AMENDED_SOW_-_Lube_Accessory_Test_Stand_Purchase.pdf

STATEMENT OF WORK

FOR

LUBE ACCESSORY TEST STAND PURCHASE

(CSN: H7TC06)

FSC: 4920

Prepared by

MICHAEL DUNNE

76 CMXG/ENC

22 MARCH, 2017

LUBE ACCESSORY Test Stand Purchase Statement Of Work

22 March 2017

CONTENTS

Section/Para Page

1 Scope of Work 2 Applicable Documents

2.1 Government Standards

2.2 Non-government Standards

2.3 Order of Precedence

3 Requirements

3.1 General

3.2 Construction

3.3 Utilities and Maintenance Access

3.4 Installation Plan

3.5 General Lube Accessory Test Stand Configuration and Performance Requirements

3.6 Electrical Classification and PMEL Spares Kit

3.7 Reliability Centered Maintenance (RCM)

3.8 Warranty

4 Quality Assurance Provisions

4.1 Responsibility for Inspections

4.2 Responsibility for Compliance

4.3 Environmental Conditions

4.4 Examination

4.5 Design Reviews

4.6 Test Readiness Review

4.7 Final Acceptance

4.8 Tests

4.9 Emergency POC

5 Technical Data

5.1. Manuals/Drawings

5.2. Work Plan Drawings

5.3. As Built Drawings

5.4. Software Documentation

5.5. Commercial Manuals

5.6. Spare Parts & Consumables List

5.7. Site Preparation Data

5.8. Installation Drawings

5.9. Installation Site Services

5.10. Factory Acceptance Test Report

5.11. Software Test Report

5.12. Correlation Test Report

5.13. Documentation

6 Training/Familiarization

6.1. Operator

6.2. Electrical/Mechanical

6.3. Calibration

6.4. Software Engineer

7 Special Provisions

7.1 Government Occupancy of Facilities & Responsibilities

7.2 Secured Area(s)

7.3 Working Hours

7.4 Safety, Foreign Object Debris (FOD), & Quality Control

7.5 Housekeeping

7.6 Tool Control and Accountability

7.7 Field Verify

8 Proposal by Contractor 9 Other Written Submittals 10 Government Furnished Property And Services

10.1. Government Furnished Property (GFP)

10.2. Shared Property Of The Government

10.3. Government Furnished Services (GFS)

10.4. Intangible Government Services

10.5. GFP Requisition Requirement

APPENDICES

Appendix A: Design Guideline 450

Appendix B: Government Furnished Property (GFP)

Appendix C: Safety Specifications

Appendix D: Glossary and Definitions

Appendix E: Environmental

Appendix F: Correlation Test Plan Appendix G: Test Results Required-Minimum Appendix H: Drawings Appendix I: UUT Test Specifications Appendix J: TDP Option Worksheet Appendix K: Reliability Centered Maintenance and Vibration Severity Chart Appendix L: Sample Operations and Maintenance Manual – Format Appendix M: Sample IPB, T.O. 33D4-6-668-4

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1. SCOPE OF WORK:

1.1 Scope: The following establishes the minimum requirement for the purchase, delivery and installation of one (1) Lube Accessory test stand with equipment and accessories specified herein; and training on the maintenance, calibration, programming and use of said test stand. The test stand will be used to test F101, F108, F110, and F118 engine lube accessory components as required and as per their relevant Technical Orders (T.O.’s). The overall project shall be considered “turnkey” type procurement.

1.2 Background: The test stand described in this document is intended for use in the Aerospace Repair Industry. The equipment shall be installed in B3001 Tank & Cooler shop Tinker AFB, OK. This shop runs on an 8 hour basis Monday through Friday with possible overtime hours on the weekend and weekdays. All installation work associated with this contract shall have no impact on production.

2. APPLICABLE DOCUMENTS AND DEFINITIONS:

Contractor, at a minimum, is required to comply with the current editions of the following requirements for design, construction, installation and safety as applicable. The term “most recent edition” shall be understood to mean, “most recently released edition as of date of issuance of contract.”

2.1. Government Standards: The following documents form a part of this purchase description to the extent stipulated herein.

2.1.1 U. S. DEPARTMENT OF LABOR

2.1.1.1 29 CFR 1910 – General Industry, OSHA Safety and Health Standards (29 CFR 1910), 2010 or most recent edition (available at http://www.osha.gov/)

2.1.1.2 (Application for copies should be addressed to the U.S. Department of Labor, 200 Constitution Ave, Washington, D.C. 20210)

2.1.2 ENVIRONMENTAL PROTECTION AGENCY

2.1.2.1 40 CFR 82 – Protection of Stratospheric Ozone, 2010 or most recent edition

2.1.2.2 (Application for copies should be addressed to the U.S. Department of Labor, 200 Constitution Ave, Washington, D.C. 20210)

2.1.3 FEDERAL STANDARDS

2.1.3.1 FED-STD-H28A – Screw Thread Standards for Federal Services, 1994 (R2001) or most recent edition http://www.osha.gov/

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2.1.3.2 FED-STD-H28/21B – Screw Thread Standard for Federal Service, Metric Screw Threads, 1984 (R2006) or most recent edition

2.1.3.3 (Application for copies should be addressed to Superintendent of Documents, Government Printing Office, Washington, D.C. 20402-001).

