Statement_of_Work.pdf

STATEMENT OF WORK

FOR

FUEL PUMP TEST STAND OC12890

UPGRADE

FSC: 4920

NAICS: 335314

Prepared by

THOMAS PHAM

76 CMXG/ENC

08 February 2019

Fuel Pump Test Stand OC12890 Upgrade Statement of Work

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CONTENTS

Section/Para Page

1 Scope of Work 2 Applicable Documents and Definitions

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 Fuel Pump Test Stand Configuration and Performance Requirements

3.6 Reliability Centered Maintenance (RCM)

3.7 Warranty

3.8 Personnel…

4 Quality Assurance Provisions

4.1 Responsibility for Inspections

4.2 Responsibility for Compliance

4.3 Environmental Conditions

4.4 Examination

4.5 Safety Analysis

4.6 Design Reviews

4.7 Test Readiness Review

4.8 Tests

4.9 Final Acceptance

4.10 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. Documentation

6 Training/Familiarization

6.1. Operator

6.2. Electrical/Mechanical

6.3. Calibration

6.4. Software

7 Special Provisions

7.1 Government Occupancy of Facilities & Responsibilities

7.2 Secure Area(s)

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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 Period of Performance and Other Written Submittals 10 Government Furnished Property and Services

10.1. Government Furnished Property (GFP)

10.2. GFP Shipment to Contractor’s Facility

10.3. GFP Return Shipment to Government

10.4. Loss of Government Property

10.5. GFP Identification Labels

10.6. Plant Clearance (Disposition) Instructions

10.7. Standard Form 30, Contract Modification

10.8. Shared Property of the Government

10.9. Shared Storage Areas

10.10. Cease to Use and Return to Government

10.11. Government Furnished Services

10.12. Intangible Government Property

10.13. Government Furnished Drawings

APPENDICES

Appendix A: 76CMXG Design Guideline

Appendix B: Government Furnished Property (N/A)

Appendix C: Safety Specifications

Appendix D: Glossary and Definitions

Appendix E: Environmental

Appendix F: Certification Test Plan Appendix G: Test Report Appendix H: Building 3907 Layout Appendix I: Unit Under Test Appendix J: Calibratable Items to be Utilized Appendix K: Reliability Centered Maintenance Appendix L: B2 Pump Module Test Stand OC14451 Manual and Drawings Appendix M: Pressure Transducer Cart Appendix N: Contract Data Requirements List (CDRL)

1. SCOPE OF WORK:

1.1 Scope: The following establishes the minimum requirement for the upgrade of one (1) Fuel Pump Test Stand OC12890, Part Number 83518-3-OC001; and training on the maintenance, calibration, programming and use of said test stand. The test stand will be used to test A-10, B-1, B-2, C-130, F-15, F-16, F-22 Fuel Pumps as required and as

SOW-2018-Fuel Pump TS Upgrade Page 4 per their relevant Technical Orders (T.O.’s). The overall project shall be considered a whole and complete procurement. That is, final acceptance requirements have been met and approved by the appropriate Government POCs and operational training has been conducted.

1.2 Background: The test stand described in this document is intended for use in the Aerospace Repair Industry. The equipment is located in Building 3907, Room 112 Tinker AFB, OK. This shop runs on a 24 hour basis Monday through Friday with possible overtime hours on the weekend. Test stand shall be installed in a National Electric Code, Class I, Division II, Group D environment, as per NFPA 70, Article 500.

Work on the test stand shall be coordinated with production with 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

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

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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, Battermarch Park, Quincy, MA 02269)

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)

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 http://www.ihs.com/

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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 (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 Fuel Pump Test Stand OC12890, P/N 83518-3-OC001, upgrade shall be using all new parts, Commercial Off-the-Shelf (COTS), unused (not a prototype) and shall be based upon the design of existing B2 Pump Module Test Stand OC14451, P/N 83518-4-OC001, currently in use at Tinker AFB, Building 3902. The Fuel Pump Test Stand OC12890 upgrade particulars are noted below:

• The upgraded configuration shall be based upon the design of B2 Pump Module Test

Stand OC14451 to test end items in accordance with Air Force (AF) Technical Orders (T.O.) listed in Appendix I.

