SOW-Fuel_Oil_Test_Stand_Purchase-Property_H8TC07_27June2018-Jandula.docx

STATEMENT OF WORK

FOR

FUEL OIL TEST STAND PURCHASE

(CSN: H8TC07)

Prepared by

TRAVIS JANDULA

76 CMXG/ENC

27 June 2018

FUEL OIL TEST STAND Purchase Statement Of Work 30 March 2017

CONTENTS

APPENDICES

Appendix A: Equipment List Appendix A.1: UUT Requirements Reference Information ATTACHMENT #4: Government Furnished Property (GFP) Appendix C: Safety Specifications Appendix D: Glossary and Definitions Appendix E: Environmental Language Appendix F: Certification Test Plan Appendix G: Design Guideline 450 Appendix H: Reliability Centered Maintenance and Vibration Severity Chart

FUEL OIL TEST STAND Purchase Statement Of Work 27 June 2018

Scope of Work:

Scope: The following establishes requirements for the purchase, delivery and installation of one (1) Fuel Oil 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 Fuel Oil Heat Exchangers (Unit Under Test UUT) as identified per their relevant Technical Orders (T.O.’s). The overall project shall be considered “turnkey” type procurement. That is, final acceptance requirements have been met and approved by the appropriate Government Engineer and operational training has been conducted.

Work Hours: Construction shall typically take place as follows:

First shift, 5:45 to 2:30 PM No work during holidays or weekends without written approval from CO.

Any additional hours shall be requested in writing and must be approved by the Contracting Officer (CO) prior to working 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. Test stands will be installed in a National Electric Code, Class I, Division II, Group D environment, as per NFPA 70, Article 500. All installation work associated with this contract shall have no impact on production.

Standard Applicable Documents and Definitions Requirements:

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.”

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

U. S. DEPARTMENT OF LABOR

29 CFR 1910 – General Industry, OSHA Safety and Health Standards (29 CFR 1910), 2010 or most recent edition (available at http://www.osha.gov/) (Application for copies should be addressed to the U.S. Department of Labor, 200 Constitution Ave, Washington, D.C. 20210)

ENVIRONMENTAL PROTECTION AGENCY

40 CFR 82 – Protection of Stratospheric Ozone, 2010 or most recent edition (Application for copies should be addressed to the U.S. Department of Labor, 200 Constitution Ave, Washington, D.C. 20210)

FEDERAL STANDARDS

FED-STD-H28A – Screw Thread Standards for Federal Services, 1994 (R2001) or most recent edition FED-STD-H28/21B – Screw Thread Standard for Federal Service, Metric Screw Threads, 1984 (R2006) or most recent edition (Application for copies should be addressed to Superintendent of Documents, Government Printing Office, Washington, D.C. 20402-001).

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

NATIONAL FIRE PROTECTION ASSOCIATION (NFPA)

NFPA 1 – Fire Code, 2010 edition or most recent edition NFPA 70 – National Electrical Code, 2014 edition NFPA 70E – Standard for Electrical Safety in the Workplace, 2011 edition or most recent edition NFPA 79 – Electrical Standards for Industrial Machinery, 2007 or most recent edition (application for copies should be addressed to National Fire Protection Association, 1 Batterymarch Park, Quincy, MA 02169)

TELECOMMUNICATIONS INDUSTRY ASSOCIATION (TIA) STANDARD

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 (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)

NATIONAL ELECTRICAL MANUFACTURERS ASSOCIATION

NEMA MG 1 – Motors and Generators, 2009 (R2010) or most recent edition NEMA ICS 6 – Industrial Control and Systems: Enclosures, 1993 (R2006) or most recent edition (Application for copies should be addressed to National Electrical Manufacturers Association, 1300 N 17th Street, Suite 1752, Rosslyn, VA 22209)

AMERICAN NATIONAL STANDARD INSTITUTE

ASTM SI 10 – American National Standard for use of the International System of Units (SI): The Modern Metric System, 2010 or most recent edition (Application for copies should be addressed to American National Standards Institute, Attn: Sales Department, 1430 Broadway, New York, NY 10018-3363)