2.2. Non-Government Standards: The following documents form a part of this document to the extent stipulated herein.

2.2.1 NATIONAL FIRE PROTECTION ASSOCIATION (NFPA)

2.2.1.1 NFPA 1 – Fire Code, 2010 edition or most recent edition

2.2.1.2 NFPA 70 – National Electrical Code, 2014 edition

2.2.1.3 NFPA 70E – Standard for Electrical Safety in the Workplace, 2011 edition or most recent edition

2.2.1.4 NFPA 79 – Electrical Standards for Industrial Machinery, 2007 or most recent edition

2.2.1.5 (application for copies should be addressed to National Fire Protection Association, 1 Batterymarch Park, Quincy, MA 02169)

2.2.2 TELECOMMUNICATIONS INDUSTRY ASSOCIATION (TIA) STANDARD

2.2.2.1 EIA/TIA-232-F – Interface Between Data Terminal Equipment and Data Circuit-Terminating Equipment Employing Serial Binary Data Interchange, 1997 (R 2002) or most recent edition

2.2.2.2 (Application for copies should be addressed to IHS International Inc., http://www.ihs.com, or call 1-800-854-7179 for U.S. and Canada)

2.2.3 NATIONAL ELECTRICAL MANUFACTURERS ASSOCIATION

2.2.3.1 NEMA MG 1 – Motors and Generators, 2009 (R2010) or most recent edition

2.2.3.2 NEMA ICS 6 – Industrial Control and Systems: Enclosures, 1993 (R2006) or most recent edition

2.2.3.3 (Application for copies should be addressed to National Electrical Manufacturers Association, 1300 N 17th Street, Suite 1752, Rosslyn, VA 22209) http://www.ihs.com/

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2.2.4 AMERICAN NATIONAL STANDARD INSTITUTE

2.2.4.1 ASTM SI 10 – American National Standard for use of the International System of Units (SI): The Modern Metric System, 2010 or most recent

2.2.4.2 (Application for copies should be addressed to American National Standards Institute, Attn: Sales Department, 1430 Broadway, New York, NY 10018-3363)

2.2.5 AMERICAN WELDING SOCIETY INC (AWS)

2.2.5.1 AWS D14.4 – Specification for Welded Joints in Machinery and

Equipment, 1997 or most recent edition

2.2.5.2 (Applications for copies should be addressed to the American Welding Society Inc, 550 North LeJeune Road, Miami, FL 33126)

2.2.6 INTERNATIONAL ORGANIZATION FOR STANDARDIZATION

2.2.6.1 ISO 4413 – Hydraulic Fluid Power – General Rules and Safety

Requirements for Systems and Their Components, 2010 or most recent

2.2.6.2 ISO 10816-3 – Mechanical Vibration – Evaluation of machine vibration by measurement on non-rotating parts, 2009 or most recent edition.

2.2.6.3 (Application for copies should be addressed to International Organization for Standardization, 1, ch. de la Voie-Creuse, Case postale 56, CH-1211 Geneva 20, Switzerland, e-mail central@iso.ch or IHS International Inc., http://www.ihs.com, or call 1-800-854-7179 for U.S. and Canada)

2.3. Order of Precedence: In the event of a conflict between the test of this specification and the references cited herein, the test of this specification takes precedence. Nothing in this document, however, supersedes applicable laws and regulations unless a specific exception has been obtained.

3. REQUIREMENTS:

3.1. General: The Lube Accessory test stand equipment shall be new and unused (not a prototype) and shall be based upon the design of an existing Lube Accessory Test Stand currently in use at Tinker AFB, Building 3001, Tank & Cooler shop. The Lube Accessory test stand particulars are noted below:

• The Lube Accessory test stand construction and working area layout shall be based upon design of existing Lube Accessory stand currently in use at Tinker AFB, B3001 Tank & Cooler shop. The overall dimensions of the Test Stand shall not exceed 20’x10’.

mailto:central@iso.ch http://www.ihs.com/

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• Original Lube Accessory test stand design drawings are the property of the USAF and relevant sheets are attached in Appendix H for reference only. These drawings shall form the basis of design and fabrication of the new Lube Accessory test stand.

Any exceptions are noted below. Intent of Appendix H is as follows:

o Provide a baseline for minimum quality of construction required as well as a suggested layout of stand consoles and panels (i.e., location of regulators, valves, bleed ports, connection ports and all other items denoted in Appendix H), drawers, and doors.

• New Lube Accessory test stand shall be a standalone unit with all necessary adapter kits, fully capable of successfully testing every Lube Accessory Component listed in Appendix I.

o Time to test a known good UUT by a certified Tinker mechanic shall not exceed the following:

F101 Fuel/Oil Cooler: 2.0 hours F101 Hydraulic Pump: 2.0 hours F101 AFT Tank Assembly: 2.48 hours F101 Lube Flow Sensor Assembly: 3.5 hours F101 Oil Level Temperature Sensor: 1.1 hours F108 Servo Fuel Heater: 2.3 hours F108 Oil/Fuel Heat Exchanger: 3.2 hours F110/F118 Fuel/Oil Cooler: 2.0 hours F110 Oil Tank Assembly: 2.9 hours F110 Oil Differential Pressure Switch: 2.5 hours F110 Fuel, Lube And Hydraulic Oil Cooler: 5.9 hours F118 Oil Tank Assembly: 4.2 hours F110 Hydraulic Pump: 1.5 hours F110 Hydraulic Cooler: 2.0 hours

• All Lube Accessory test stand components shall be available as commercial off the shelf (COTS) items.

• All items requiring calibration shall be listed in AFMETCAL as approved devices.