• The upgraded configuration shall comply with the requirements of Technical Manuals 1TL32-83518-1 Revision 3.19, dated 14 September 2016 and 1TL32-83518-4 Revision 2.1, dated 09 Oct 2018, to include all appendices found in the applicable Technical Manuals. The test stand technical manuals are listed in Appendix L.

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

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• The Contractor may request the Contracting Officer (CO) to provide a copy of the test sections of the end items and test stand technical orders listed in Appendices I and L.

The request shall be by e-mail. The Contractor shall sign Non Disclosure Agreement and shall not disclose the data provided for any purpose or in any manner not specifically authorized or required by this SOW or the contract.

• The Test Stand OC12890 consists of two (2) main components, the Test Stand and the

Power Module. The Test Stand is located in a Class 1 Division 2 environment at Post B16, Room 112, Building 3907. The Power Module is located in a non-hazardous environment in Room 118, Building 3907 about 271ft from the Test Stand as shown in Appendix H (see drawing).

• The contractor shall provide a new remote electrical enclosure with 1ea Programmable

AC Power Supply (10kVA minimum, 3 phase, 150-500VAC, 45-500HZ), 1ea Programmable DC Power Supply SGA330X30C (10kW, 0-330 Vdc), 1ea Harmonic Power Analyzer Valhalla 2400 or equivalent.

• The Contractor shall calculate heat from all components (power supplies, power analyzer) inside the remote electrical enclosure and ensure adequate ventilation per manufacture specifications. The remote electrical enclosure shall be installed next to the existing Power Module (see drawing, Appendix H). The contractor shall run electrical conduit and wiring from the electrical enclosure to the Test Stand. The 400hz shall be a separate conduit. The contractor shall install a Double Throw Switch between new power supplies and the existing Power Module (used as back up). There is 28VDC, 270VDC, 200VAC, and 400VAC power. The power supplies shall be interlocked so that only one power source can be turned on at time. The power control shall be based on the power control of the B2 Pump Module Test Stand OC14451.

• New consoles or modules shall be powder coated white on the interior and powder coated light gray or Air Force blue on the exterior. All painting shall be performed at the contractor’s facility.

• The test stand upgrade shall provide a minimum of three (3) emergency stop buttons.

One (1) shall be located at the middle left on the front panel of the Test Stand, one (1) shall be located at the middle right on the front panel of the Test Stand, and one (1) shall be located on the remote electrical enclosure. All buttons shall remove power from all energy sources including but not limited to the compressed air system, the fuel system, the chilled water system, and electrical system. All emergency stops shall be hard wire controlled. Emergency stops shall be configured so that computer, software and all sensitive electronic equipment will not be damaged due to emergency stop.

• The contractor shall verify the B2 Pump Module Test Stand OC14451. Calibration

Fluid System of the Test Stand OC12890 upgrade shall be based on the calibration fluid system of the B2 Pump Module Test Stand OC14451. All required modifications to the calibration fluid system and all components shall comply with the latest version of NEC, NFPA, ASME 31.1 Power Piping and ASME 31.3 Process Piping. The

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Contractor shall provide Code Compliance Reports signed by a licensed professional engineer.

• The requirement is to have a backup to the B2 Pump Module Test Stand OC14451. The tubing, Fittings, Hoses, Valves and all other necessary items shall be interchangeable between stands.

o Tubing and Fittings. All tubing shall be seamless stainless steel. All bulkhead fittings on the operator front panel shall be stainless steel with stainless steel caps and lanyard cables connected to caps and test stand front panel. All bulkhead fittings sizes on the operator front panel shall match the existing test stand. All other fittings shall be stainless steel or cadmium or zinc plated steel.

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

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

o All valves shall be rated for the required maximum working pressure of the required highest end item test pressures and temperatures in a required circuit.