AMERICAN WELDING SOCIETY INC (AWS)

AWS D14.4 – Specification for Welded Joints in Machinery and Equipment, 1997 or most recent edition (Applications for copies should be addressed to the American Welding Society Inc, 550 North LeJeune Road, Miami, FL 33126)

INTERNATIONAL ORGANIZATION FOR STANDARDIZATION

ISO 4413 – Hydraulic Fluid Power – General Rules and Safety Requirements for Systems and Their Components, 2010 or most recent edition ISO 10816-3 – Mechanical Vibration – Evaluation of machine vibration by measurement on non-rotating parts, 2009 or most recent edition.

(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) 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.

Standard Government Occupancy of Facilities & Responsibilities Requirements:

Facility: The Contractor shall install this equipment in an operational facility that is engaged in the production of flight worthy aircraft parts. This shop is in operation 24 hours per day Monday through Friday and engages in overtime on the weekend on a regular basis. Contractor shall be required to consult with Project Engineer and the Government POC to develop a timeline that accommodates the continued performance of user’s mission function during the installation. Contractor shall be responsible for cordoning off work areas.

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) at Critical Design Review, minimum 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. This dates should be included in the Integrated Master Project Schedule identified in chapter 8.2. 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 chemicals required for the installation and start-up of the Fuel Oil 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 information will be made available to Contractor by Government POC, as needed.

Prohibited Materials:

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

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

Lead Based Paint: Lead based paint and materials containing heavy metals shall not be used on or in the machine.

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

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

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.

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.

Other Environmental Compliance: Contractor shall comply with all environmental requirements as stipulated in Appendix E Secured Area(s): Project is located in a secured area. Contractor personnel will be issued site badges by the Security Office located on the north side of Tinker just north of the Air Depot security gate. Badge issuance process shall be coordinated by the Government POC. Badges (including temporary badges) shall be displayed at all times while on the base. Access badges allowing Contractor personnel access to the secured areas shall be coordinated by the Government POC following issuance of site badges. Equipment and large items shall be required to enter base through the Truck Gate located just north and east of the Air Depot and 59th Street intersection. The Government reserves the right to inspect any and all deliveries being made to the base before entrance is permitted.

Safety and Quality Control.

Contractor is responsible for ensuring and enforcing industry safety practices, and quality control of the job site.

Contractor shall comply with all safety practices posted in the assigned work area and Personal Protection Equipment (PPE) requirements. PPE shall include, but is not limited to, safety glasses and hearing protection.

Contractor and his/her representatives shall have appropriate environmental and safety training required by the state and federal government according to Resource Conservation Recovery Act (RCRA).

The Contractor is advised that electric service is in the work area. Fall protection, PPE, and any other safety related material needed shall be provided by the Contractor for contract employees. All safety signage in the work area and OSHA regulations shall be strictly followed by the Contractor. The Contractor’s onsite supervision shall be responsible for ensuring personnel related to this project observe and follow the safety guidelines and properly wear the correct PPE. Hard hats shall be required in the facility periodically due to the ongoing construction, as well as hearing and eye protection and safety glasses.

FOD and DOP.

All Contractor personnel and their subcontractors working on this project are required to comply with AFMCI 21-122.

Contractor shall be responsible for ensuring and enforcing compliance with FOD requirements of the job site.

All Contractor personnel and their subcontractors working on this project are required by AFMCI 21-122 to receive FOD/DOP Awareness and Prevention Training.

The work to be performed in this area will require Contractor to work in or travel through areas near equipment producing flight capable parts for use on military aircraft, engines, munitions, missiles, support equipment, and/or Aerospace Ground Equipment (AGE).

Trainers and/or the Contractor personnel may be operating vehicles and equipment in maintenance areas.

FOD/DOP Awareness and Prevention Training is available on the Tinker Intranet, https://org.eis.afmc.af.mil/sites/76MXW/QA/76%20MXW%20FOD%20Program/Forms/AllItems.aspx?RootFolder=%2fsites%2f76MXW%2fQA%2f76%20MXW%20FOD%20Program%2fOC%2dALC%20FOD%20Information%2fVisitors%20FOD%20Awareness%20Information&FolderCTID=&View=%7b7C5D8240%2d301C%2d446C%2d99C9%2d7EE85CBB77C0%7d

This training is available via CD-ROM upon request by the Contractor for an alternate form of training.