• Software assurance shall be designed into the software and shown as part of the

Software Acceptance Test Procedure.

• The Data Acquisition system shall utilize LabVIEW to develop a test program to communicate with Siemens S7 PLC controller.

• No proprietary software or technical data is allowed. The USAF shall have unlimited rights for all technical data and non-COTS software developed for this effort. All non-COTS source code and technical data developed shall be delivered along with the COTS licenses at the end of the contract.

• Delivery date for the new Lube Accessory Test Stand shall be no later than fifteen

(15) months after date of contract.

• Test variables shall be indicated one of three ways: red if out of limits (OOL) – High, green if in limits, and yellow if (OOL) – Low.

• Required calibration features for test stand are detailed below:

o Real-time feedback on HMI of item being calibrated o A minimum of 20 data points available for each item requiring calibration

SOW-2017-LUBE ACC Page 5 o As Found and As Left data broadcast to HMI during calibration with an option to save data to hard drive during calibration process o Raw signal and final units shown on HMI for items requiring calibration o Five (5) alignment points minimum for items requiring calibration

3.1.1 Dimensional Systems: U.S. Customary System of Units (US) shall be used in the design and construction. In this specification, all measurements, dimensions, sizes, and capacities are given in the U.S. Customary System of Units (US).

3.1.2 Measuring/Indicating Devices: All measuring and indicating devices, such as dial indicators, pressure gages, temperature indicators, depth stops, and other similar devices used on the machine, shall be in the inch-pound unit system. Marking on all measuring and indicating devices shall be permanently and legibly engraved or etched on a non-glare background. All dials and other type indicating devices shall be securely mounted in place. Such devices shall be located so as to allow reading from the operator’s normal workstation.

3.1.3 Safety and Health: Covers, guards and other safety devices shall be provided for all parts of the machine that present safety hazards. The safety devices shall not interfere with the operation of the machine. The safety devices shall prevent unintentional contact with the guarded part and shall be removable to facilitate inspection, maintenance and repair of the parts. All machine parts, components, mechanisms and assemblies furnished on the machine shall comply with all of the requirements of 29 CFR 1910.

3.1.4 Cautions–Warning Plates: Corrosion resistant “Caution” or “Warning” Plates shall be securely attached to the equipment in visible locations with any safety precautions to be observed by the operator or maintenance personnel permanently mark on the plates.

3.1.5 Noise Levels: The noise level emitted by the equipment under load shall not exceed 80 dBA when measured at the operator’s workstation or at any other point at a distance of three (3) feet from any of the equipment associated with the Lube Accessory test stand unit as measured on the “A” weighted scale of a standard Type II sound level meter.

3.1.6 Chemicals: The Contractor shall furnish to the Government POC a list of all chemicals used in conjunction with installation and maintenance of the equipment, and their Safety Data Sheets (SDS) 90 days prior to delivery of equipment. If time frame specified does not match with expected delivery schedule then the Contractor shall propose an alternate schedule that makes delivery of chemical information to the Government prior to installation with a minimum of 4 weeks for review of the data and comments by all interested Government parties. If necessary, the delivery of the equipment shall be delayed to allow for the chemical review and comment period. Additional delivery delays may be required if the Government requests alternative chemicals. The Contractor shall submit this proposed schedule at time of contract award for Government approval. The Contractor shall furnish all

Page 6 SOW-2017-LUBE ACC chemicals required for the installation and start-up of the Lube Accessory test stand.

All other fluids required prior to test stand acceptance shall be provided by the Contractor and properly disposed of by Contractor following acceptance. The government reserves the right to reject use of any chemicals and request alternative(s) be proposed for completion of the installation. Proper use, storage and removal of any chemical required during commissioning of test stand shall be coordinated with the Tinker Unit Environmental Coordinator (UEC). UEC info will be made available to Contractor by Government POC, as needed.

3.1.7 Prohibited Materials:

3.1.7.1 Mercury restriction: The machine shall contain neither mercury nor mercury compounds, or be exposed to free mercury during manufacture.

3.1.7.2 Asbestos restriction: Asbestos and materials containing asbestos shall not be used on or in the machine.

3.1.7.3 Polychlorinated Biphenyl (PCB) restriction: The use of polychlorinated biphenyl on or in the machine is prohibited.

3.1.7.4 Lithium restriction: Lithium batteries used in the computer system are exempt from this requirement.

3.1.7.5 ODC Restrictions: Class I ozone depleting substances in accordance with section 602(a) of the Clean Air Act Amendments 1990, 42 USC 7671a(a) as implemented by 40 CFR 82 Protection of Stratospheric Ozone, shall not be contained within or used on this equipment.

3.1.8 Environmental Protection: Under the operating, service, transportation and storage conditions described herein the machine shall not emit materials hazardous to the ecological system as prohibited by federal, state or local statutes in effect at the point of installation.

3.1.9 Other Environmental Compliance: Contractor shall comply with all environmental requirements as stipulated in Appendix E.

3.1.10 Instruction Plates: All words on instruction plates shall be in the English language.

Words shall be engraved, etched, embossed or stamped in boldfaced letters on a contrasting background. Lettering shall be a minimum of 18 point font and the plates shall be sized accordingly to accommodate all standard text in this point size.

Plates and lettering shall be fully compatible with MIL-PRF-7808, fluid and suffer no degradation when subjected to it.