All valves shall comply with the latest version of the National Fluid Power Association, ASME 31.1 Power Piping and ASME 31.3 Process Piping.

• The contractor shall provide a Pressure Transducer Cart with 1ea Explosion Proof enclosure, 1ea Dual Differential Pressure Transducer 2942024-103 and 1ea Adapter 500-832500-101 similar to the X200948405 (with Government approval) as shown in Appendix M. The Pressure Transducer Cart is used in conjunction with the test stand.

• The contractor shall provide 1ea F22 Boost Pump Mid/aft mode control cable (CBL 301), 1ea F22 Boost Pump Forward mode control cable (CBL 302), 1ea F22 Transfer Pump instrument cable (CBL 303), 1ea F22 Boost Pump power cable (CBL 304), 1ea F22 Transfer Pump power cable (CBL 305) per drawing set D-3012-012 in Appendix L.

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• The Contractor shall provide one (1) each printer for the test stand upgrade to print F- 22 Pump test reports as shown in Appendix G. The printer shall be located in Room 111 about 108ft from the test stand. The printer shall be capable of color printing with a minimum input paper tray size of 250 pages of 8-1/2 X 11 inch paper. The minimum ISO print speed for black and white shall be 8 pages per minute. The minimum ISO print speed for color shall be 6 pages per minute. The minimum print resolution shall be 600 x 600 dpi for both color and black and white. The manufacturer recommended monthly printed page volume shall be a minimum of 1500 pages. The printer shall have a Hi Speed USB minimum 2.0 compatible connection.

• Test stand shall be self-contained.

• Turnkey Installation and Start-up.

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 test stand, shall be graduated in inch-pound units. 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. All measuring and indicating devices shall be calibrated by OC-ALC PMEL (Precision Measurement Equipment Laboratory).

Any measuring and indicating device are not in AFMETCAL, the contractor shall provide Standard and procedure for calibration.

3.1.3 Safety and Health: Covers, guards and other safety devices shall be provided for all parts of the test stand that present safety hazards. The safety devices shall not interfere with the operation of the test stand. 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 test stand 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 Prohibited Materials:

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

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

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

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

3.1.5.5 Ozone Depleting Chemicals (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.

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

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

3.1.8 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-7024, Type II calibration fluid and suffer no degradation when subjected to it.

3.1.9 Nameplate: A corrosion resistant metal nameplate permanently and legibly marked with the following information shall be securely attached to the test stand in a readily visible location. Nameplate and lettering shall be fully compatible with MIL-PRF-7024, Type II calibration fluid and shall suffer no degradation when subjected to it. Lettering shall be a minimum of 18 point font.

Nomenclature of the test stand Manufacturer’s Name and Address Manufacturer’s Model Number Manufacturer’s Serial Number Date of Manufacture Contract Number

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3.2. Construction: The Fuel Pump Test Stand Upgrade shall be constructed of parts that are new, without defects, commercial-off-the-shelf (COTS), and free of repairs and modification. Quality of materials used in construction shall be equivalent to or superior to those used in construction of existing B2 Pump Module Test Stand OC14451 located in B3902. Metals shall be of corrosion resistant materials unless suitably protected to resist corrosion. The Fuel Pump Test Stand Upgrade 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 Fuel Pump Test Stand Upgrade shall be capable of withstanding all forces encountered during operation of the test stand 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 Pump Test Stand Upgrade shall be built in compliance with 76CMXG Design Guideline 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 test stand. 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.

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 test stand.

3.2.5 Painting: The contractor shall cover all openings with sheet metal when items are removed and paint the covers to match the existing test stand color.

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3.2.6 Screw Threads: All threaded parts used on the test stand 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 test stand shall be designed and constructed to permit effective maintenance. The test stand 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 Contractor shall run electrical conduit, wiring, and all other required electrical components from the existing electrical panel HE16 to the new power supplies and from the power supplies to the test stand in order to make the stand fully operational electrically. The distance from the electrical panel HE16 and the power supplies is about 30 feet and from the power supplies to the test stand is about 271 ft.