Housekeeping.

Contractor shall keep the work areas clean and neat in accordance with Industry Standards, Occupational, Safety and Health Administration (OSHA), fire and safety standards and this SOW. Cleanup at the end of each day is required. All tools shall be properly stored in a lockable tool box and trash removed. All hardware shall be properly stored in Ziploc bags and the work area in orderly condition, no exceptions.

Packing material, material remnants, rubbish and debris shall be removed from Government property daily, unless otherwise directed, to avoid accumulation at the work site. Materials that cannot be removed DAILY (NO EXCEPTIONS) shall be stored in areas specified by the government project engineer.

Tool Control and Accountability: While performing contract services in or around Maintenance Production Shops including Ramp areas, Contractor shall comply with AFMCI 21-107, Tool Control and Accountability Program and Tinker Instruction 21-112, Tool Management.

Tool Listing: Contractor shall identify and list each tool separately on a “tool listing” kept inside each container or bag.

Securing Tools: Contractor personnel shall ensure all tools are secured when not in use.

Unattended Tools: Contractor personnel shall ensure no tools are left unattended at any time.

Beginning Inventory: Contractor personnel shall inventory the container or bag of tools at the beginning of the day.

Ending Inventory: Contractor personnel shall inventory the container or bag of tools at the end of each day.

Missing Tools: Contractor personnel shall immediately notify the Government POC of any tools that are missing.

GOVERNMENT FURNISHED PROPERTY AND SERVICES.

Government Furnished Property (GFP).

The Government will provide, without cost, the authorized GFP listed in Attachment #4. The Contractor shall comply with the contract terms and conditions which includes this SOW.

The Contractor shall ensure all GFP is secured at the close of each workday. This GFP shall only be used as needed for the performance of this contract. The Government retains title to all GFP, until the Government properly disposes of the GFP as authorized by law or regulation.

The Contractor shall be responsible for all cost related to making the GFP available for use to complete the contractual requirements.

GFP Shipment from Government to Contractor’s Facility. The Contractor shall requisition the authorized GFP in accordance with SOW 4.6, GFP Requisition Requirement. The Government will be responsible for packaging and shipping the GFP to the Contractor’s facility, Free-On-Board (FOB) Destination, (Government expense).

NOTE: See SOW 4.6 GFP Requisition Requirement.

The Loan Control Officer (LCO) Process or Government Furnished Material (GFM) Process is Applicable.

GFP Return Shipment to Government.

When the GFP is no longer required for the performance of this contract, the Contractor shall request written disposition instructions from the Initiator/Program Manager (PM) or designated Government POC. The Initiator/PM will obtain written disposition instructions from the Source of Supply (SOS)-Item Manager (IM). The Initiator/PM will provide the written disposition instructions to the Contractor, the SOS-LCO or SOS-GFM Officer and the Contracting Officer (CO).

The Contractor shall not dispose of any GFP until authorized to do so in accordance with the written disposition instructions from the SOS-IM. The Contractor shall comply with the written disposition instructions. The Plant Clearance Automated Reutilization Screening System (PCARSS) is not required for GFP disposition, unless cited as a requirement in the written disposition instructions.

The Contractor shall package and ship the GFP to the Government, FOB Destination (Contractor's expense). Within eight (8) work hours of the GFP shipment, the Contractor shall provide the shipment date and tracking information to the Initiator/PM. The Initiator/PM will provide, in writing, the shipment date and tracking information to the SOS-IM, SOS-LCO or SOS-GFM Officer, and the CO.

Loss of Government Property.

In accordance with the Government Property contract clauses.

Additional, Replacement, or Removal of GFP.

When applicable, Additional, Replacement, or Removal of GFP from the contract requires the Contracting Officer’s approval documented by a bilateral contract modification, using the Standard Form (SF) 30.