3.1.11 Nameplate: A corrosion resistant metal nameplate permanently and legibly marked with the following information shall be securely attached to the machine in a readily visible location. Nameplate and lettering shall be fully compatible with MIL-PRF-

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7808 fluid and shall suffer no degradation when subjected to it. Lettering shall be a minimum of 18 point font.

Nomenclature of the Machine Manufacturer’s Name and Address Manufacturer’s Model Number Manufacturer’s Serial Number Date of Manufacture Contract Number Services Requirements – All service requirements to be included.

3.2. Construction: The Lube Accessory test stand shall be constructed of parts that are new, without defects, commercial-off-the-shelf (COTS), and free of repairs. Quality of materials used in construction shall be equivalent to or superior than those used in construction of the existing Lube Accessory test stand located in B3001. Metals shall be of corrosion resistant materials unless suitably protected to resist corrosion. The machine construction shall include all components, parts and features necessary to meet the performance requirements specified herein. All parts subject to damage from environmental hazards shall be sealed or otherwise protected. The machine shall be capable of withstanding all forces encountered during operation of the machine at its maximum rating and capacity without distortion or failure. Welding, plugging, or filling with solder or paste shall not be employed as repair or reclamation measures for defective parts. All screws, pins, bolts and similar parts shall be installed with means of preventing loss of tightness. All parts subject to removal or adjustment, shall not be swaged, peened, staked or otherwise permanently deformed. The Lube Accessory test stand shall be built in compliance with Design Guideline 450 as shown in Appendix A.

3.2.1 Castings and Forgings: All castings and forging shall be free from defects, scale or mismatching. Processes such as welding, peening, plugging, or filling with solder or paste shall not be used on casting and forgings for reclaiming any parts of the machine. Such processes may only be used for enhancing surface finish and appearance.

3.2.2 Welding, brazing and soldering: Welding, brazing or soldering shall be employed only where those operations are included in fabrication of the original design.

These operations shall not be employed as repair or reclamation measures for defective parts. Any excess material used for such operations shall be thoroughly removed from the part(s) upon completion of the operations. Weldments shall comply with AWS D14.4.

3.2.3 Surface Finish: All surfaces of castings, forgings, molded parts, stampings and welded parts shall be clean and free from sand, dirt film, sprues, flash, scale flux and other harmful or extraneous materials. External surface edges shall be either rounded or beveled unless sharpness is required to perform a necessary function.

Except as otherwise specified herein, the condition and finish of all surfaces shall be commensurate with the manufacturer’s standard commercial practice.

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3.2.4 Gears: All gears and pinions, if applicable, shall be designed and manufactured of a suitable ferrous material with proper width and size to transmit full-rated torque and horsepower throughout the speed ranges without failure for the expected service life of the machine.

3.2.5 Painting: Test stand shall be painted Air Force Blue or equivalent. Yellow or orange safety color-coding shall be used for designated physical hazards.

3.2.6 Screw Threads: All threaded parts used on the machine and its related attachments and accessories shall conform to FED-STD-H28 or FED-STD-H28/21B.

3.2.7 Interchangeability: To provide for replacement of worn parts, all parts bearing the same part number shall be functionally interchangeable and dimensionally identical within the manufacturer’s tolerance limits. Records, including detailed parts drawings, shall be maintained by the equipment supplier by part number throughout the life of the equipment in order than any replacement part can be supplied to the customer.

3.2.8 Maintainability: The machine shall be designed and constructed to permit effective maintenance. The machine shall be equipped with access covers (if applicable) to facilitate inspection, cleaning, repair and replacement of parts.

3.2.9 Lubrication: Means shall be provided to insure adequate automatic lubrication for all moving parts. Recirculating systems shall include filters which are cleanable or replaceable. Each lubricant reservoir shall have visible or mechanical means for determining fluid level. All oil holes, grease fittings and filler caps shall be accessible. Parts consuming fluids shall be clearly identified as such along with the recommended periods of additions and the type of fluid that should be used.

3.3. Utilities and Maintenance Access: The Contractor shall provide maintenance access to the control panel, filters, pumps, and other parts requiring periodic maintenance or repair. All equipment access doors, control panels and process sensitive areas shall be lockable. Keying configurations and methods of locking shall be discussed in the design reviews. The Contractor shall label each breaker pulled from the main electrical panel. Electrical schematic(s) shall be attached inside of the control panel with all components labeled and identified. A listing of all components and their ratings shall be provided. Unions and isolation valves shall be placed inline before and after each pump to allow for better maintenance access to the equipment. Catwalks, ladders, platforms and other access considerations shall be the responsibility of the Contractor.

Ladders exceeding twelve (12) feet in height shall contain fall protection. Contractor shall denote on the test stand main electrical device(s) the source panel name, location and circuit breaker number(s) used to feed the electrical device.

3.3.1. Utilities Interconnection: The Government will provide all required utilities within twenty-five (25) feet of the test stand location. Contractor shall make final terminations of utilities to test stand.

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3.3.2. Surge Protection: All equipment shall utilize surge protection provided by Contractor with Government approval.

3.4. Installation Plan: Contractor shall submit an Installation Plan to the Government POC for review and approval. Installation Plan shall include:

• Drawing denoting test stand location onto existing floor plan

• Drawing denoting conduit sizes, conductor types and sizes, seal off locations, test stand electrical interconnect drawing and over-current protection devices and sizes.