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 but not limit to:

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• Drawing denoting test stand locations 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.

• Electrical hook ups

• All subcontractor and partnership information Complete installation drawing to be approved by the Government POC.

Installation Plan shall be submitted to the Government POC a minimum of ninety calendar (90) days After Date of Contract (ADC). Stands 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. Fuel Pump Test Stand Upgrade Configuration and Performance Requirements: The

Fuel Pump Test Stand Upgrade OC12890 shall generally be configured, calibrated and tested as noted below:

3.5.1 Configuration. Fuel Pump Test Stand Upgrade OC12890 shall be based upon design of the B2 Pump Module Test Stand OC14451 currently in use at Tinker AFB, B3902. See Appendix L for general test stand configuration and Appendix J for required calibratable items.

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 Test Stand Interior-Electrical Items: All electrical/electronic components and connections located within Fuel Pump Test Stand Upgrade footprint, floor to ceiling shall be Class I Division I Group D rated as defined in NFPA 70 Article 500.

3.5.3 Test Stand Exterior-Electrical Items: All electrical/electronic components outside the area detailed in immediately preceding paragraph shall be a minimum of Class I Division II Group D rated as defined by NFPA 70 Article 500 and shall be mounted in an enclosure(s). Enclosure(s) interior shall only be accessible from outside the Test Stand envelope.

3.5.4 If purge air cabinets are utilized, the Contractor shall be responsible for tapping into existing supply duct in Building 3907 as necessary for any required feed to purge air system/fan and shall include a manual volume damper for flow control. Purge air systems shall conform to NFPA 496 and ISA 12.4 standards and be UL classified. Purge air system and enclosures shall be protected from overpressurization. The electric power shall be shut down when losing purge air

SOW-2018-Fuel Pump TS Upgrade Page 14 pressure. The purge air system shall have a by-pass switch that shall keep the power on when no air pressure.

3.5.5 Professional Computer (PC) and Programmable Logic Controller (PLC) Control System:

• Data acquisition system shall be functionally equivalent to the data acquisition system of the B2 Pump Module Test Stand OC14451

• Latest version COTS Programmable Logic Controller (PLC) using LabVIEW

• The obsolete Siemens S7 PLC controller shall not be used

• Window 10 Operation System or latest

• CPU: Quad Core i7 (minimum)

• Redundant Array of Independent Disks (RAID) array based with a minimum of 1TB Solid State Drive SSD’s

• 8GB Synchronous Dynamic Random - Access Memory (SDRAM)

(minimum)

• 19” color flat screen (touch screen) HMI (minimum) with adjustable

StrongArm (or equivalent) mounted to test stand

• Detachable, standard 101 key computer keyboard and mouse, Class I, Division II, Group D rated

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

• No custom proprietary software shall be used

• LAN connection capability to existing LAN system allowing full interface with and backup capability of the test stand PC and PLC

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

Manual loading (keying in) of flowmeter calibration data shall not be required.

• All USB ports shall be inside the enclosure

• 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.

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3.5.6 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 test stand.

3.5.7 Test Stand component electromagnetic compatibility and interference (EMI) requirements: Electromagnetic performance requirements for replaceable electronic modules (REMs) are specified. Suitable items shall have the following features: removable/replaceable electronic circuit modules that plug into an equipment rack or frame both located on the interior or exterior of the test stand, with electrical interconnections primarily through edge connectors that interface directly with a backplane, and electrical power input derived from the backplane power sources. EMI requirements of these REMs shall be based on MIL-STD-461E system/equipment level electromagnetic interference (EMI) controls. The conducted and radiated requirements, limits, and test methods were adapted to provide risk reduction of REM EMI in an integrated system/equipment.

3.5.8 Test Stand Preliminary/Final Calibration: Preliminary 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 the upgrade, 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:

• 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 Fuel Pump Test Stand Upgrade with PMEL personnel present

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• 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 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.

Repeated calibration attempts using Government employees may be subject to Government considerations.