All packaging and transportation costs associated with additional, replacement, or removal of GFP from the contract shall be IAW the GFP Shipment Instructions cited in SOW 4.1.1. and SOW 4.1.2.

GFP Identification Labels.

When applicable, the Contractor shall clearly label (without damaging) Government Furnished Property to distinguish it from Contractor Furnished Property, in accordance with the contract terms and conditions.

Plant Clearance (Disposition) Instructions Plant Clearance Automated Reutilization Screening System (PCARSS) shall not be required for disposal of GFP. The Contractor shall use the GFP Return Shipment to Government instructions cited in this SOW Section 4.1.2.

Government Property Incidental to a Government Installation or Site.

Note: Formerly referred to as Shared Property of the Government.

Incidental Government Property (GP).

In accordance with Government procedures, the Contractor is authorized to share Incidental Government Property, without cost, with Government personnel at Tinker AFB, OK, for the duration of this contract and only as needed for performance of this contract. The Government retains title to all Incidental Government Property until the Government properly disposes of this property as authorized by law and regulation. The Government will maintain accountability (property records) of this property for Government reporting requirements.

This Incidental Government Property is not considered GFP requiring property administration in accordance with FAR Parts 45 and 52.245 plus supplements. However, this Incidental Government Property will be administered IAW the provisions of this PWS and FAR 52.237-2, Protection of Government Buildings, Equipment, And Vegetation. The Contractor shall comply with the contract terms and conditions and this SOW.

4.2.2 Incidental GP-Shared Storage Areas.

The Contractor shall make arrangements with the Government POC for storage of Contractor materials, equipment, and incidentals between its delivery and its installation, as availability of space and security during non-working hours cannot be guaranteed. These areas are on a first-come first-served basis and are very limited.

4.2.3 Incidental GP-Cease to Use and Return to Government.

During the contract, contract completion, or termination, the Contractor shall cease to use and shall return (when applicable) all Incidental Government Property to the Government POC.

4.3 Government Furnished Services (GFS).

The Government will furnish the following services at Tinker AFB (TAFB), OK:

4.3.1 Security Forces.

The Government will provide general on-base security forces’ service. The security forces’ telephone numbers are 911 for emergencies, 405-734-2000 for crimes in progress and 405-734-3737 for non-emergency calls. The off-base 911 center receives 911 cell phone calls. Cell phone callers need to advise the 911 off-base center they are on TAFB in order to be connected with the on-base 911 center.

4.3.2 Fire Emergency and Routine Services.

The Government will provide general on-base fire protection services. The Contractor shall comply with fire prevention rules and regulations enforced by the TAFB Fire Prevention Branch. For emergencies call 911. For routine fire prevention matters call 405-734-3981 or 405-734-3982. For after hours, weekends, and routine calls to dispatch call 405-734-7964.

4.3.3 Utilities.

The Government will provide utility services. These utilities include natural gas, electricity, water, and sewer for the sole purpose of accomplishing this contract. If the Contractor requires additional utility services, it shall be the Contractor’s responsibility to provide. The Contractor shall use due care and diligence in efforts to conserve utilities to reduce utility costs.

4.3.4 Refuse Collection.

The Government will provide refuse collection services limited to the extent provided in the Base Refuse Collection Contract(s) for the Government provided facilities. The Government will only allow non-hazardous refuse to be emptied into the nearest authorized refuse dumpster for trash collection. Do not use Government dumpsters to dispose of construction debris.

4.3.5 Custodial Services.

The Government will provide custodial services limited to the extent provided in the Base Custodial Contract(s) for the Government provided facilities.

4.3.6 Insect and Rodent Control.

The Base Civil Engineering Entomology will provide service for Government provided facilities.

4.3.7 Grounds Maintenance.

The Government will provide grounds maintenance services limited to the extent provided in the Base Grounds Maintenance Contract(s) for the Government provided facilities.

4.3.8 Real Property Maintenance/Repair.

The Government will provide maintenance and repair of Real Property in accordance with and compliance with Government procedures. The Contractor shall submit written requests to the Government POC for Real Property maintenance and repairs.