• All subcontractor and partnership information

Installation Plan shall be submitted to the Government POC a minimum of sixty (60) calendar days prior to deliver of test stand. Stand shall not be delivered until written approval of plan has been received by Contractor from the Government POC. The government shall have 14 calendar days to review the Installation Plan and initiate contact with Contractor to discuss/review/resolve any issues. Following resolution, Contractor shall have 7 calendar days to resubmit revised Installation Plan to Government POC for review and approval.

3.5. General Lube Accessory Test Stand Configuration and Performance Requirements:

The LUBE ACCESSORY test stand shall generally be configured, calibrated and tested as noted below:

3.5.1 General Configuration. The Lube Accessory test stand construction and suggested layout shall be based upon the design of the existing Lube Accessory test stand currently in use at Tinker AFB, B3001 Tank & Cooler shop. See Appendix H for general test stand configuration.

General location of various components are denoted in Appendix H for reference only. Data acquisition chassis, controllers and cards shall have at least one (1) secondary, independent manufacturer as identified by Contractor that provides a COTS functional replacement.

3.5.2 PC and PLC Control System: The GE control system as originally designed is obsolete and is no longer available. Consequently, the Lube Accessory test stand shall be controlled using a PC/PLC configuration as noted below:

• PLC shall be Siemens S7 architecture and controlled using LabVIEW, no substitutes accepted

• Latest Air Force approved Windows Enterprise version

• CPU: Quad Core i7 (minimum)

• RAID array based with a minimum of 1TB SSD’s

• 8GB SDRAM (minimum)

• 17” color flat screen (touch screen) HMI (minimum) mounted to test stand

• Detachable, standard 101 key computer keyboard and mouse

• Built-in DVD-ROM/CD-RW and USB mass storage device ports

• No custom proprietary software shall be used

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• System shall be configured to allow flowmeter calibration data to be uploaded to test stand thru a USB port or similar (subject to Tinker approval).

• Hardware shall be chosen, where feasible, that has error handling capabilities

PLC software shall be password protected at three separate levels as noted below:

• Operator level: allows access for testing of UUT’s alone. Software changes and access to calibration data are NOT allowed at this level

• PMEL Tech level: allows access to Operator level as well as Calibration level to permit test stand calibration including entry of calibration data.

Software changes are NOT allowed at this level

• Administrative level: allows access to all previous levels as well as capability to modify any test stand software as necessary. Any changes to software shall cause the associated Rev level of the software to change to the next logical level, i.e., Rev levels shall not be check sum based.

3.5.3 Lube Accessory Test Stand Component Labeling: All test stand components shall be labeled with an embossed metal tag denoting part number as per the Illustrated Parts Breakdown (IPB). All hoses shall also be labeled with an embossed metal tag and hose schedule included in the IPB that details required pressure rating of hose, hose size, length, fluid compatibility requirements, maximum temperature and nominal location. All electrical wiring shall have heat shrink labels (or equivalent) placed on either end of wire and labels and lettering shall suffer no degradation when subjected to any fluids associated with the Lube Accessory test stand.

3.5.4 Lube Accessory Test Stand Anchoring: If Lube Accessory test stand is required to be anchored to the slab, anchors shall be no longer than three and three-quarter inches (3.75”) in length. All holes required to be drilled into the slab shall be no more than four inches (4”) deep. Any damage to the existing vapor barrier due to holes deeper than those allowed shall be fully repaired by the Contractor. Repair method and final repair shall be reviewed and approved by Tinker AFB Civil Engineering.

3.5.5 Lube Accessory Test Stand Preliminary/Final Calibration: Calibration process shall be delivered by Contractor for review at Intermediate Design Review. Review comments will be delivered via the GOVERNMENT POC back to Contractor within 14 calendar days. Contractor shall fully incorporate comments as necessary and resubmit revised procedure prior to Critical Design Review for review.

Following installation of Lube Accessory test stand at Tinker AFB, Contractor shall complete and prove out the entire approved calibration process prior to contacting PMEL personnel. Preliminary calibration process shall include a spreadsheet summation completed by Contractor detailing the following:

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• Each item calibrated and calibration results (Pass or Fail)

• Initials of technician who performed item calibrated and date the calibration was completed

• As Left values for each item calibrated

• Any alignments or adjustments performed during calibration

Final Calibration process shall be carried out as follows (please note that additional calibration procedure changes may be discovered during Final Calibration, see below):

• Review and perform entire calibration process step-by-step on the Lube Accessory test stand with PMEL personnel present

• Modify calibration procedure as recommended and agreed to by PMEL personnel, as necessary

• Modify test stand calibration software as recommended and agreed to by PMEL personnel

• Once the calibration procedure is finalized, revised and resubmitted by Contractor, PMEL will formally calibrate the Lube Accessory test stand.

Contractor shall have appropriate personnel present during the entire Final Calibration process. Limitations on the calibration are not acceptable and any limitations noted by PMEL shall be fully resolved by Contractor.

3.5.6 Lube Accessory Test Stand IVV and As-Built Drawing Review: Following Final

Calibration, the Contractor shall hire a Consultant to provide an Independent Validation and Verification (IVV) of the Lube Accessory software programming versus testing procedures as per each UUT T.O. Contractor shall also provide 555 SMXS/MXDEF CD-ROM discs and installation procedures for the executive and UUT software so that any current software on the test stand can be removed and installed from the CD-ROM’s per installation procedures. 555 SMXS/MXDEF POC for this effort is Mr. Casey Bynum, 405-736-8782. The IVV shall include the following:

• Verify each step of UUT testing and associated subroutines are properly and completely implemented

• Verify that all UUT operational tolerances are present and accurate

• Verify all UUT test reports can be printed and that the test reports are complete and accurate.

