Critical Design Review meeting to complete the review. Should the Government disapprove the proposed Acceptance Test Report, the Contractor shall have 7 fourteen (14) calendar days to submit the revised Acceptance Test Procedure to the Government POC. The Government will provide approval or comments within seven (7) calendar days.

5.2. The Contractor shall execute the acceptance test procedure developed IAW Paragraph 5.1.1., Acceptance Test Procedure, for each asset listed in Table 1-1.

The Contractor shall perform acceptance testing on the test stand after installation of the upgrade and calibration is complete.

TABLE 1-1. End Item Acceptance Test

5.3. The Contractor shall provide an Acceptance Test Report after the successful

Acceptance Testing is complete. The Contractor shall provide three (3) hard copies and one (1) electronic copy of the Acceptance Testing Report to the Government NLT fourteen (14) calendar days after the successful date of testing.

The Government will have seven (7) calendar days after receipt of the Acceptance Test Report to review and provide comments to the Contractor.

5.4. The acceptance testing of the test stand shall verify the design. The Government will verify the design after receipt of the Acceptance Test Report.

Item Description Part Number T.O. Test Type

Augmentor Fuel Pump 749091, 773220, or 759057 6J10-4-80-3 Three run correlation

Augmentor Fuel Pump 441991-11 6J10-2-18-3 Three run correlation

5.5. The Government will perform infrared, vibration, motor analysis, and airborne ultrasound inspection to ensure new hardware is in compliance with referenced standards. The inspection will include before and after upgrade data collection.

The Government will perform baseline inspection and gather data the week prior to the Contractor installation start date. The Government will develop a report from the data. The report will be used for comparison after the installation of the upgrade. The standards include ISO 10816-1 and National Aeronautics and Space Administration (NASA) Reliability Centered Building and Equipment Acceptance Guide (2004) for Vibration, National Electrical Manufacturers Association (NEMA) MG-1, Electrical Apparatus Service Association (EASA) Standard AR100-2010, and NASA Reliability Centered Building and Equipment Acceptance Guide (2004) for Motor Analysis, NASA Reliability Centered Building And Equipment Acceptance Guide (2004) for Infrared Thermography, and NASA Reliability Centered Building And Equipment Acceptance Guide (2004) for Airborne Ultrasound.

6.0 TRAINING

6.1. The Contractor shall provide four (4) separate training sessions.

6.2. The Contractor shall provide a training session for four (4) calibration support technicians IAW the Contractor developed Training Plan. The training shall begin after installation and initial start-up of the test stand and prior to acceptance testing.

6.3. The Contractor shall provide a training session for three (3) test operators IAW the Contractor developed Training Plan. The training shall begin after final successful acceptance testing of the test stand upgrade.

6.4. The Contractor shall provide a training session for five (5) maintenance technicians IAW the Contractor developed Training Plan. The training shall begin after final successful acceptance testing of the test stand upgrade.

6.5. The Contractor shall provide a training session for two (2) software programmers IAW the Contractor developed Training Plan. The training shall begin after final successful acceptance testing of the test stand upgrade

7.0 MANUALS, INSTRUCTIONS, AND PROCEDURES

7.1. The Contractor shall develop and provide manuals for the test stand in Microsoft Word Version 2007 or higher. The manual shall have separate sections which include Operation instructions, Maintenance instructions, Calibration instructions, Programming instructions, Detailed Drawings, Schematics and Illustrated Parts Breakdown. The Contractor shall provide a total of two (2) hard copies and five

(5) electronic copies NLT seven (7) calendar days after the completion of the final acceptance of the upgraded test stand to the Government POC. The Contractor shall provide the COTS operation, maintenance, calibration and programming manuals from the component manufacturer for the equipment and software provided.

7.2. Operation Instructions

7.2.1. The Contractor shall provide a complete set of instructions on the operation of the individual controls for each equipment item on the test stand in Microsoft Word Version 2007 or higher. The instructions shall include operation of the touch screen and controls. The operation instructions shall also include daily, weekly and monthly test stand inspections and checklists which would be performed by the operator(s). The delivery time and quantities shall be provided per Paragraph 7.1.

7.3. Maintenance Instructions

7.3.1. The Contractor shall provide a complete list of materials and description, including manufacturer and model number, for all components used in the test stand upgrades. The list shall also include a vendor source for all materials and parts. The Contractor shall provide detailed drawings for all materials and equipment specified in the list. The drawings shall consist of a complete list of equipment and materials, including manufacturer's descriptive and technical data, catalog cuts and any special installation instructions which may be required. Drawings shall show applicable schematic diagrams and equipment layout. The Contractor shall provide a spreadsheet listing of the electrical wire used in the upgrade. As a minimum, the electrical wire spreadsheet shall include the source identifier, destination identifier, type circuit, wire color and wire size.

The Contractor shall provide the electronic copies of the drawings in AutoCAD 2007 or higher. The delivery time and quantities shall be provided per Paragraph 7.1.

7.4. Programming Instructions

7.4.1. The Contractor shall provide commercial manuals for all software delivered as part of the upgrades. The delivery time and quantities shall be provided per Paragraph 7.1.

7.5. Calibration Instructions

7.5.1. The Contractor shall provide a step-by-step instruction manual including required metrology equipment for the complete calibration of the test stand in Microsoft Word Version 2007 or higher. The instruction manual shall provide all calibration procedures and unique support equipment required for calibration of the replaced components. The components shall include all transducers and instrumentation required for testing of the end items and verification of all service transducers and instrumentation. Unique support equipment would include any equipment which is not currently referenced in existing TOs other than common tools. The Calibration instructions shall be submitted to the Government POC as part of the Critical Design Review. The Government will have fourteen (14) calendar days after the on-site meeting to complete the review and provide comments to the Government POC. If revised Calibration Instructions are required, the Contractor shall have fourteen (14) calendar days to submit the revised Calibration Instructions to the Government POC. The Government will complete the review of the revised Calibration Instructions and provide comments to the Government POC. The delivery time and quantities shall be provided per Paragraph 7.1.

8.0 DOCUMENTATION

8.1. All documentation provided by the Contractor shall have the following disclosure notice statement on the cover page:

“DISCLOSURE NOTICE: This information is furnished upon the condition that it will not be released to another nation without the specific authority of the Department of the Air Force of the United States, that it will be used for military purposes only, that individual or corporate rights originating in the information, whether patented or not, will be respected, that the recipient will report promptly to the United States, any known or suspected compromise, and that the information will be provided substantially the same degree of security afforded it by the Department of Defense of the United States. Also, regardless of any other markings on the document, it will not be downgraded or declassified without written approval of the originating United States agency.”

8.2. All documentation provided by the Contractor shall have the following…