4.3.9 Workspace.

The Government will provide access to the equipment and adequate workspace around the equipment.

4.4 Intangible Government Property.

4.4.1 Intangible Government Property is not covered by FAR Part 45 plus Supplements, but is covered by FAR Part 27 and DFARS Part 227 plus supplements.

When applicable and in accordance with Government procedures, the Government will furnish, without cost, Intangible Government Property to the Contractor. All Intangible Government Property shall remain at all times sole property of the U.S. Government. All Intangible Government Property used, input, processed, acquired, modified, developed, and/or generated by the Contractor in support of this contract, in any media, shall remain at all times sole property of the U.S. Government.

The Contractor may not use or disclose any Intangible Government Property for any purpose or in any manner not specifically authorized or required by the contract and this SOW.

The Contractor shall ensure all Intangible Government Property is secured at the close of each workday. The Contractor shall use reasonable care to avoid losing and/or damaging Intangible Government Property. If the Contractor’s failure to use reasonable care causes loss and/or damage to Intangible Government Property, the Contractor shall be liable for the cost to replace the Intangible Government Property, which may be deducted from the contract price.

The Contractor shall use, input, process, maintain, and return all Intangible Government Property in the English language, readable and in a readily retrievable format, which requires no additional software or tools to read and retrieve beyond those already installed on the affected U.S. Government computers. The Contractor shall not return any Intangible Government Property by Universal Serial Bus (USB) thumb drives or equivalent devices.

During contract performance, contract completion, or termination, the Contractor shall return all Intangible Government Property to the Government POC. The Contractor shall comply with the applicable contract clauses and this SOW.

4.4.2 Government Furnished Drawings.

All work plan drawings prepared by the Government for this project are available in electronic format (Autocad, .dwg) from the Government Engineer.

4.5 Contractor Acquired Property (CAP), Time & Material (T&M), Labor Hour (LH), Cost Reimbursable (including Travel) Contract Line Item Numbers (CLINS).

Not Applicable.

4.6 GFP Requisition Requirement.

The Contractor shall be responsible for all costs associated with obtaining the appropriate electronic means, i.e., Military Standard Requisitioning and Issue Procedures (MILSTRIP) capability to submit requisitions through the MILSTRIP/DLA Logistics Management Standards (DLMS) for authorized GFP. The three (3) known DoD systems, to submit authorized GFP requisitions, include DLA Automated Message Exchange System (DAMES), Web Requisitioning (WEBREQ), or FedMall (formerly DoD EMALL). Reference the following Defense Logistics Agency (DLA) Websites:

https://www.transactionservices.dla.mil/daashome/dame.asp https://www.transactionservices.dla.mil/daashome/webreq.asp https://www.fedmall.mil (formerly https://dod.emall.dla.mil/acct/)

The DAMES system DOES NOT require a DoD-approved Common Access Card (CAC), Public Key Infrastructure (PKI) or External Certificate Authority (ECA).

The WEBREQ and FedMall (formerly DoD EMALL) systems DO require a DoD-approved Common Access Card (CAC), Public Key Infrastructure (PKI) or External Certificate Authority (ECA).

Standard Warranty Requirements:

The Contractor shall warranty all equipment and workmanship free of defects for a period of no less than 730 calendar days. The Contractor shall be notified of defects by the Government in writing. The contractor shall reply to the Government on reported problems within 72 hours and make arrangements to coordinate repairs of defects. Defects shall be remedied at no cost to the Government. 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 730 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 Engineer has issued their final acceptance of the Fuel Oil test stand.

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 for Surveillance. 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 Fuel Oil 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 identified by OC-ALC as urgent or routine. Response time for urgent problem reports shall be seventy two (72) hours or less. 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.

Standard Training/Familiarization Requirements:

The training plan shall address all training requirements specified herein. 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 class. 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 standard format sign-in sheet(s).