• Note all deficiencies and submit list to the Contractor for correction.

Once program corrections, if any, have been made and test stand is complete, 555 SMXS/MXDEF shall submit a signed and dated document noting that Lube Accessory test stand testing of all UUT’s, including test reports, are in full compliance with all UUT T.O.’s. Software Rev level(s) shall be noted in document.

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Contractor shall also hire an independent Consultant to verify the accuracy of all As-Built drawings. Following review, Consultant shall list all deficiencies noted and submit list to Contractor for correction. All deficiencies shall be corrected by Contractor prior to final As-Built drawing submittals. Once finalized, Consultant shall submit a signed and dated document noting that As-Built drawings are 100 percent accurate. Please note that Level 3 drawings as per MIL-STD-31000A are required. Document shall include a detailed list of As-Builts including:

• Drawing name, date and rev level of each drawing associated with the Lube Accessory test stand.

3.5.7 Lube Accessory Test Stand Fixtures and Adapter Kits: Contractor shall provide all fixtures and adapter kits necessary for mounting and testing each Lube UUT onto the Lube Accessory test stand as noted in appendix I. Adapter Kits and Fixtures may be reverse engineered and must be used for correlation and functional testing of each UUT as stipulated in Appendix F.

3.5.8 Software: The Contractor shall develop a Test Executive as well as individual UUT Computer Software Configuration Items (CSCI’s) so that they can have separate configuration management at the completion of the contract. The software shall be developed utilizing an object oriented design such that there is an Executive piece that calls independent pieces for each UUT.

3.5.8.1 Self-Test: The Contractor shall develop self-test software to identify faulty equipment in the test stand and be used for troubleshooting of the stand.

3.5.8.2 Executive Software: Contractor shall develop executive software that is common to all UUT types tested.

3.5.8.3 Unit Under Test (UUT) Software: Contractor shall develop menu screens that shall be used for unit under test (UUT) test screens. The Test Points (TPs) shall be formatted in accordance with the target test equipment style requirements. The main menu shall list each individual TP. Naming convention shall reflect the primary attribute (for example, variable, procedures, object, function, and class names.) that they represent.

Reserved words of each language shall be identified in the target test equipment style guide. Hardware and Operator Error handling shall be integrated into the software.

Test results shall be permanently stored electronically in Lube Accessory test stand PC and available for easy retrieval by Operator in PDF format.

Test results may not be allowed to be electronically changed in any way and may only be allowed to be removed from the PC at the Administrative level.

Test results in PDF format shall also be capable of being printed out in hard copy for every UUT and every required test point (see Appendix G for minimum content required). All tests are to be programmed and carried out

SOW-2017-LUBE ACC Page 13 in accordance with UUT Technical Orders (T.O.’s) including applicable AF Form 202’s.

3.6 Electrical Classification and PMEL Spares Kit:

3.6.1 Electrical System: The machine shall be designed to operate from a single 480 volt, 3 phase, 60-hertz (HZ) power source. All electrical equipment shall comply with NFPA 79, NFPA 70 and NFPA 70E standards.

3.6.2 Extended Spares Kit: The Contractor shall provide a list of suggested extended spare parts, with quantities and expected service life, for the system. The list shall include both individual items and kitted parts with unit pricing for each item or kit.

This list shall take into account which items are most susceptible to damage and wear and the mean time between failures, if established, for replaceable parts. The listing shall include those parts needed for maintenance of the Lube Accessory test stand for the first and second year of operation, assuming 2500 hours of actual run time in the year, from the most used/needed to the least used/needed items.

Contractor shall supply a full set of spare flowmeters as used in the Lube Accessory test stand. Contractor shall also supply a full set of Test Replaceable Units (TRU’s) for all items checked under the software self-test routine.

3.7 Reliability Centered Maintenance (RCM)

3.7.1 RCM Acceptance Testing with Baseline Data

Baseline data is condition monitoring information that is representative of equipment in a new and / or properly operating condition. The baseline data is the foundation of the predictive trending analysis required to forecast equipment condition. Baselining, including Equipment Health Checkout, is detailed in Appendix K and shall be completed by personnel from 76 MSXG/MXDEQ. This effort shall be performed following Final Calibration of Lube Accessory test stand and prior to commencement of Correlation Testing and shall be attended by a Contractor’s technical representative. Additional information requested in Appendix K shall be provided to the GOVERNMENT POC for distribution.

3.7.2 Vibration Baseline Testing

Following factory alignment by the Contractor, Contractor shall complete a vibration baseline at the factory for each motor, motor/drive and pump/motor combination. All data shall be taken in accordance with ISO10816-3 and acceptable vibration levels are as per the “New machine condition” range detailed in the ISO 10816-3 Vibration Severity Chart (see Appendix K). This data will form the vibration baseline for each motor and pump/motor combination, provided all data is in Good Condition or better, as per ISO10816-3. Vibrations that are not unacceptable as per the ISO10816-3 Vibration Severity Chart, New Machine

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Condition shall be remediated at the factory prior to shipment. Vibration data shall be submitted to Government POC for review prior to shipment of stand.