Operator: Within 10 calendar days of acceptance at Tinker AFB, the Contractor shall conduct a minimum of 24 hours of on-site familiarization and training over three (3) consecutive workdays, during the hours of 0545 to 1430 for up to two (2) Fuel Oil Test Stand operators. Training/familiarization shall be scheduled so as not to interfere with Federal Holidays or weekends. Training shall be conducted at Tinker AFB following full installation of Fuel Oil test stand and completion of correlation work and shall include at a minimum the following:

General familiarization with the stand Instruction and demonstration of test stand operation Unique features of the test stand Process for printing test reports Process for retrieving current and archived test reports Informal testing of a single UUT provided by Tinker AFB.

Electrical/Mechanical: The Contractor shall provide one (1), two (2) day maintenance familiarization session for mechanical maintenance and electrical familiarization with the Fuel Oil test stand. Familiarization session shall be conducted at Tinker AFB following final installation of Fuel Oil test stand. Familiarization shall be provided for a total of four (4) maintenance personnel. On-site maintenance familiarization shall be conducted during the hours of 0630 to 1430. Maintenance familiarization shall be scheduled so as not to interfere with Federal Holidays or weekends. Training shall be conducted at Tinker AFB following completion of Final Calibration or any time thereafter and shall include at a minimum the following:

General layout of Fuel Oil test stand Information on the frequency of preventative maintenance Types of preventative maintenance required Hands-on experience Review of maintenance portion of manual Calibration: The Contractor shall furnish a training session for one (1) to four (4) GOV Industrial Metrology personnel to review calibration procedures. This session shall be a minimum of two (2) days in length and shall be conducted during the hours 0630 to 1430. Calibration training shall be scheduled so as not to interfere with Federal Holidays or weekends. Training shall be conducted at Tinker AFB following completion of Final Calibration or any time thereafter and shall include at a minimum the following:

Full review of the step-by-step calibration procedures and implementation of changes into Contractor procedures, as agreed to Full review of the calibration process on the Fuel Oil Test Stand as per Contractor procedures following implementation of changes agreed to above Software Engineer: The Contractor shall furnish a training session for one (1) to two (2) engineer(s) that are associated with Commodities (aka 76 CMXG/ENC). This session shall be a minimum of two (2) days in length and shall be conducted during the hours 0730 to 1630. Engineer training shall be scheduled so as not to interfere with Federal Holidays or weekends. Training shall be conducted at Tinker AFB following completion of Final Calibration or any time thereafter and shall include at a minimum include the following:

Overview of the Data Acquisition/computer systems including how these systems interact with one another Review of the testing software and process for making software changes Process for backing up all programs as necessary General layout of SSD’s including where test data resides.

Standard Equipment Requirements:

Personnel: The contractor shall have the following minimum personnel intimately involved and their expertise will be applied directly to this project:

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 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).

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.

Units required by UUT technical orders must be displayed directly. No calculation or manipulation shall be required by Technician.

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 but easily removed if required for calibration. Such devices shall be located so as to allow reading from the operator’s normal workstation.

Construction: The Fuel Oil Test Stand shall be new, unused (not a prototype) constructed of parts that are new, without defects, commercial-off-the-shelf (COTS), and free of repairs. Metals shall be of corrosion resistant materials unless suitably protected to resist corrosion. The framework shall be constructed of per-formed metal sections welded into ridge units. Test stand base shall incorporate fork lift slots to assist moving and inclined drip pan fitted with a separate drain catch and remove any leakage. 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 Fuel Oil Test Stand shall be built in compliance with Design Guideline 450 as shown in Appendix G.

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.

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.

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.

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.

Painting: The equipment shall be painted in accordance with the manufacturer’s standard commercial practice. Test stand shall be painted Medium Blue, FS 35177, and RGB Hex Code 436F94 as per Fed-Std-595 “Air Force Blue” or equivalent. Yellow or orange safety color-coding shall be used for designated physical hazards.

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.

Electrical: Power and low voltage signal wire most be separated and signal wires must be appropriately shielded to avoid signal noise.

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.

Ergonomics: The Fuel Oil Test Stand shall consider ergonomics and implement engineering controls which consider posture, force, repeatability, and difficulty, to reduce physical stress to operator. Design should at a minimum include, minimized distance between load and the body, loads lifted from knuckle height, and minimize bending/twisting.