Following Final Calibration of installed Lube Accessory test stand at Tinker AFB and prior to Correlation Testing, all motor and pump/motor vibrations shall be re-checked by 76 MXSG/MXDEQ personnel. Any vibration reading that has increased by twenty-five (25) percent or more from factory readings or falls outside of New Machine Condition, as per ISO10816-3 Vibration Severity Chart shall be remediated by Contractor, as necessary. Following successful remediation, a final vibration report noting all components/combinations tested, RMS and “Derived Peak” vibration data in inches per second (ips) as read at both the factory by Contractor and at Tinker by 76 MXSG/MXDEQ shall be completed by Contractor and submitted to the GOVERNMENT POC for review. Report shall also include class of motor, motor/drive and pump/motor combination tested and zonal results, all as per ISO10816-3.

3.7.3. Monthly Status Reports: Monthly reports shall specify progress to date, any changes to estimated completion date and status of all major milestones. These reports shall be sent to the Government POC by the 5th of each month.

3.7.4. Test Plan: The test plan shall address all testing requirements specified in section

4. Additionally, the Contractor shall conduct software acceptance tests in accordance with a Lube Accessory test stand Software Acceptance Test Procedure (SATP) developed by the Contractor and approved by Tinker personnel.

Contractor shall clearly identify tests to be performed, evaluation criteria, and a testing schedule to assure complete compliance with this SOW.

3.7.5. Training Plan: The training plan shall address all training requirements specified in section 6. The Contractor shall clearly identify content and scheduling of the training in such a manner as to assure complete compliance with this SOW. All training shall occur during normal operation times and be scheduled at least 10 working days in advanced of the classes. Training shall be conducted after successful operational testing and approved implementation audit. Trainers shall have a sign-in sheet to record personnel attending the training sessions. The Government shall supply the sign-in sheet(s).

3.8. Warranty: The Contractor shall warranty all equipment and workmanship free of defects for a period of no less than 365 calendar days. The Contractor shall be notified of defects by the Government in writing. The Contractor shall respond to all reported problems within 24 hours. Defects shall be remedied at no cost to the Government within 10 calendar days. Contractor shall be responsible for correcting any found defect or inconsistency with this SOW to the Government’s satisfaction. If the defect or inconsistency persists beyond the 365 calendar day period or the standard warranty period, whichever is longer, the Contractor shall still be responsible for corrective action until the issue is rectified. All equipment will be subject to usage 24 hours a day, 7 days a week. Warranty shall start after all training, implementation audit(s), testing, deliverables, and final approval(s) are completed and the GOVERNMENT POC has issued their final acceptance of the Lube Accessory test stand.

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Any spills caused by an equipment defect shall be cleaned up within 2 hours at no cost to the Government. Contractor shall be responsible for damages caused by the defect.

All materials and labor for corrective action, modifications, and defects shall be supplied by the Contractor, including a tracking number and carrier name e-mailed to the government POC. The period of performance for this contract shall include a minimum of one (1) year warranty. The warranty shall not be considered null and void if governmental personnel are required to perform emergency shutdown or repairs to the equipment due to a defect that present a clear and present danger, such as could cause grave damage to the environment (i.e. toxic release of chemicals), present a health hazard to personnel working in and around the equipment, or presents a safety hazard to the building, personnel within the building or other equipment surrounding the Contractor’s equipment.

Contractor shall provide a method for reporting problems encountered with Lube Accessory test stand following installation and throughout the warranty period. Upon receipt of problem report, Contractor shall analyze and respond with their planned corrective action and recommendations to the Oklahoma City Air Logistics Center (OC-ALC). Problem reports shall be classified as by the OC-ALC as urgent or routine.

Initial response time for urgent problem reports shall be forty eight (48) hours or less.

Initial response time for routine problem reports shall be seven (7) calendar days.

Contractor shall provide contact information (phone, e-mail address, etc.) for a primary and back-up POC for reporting problems.

3.9 Personnel: The contractor shall have the following minimum personnel on staff:

• At least one mechanical engineer with minimum of ten (10) years of experience in test stand construction and configuration.

• At least one technician with at least ten (10) years of experience with Labview and

PLC systems.

• At least one National Instruments Certified LabVIEW Architect.

At least one technician with at least ten (10) years of experience in the design, fabrication and installation of aircraft component testing equipment

4. QUALITY ASSURANCE PROVISIONS

4.1. Responsibility for Inspections: The Contractor shall be responsible for the performance of all inspection requirements (examinations and tests) as specified herein. The Contractor may use his own, or any other facilities suitable for the performance of the inspection requirements specified herein, unless disapproved by the government. The Government reserves the right to perform any inspections set forth in the specification where such inspections are deemed necessary to ensure the machine, supplies and services conform to the prescribed specifications. The Contractor shall provide all tooling, adapters, measurement indicating devices, material and programs required for compliance, accuracy, alignment and machining acceptance tests.

4.2. Responsibility for Compliance: All items shall meet the requirements of Section 3.

The inspections set forth in this specification shall become a part of the Contractor’s overall inspection system or quality program. The absence of any inspection

Page 16 SOW-2017-LUBE ACC requirements in the specification shall not relieve the Contractor of the responsibility of ensuring that all products or supplies submitted to the government for acceptance comply with all requirements of the contract. Sampling inspection, as part of manufacturing operations, is an acceptable practice to ascertain conformance to requirements, however, this does not authorize submissions of defective material, either indicated or actual, nor does it commit the Government to accept defective material.

4.3 Environmental Conditions: All tests shall be performed in an indoor facility with ambient conditions of 41° F to 104° F and 20% to 95% relative humidity.

4.4. Examination: The Lube Accessory test stand shall be visually examined to determine compliance with all requirements within section 3.