Location of valves, transducers, motors, tanks, pumps, etc. shall be accessible by the average adult without unnecessary strain or special tools, during operation or maintenance.

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 Fuel Oil Test Stand unit as measured on the “A” weighted scale of a standard Type II sound level meter.

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.

Documentation: All documentation, i.e. operation manuals, maintenance manuals, repair manuals, programming manuals, student training materials, drawings, vendor literature, laminated note cards, metal name and service plates, service bulletins, upgrade bulletins, and all associated charts/graphs, shall be written in the English language and grammatically correct. All technical data shall identify manufacturer’s name, model number, serial number and contract number. The machine layout shall be furnished in AutoCAD (.dwg, version) editable format as well as .pdf. The data furnished shall include copies of the OEM manuals and data sheet for all subcomponents of the system (i.e. PC manual, pump manuals, etc.)

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, MIL-PRF 7024, and PD 680 fluids and suffer no degradation when subjected to it.

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. Removable panels and folding doors which permit access to the interior for inspection and maintenance.

All components shall be located and mounted so that any major item may be removed without the necessity of altering framework or major disassembly of other items.

Component Labeling: All test stand components including but not limited to motors, pumps, valves, transducers, flow meters, etc. shall be labeled with an embossed metal tag denoting unique functional part number consistent with drawings and schematics provided with equipment. All hoses shall also be labeled with an embossed metal tag and hose schedule included in the Integrated Parts Breakdown (IPB) that details required pressure rating of hose, hose size, length, fluid compatibility requirements, maximum temperature and nominal location, e.g., Pump ABC suction, etc. 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 Fuel Oil test stand.

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-7808, MIL-PRF 7024, and PD 680 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 Commercial Maintenance Manual Number 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.

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.

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) (explosion proof box, disconnect, etc.) the source panel name, location and circuit breaker number(s) used to feed the electrical device.

Reliability Centered Maintenance (RCM) Acceptance Testing with Baseline Data - Baselining, including Equipment Health Checkout, is detailed in Appendix H and shall be completed by contractor and verified by GOVPOC. Any baselines that are unacceptable as per Appendix H (New Machine Condition) shall be remediated by contractor.

Following Final Calibration of installed Fuel Oil 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. review. Report shall also include class of motor, motor/drive and pump/motor combination tested and zonal results, all as per ISO10816-3.

Standard Software requirements:

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. All tests are to be programmed and carried out in accordance with UUT Technical Orders (T.O.’s) including applicable AF Form 202’s.

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

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

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. General layout of individual test screens will be standardized. Meaning if UTT 1, 2, and 3 all use the same flow meter that flow meter will be in the same location e.g. top right for all test screens. 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 Fuel Oil 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, may be extracted in an electronic format capable of being imported into standard data analysis software (Excel) 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.

Software Documentation:

Concept Requirements:

System/Subsystem Specification (DI-IPSC-81431A) Software Requirements Specification (DI-IPSC-81433A) Design:

System/Subsystem Design Description (DI-IPSC-81432A) Software Design Description (DI-IPSC-81435A) Interface Design Description (DI-IPSC-81436A) Qualification/Test Products.

Software Test Plan (DI-IPSC-81438A) Software Test Description (DI-IPSC-81439A) Software Test Report (DI-IPSC-81440A) User/Operator Manuals:

Software Programmer’s Guide (DI-IPSC-81633) Software:

Software Product Specification (DI-IPSC-81441A) Software Version Description (DI-IPSC-81442A) Software assurance shall be designed into the software and shown as part of the Software Acceptance Test Procedure.

Copies of all software/licenses and initial backup/recovery options shall be delivered with equipment.

This is shall be updated anytime there are any changes made by any non-government entity during any warranty period as well as and the end of the warranty. Government shall own all software and must always have the most current versions on hand at all times.

Standard PC and PLC Control System Requirements:

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 GOV Industrial Metrology 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.

All access, to include but not limited to USB, connectors, and DVD drives must be physically secured and separated from all other items that require routine maintenance. Access to software will require keyed access different than that of other maintenance panels.

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.