4.5. Design Reviews

4.5.1. Preliminary Design Review: The Contractor shall provide a Preliminary Design

Review. The design review shall be completed at the five to ten percent (5-10%) test stand design stage. The Contractor shall be required to conduct a meeting at the OC-ALC for the Preliminary Design Review. The GOVERNMENT POC will coordinate and attend the on-site meeting with the GOVERNMENT POC identified Technical Point of Contact (POC) and the Contractor. The Contractor shall submit two (2) complete hard copy data packages and one (1) electronic data package. These packages shall include the engineering data, specifications, certificates, and reports and final products including catalog excerpts and salient characteristics. The submittal shall be sent to the GOVERNMENT POC no later than (NLT) seven (7) calendar days prior to the on-site meeting. The GOVERNMENT POC will provide the two (2) complete hard copy data packages and one (1) electronic data package to the GOVERNMENT POC identified Technical POC within two (2) calendar days of receipt of the packages from the Contractor in order to allow time for the GOVERNMENT POC Identified Technical POC to review prior to 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.

4.5.2. Intermediate Design Review: The Contractor shall provide an Intermediate Design Review. The design review shall be completed fifty percent (50%) into the test stand design stage. The Contractor shall be required to conduct a meeting at the OC-ALC for the Intermediate Design Review. The GOVERNMENT POC will coordinate and attend the on-site meeting with the GOVERNMENT POC identified Technical POC and the Contractor. The Contractor shall submit two (2) complete hard copy data packages and one (1) electronic data package. These packages shall include the engineering data, specifications, certificates, reports, test plans, etc. and final products including catalog excerpts and salient characteristics. The submittal shall be sent to the GOVERNMENT POC NLT seven (7) calendar days prior to the on-site meeting. The GOVERNMENT POC will provide the two (2) complete hard copy data packages and one (1) electronic data package to the GOVERNMENT

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POC identified Technical POC within two (2) calendar days of receipt of the packages from the Contractor in order to allow time for the GOVERNMENT POC Identified Technical POC to review prior to 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.

4.5.3. Critical Design Review: The Contractor shall provide a Critical Design Review. The design review shall be completed ninety percent (90%) into the test stand design stage. The Contractor shall be required to conduct a meeting for the Critical Design Review (CDR). Preferred site for the CDR is the Contractor’s location where the Lube Accessory test stand is being fabricated, however the CDR may be held at OC-ALC. Actual location of CDR will be determined by Tinker personnel and info conveyed to the Contractor via the GOVERNMENT POC. The GOVERNMENT POC will coordinate and attend the meeting with the GOVERNMENT POC identified Technical POC and the Contractor. The Contractor shall submit two (2) complete hard copy data packages and one (1) electronic data package. These packages shall include the engineering data, specifications, certificates, reports, etc. and final products including catalog excerpts and salient characteristics. The proposed and baseline hardware and software configurations shall be reviewed to ensure that both are fully, commercially supportable and that a single baseline can exist.

The submittal shall be sent to the GOVERNMENT POC NLT seven (7) calendar days prior to the meeting, regardless of location. The GOVERNMENT POC will provide the two (2) complete hard copy data packages and one (1) electronic data package to the GOVERNMENT POC identified Technical POC within two (2) calendar days of receipt of the packages from the Contractor in order to allow time for the GOVERNMENT POC Identified Technical POC to review prior to the meeting. The Contractor shall be responsible for taking minutes during the meeting and shall provide one (1) electronic copy to the GOVERNMENT POC NLT seven

(7) calendar days after the meeting date.

4.6. Test Readiness Review: The Contractor shall have a Test Readiness Review (TRR) at

Contractor site prior to the delivery, installation and acceptance of the Lube Accessory Test Stand to ensure that the system is ready to proceed into formal test at final installation site. The TRR will assess the test objectives, test methods and procedures, scope of tests, and safety and confirm that required test resources have been properly identified and coordinated to support planned tests.

4.7. Final Acceptance: Final acceptance shall be at destination upon completion of installation Tinker AFB, OK. Final acceptance of the Lube Accessory test stand shall be made after the following items have been documented as completed, received, and approved:

• Successful performance demonstration by accomplishing all test plan requirements

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• Software Test Report

• Factory Acceptance Test Report

• Correlation Test Report

• Signed and dated IVV reports

• Vibration Report

• Test and warranty documentation.

• Lube Accessory test stand manuals, engineering drawings, and As-Built drawings.

• Software o Licenses o Source code

• Spare Parts

• UUT Adapter Kits and Hoses

• Completion of all required training.

• Completion of the Tinker AFB Implementation Audit which includes, but is not limited to:

o Bio-Environmental o Tinker Fire Department o Tinker Safety Department o Air Quality o Engineering o MXSG Maintenance

Personnel from the above mentioned departments shall be involved from the 25% review forward. These personnel shall buy-off any and all equipment installed at Tinker AFB.

4.8. Tests: All the following tests shall be accomplished at origin and destination unless otherwise noted.

4.8.1 Lube Accessory Test Stand-UUT Factory Witness Test: Prior to performing this witness test, Contractor shall complete a full, successful Lube Accessory Test Stand calibration and software driven self-test shall be accomplished. Contractor shall run a Lube Accessory factory witness test using a Lube Accessory Component supplied by Tinker AFB. Contractor shall run the full test as required by the UUT T.O. and with Tinker personnel present. Following successful completion of testing, UUT shall be return shipped to Tinker AFB.