3.5.9 Test Stand Validation/Verification and As-Built Drawing Review: Following Final

Calibration, Contractor shall provide guidance (hands-on) to the Government POC to complete Validation and Verification of software programming versus testing procedures as per each UUT T.O. Contractor shall provide the Government a list of Sensors Usage and software lines of code versus Testing Procedures as per each UUT T.O. Contractor shall provide CD-ROM discs and installation procedures for the executive and UUT software so that any current software on the stand can be removed and installed from the CD-ROM’s per installation procedures. The contractor with the Government POC present shall:

• 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 test reports can be printed on the new printer and that test reports are complete and accurate.

• The Contractor and the Government POC shall take note all deficiencies and submit list to the Contractor for correction.

• The Validation/Verification shall comply with Institute of Electrical and

Electronics Engineers (IEEE) (1012-2016) “Standard for System, Software, and Hardware Verification and Validation”

Once program corrections, if any, have been made and stand is complete, Contractor shall submit a signed and dated document noting that Fuel Pump 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.

Contractor shall coordinate with the Government POC’s schedule and shall verify the accuracy of all As-Built drawings with the Government POC. All deficiencies shall be corrected by Contractor prior to final As-Built drawing submittals. Once finalized, Contractor shall submit a signed (by Contractor) and dated document noting that As-Built drawings are 100 percent accurate. Document shall include a detailed list of As-Builts including drawing name, date and rev level of each

SOW-2018-Fuel Pump TS Upgrade Page 17 drawing associated with the test stand. All drawings for the upgrade shall be Level 3 as per MIL-STD 31000B.

3.5.10 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.

3.5.10.1 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.

Self-test software shall include checks/tests for any test stand equipment item (meters, valves, etc.) that has the capability to be checked/tested for status and/or functionality.

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

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

Each test screen shall have a message “Must Verify All Data IAW Tech Order”.

3.5.11 Electrical System: All electrical equipment shall comply with NFPA 79, NFPA 70 and NFPA 70E standards.

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3.6 Reliability Centered Maintenance (RCM)

3.6.1 Following calibration of the test stand, Contractor shall complete RCM on the upgrade per Appendix K.

3.6.2 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 will be completed by personnel from 76 MSXG/MXDEQ. This effort shall be performed following Final Calibration of the Fuel Pump 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.

Contractor shall be required to meet RCM per Appendix K Repeated RCM attempts using Government employees may be subject to Government considerations.

3.7. Warranty: The Contractor shall warranty all equipment and workmanship free of defects for a period of no less than 365 calendar days. The Contractor will be notified of defects by the Government in writing or email. 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 final payment in WAWF.

Any spills caused by an equipment defect shall be cleaned up within 2 clock 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.

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Contractor shall provide a method for reporting problems encountered with Fuel Pump Test Stand Upgrade 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 Complex (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) clock 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 at a minimum) for a primary and back-up POC for reporting problems.

Corrective Action Plan: The contractor shall plan a response in the event issues discovered, including:

• Timeline to mitigate issues found

• Method for mitigating issues, e.g., all necessary expertise will be applied to resolve issues

• Plan to substantiate that the issue has been successfully addressed prior to re-engagement of Government personnel

• Mitigation process for any other remaining issues

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

• At least one engineer with minimum of five (5) years of experience in test stand construction and configuration.

• At least one technician with at least five (5) years of experience with LabVIEW and PLC systems.

• At least one National Instruments Certified LabVIEW Architect.

• At least one technician with at least five (5) years of experience in the design, fabrication and installation of aircraft component testing equipment.

• Personnel listed above shall be used to perform this upgrade.

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 test stand, supplies and services conform to the prescribed specifications. The Contractor shall provide all tooling, fixturing, 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 of the SOW. 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

SOW-2018-Fuel Pump TS Upgrade Page 20 inspection 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 Fuel Pump test stand shall be visually examined to determine compliance with all requirements within section 3 of the SOW.

4.5. Safety Analysis: The Contractor shall provide a Cause and Effect Matrix (Alarms and Shutdowns) and a Test Stand Safety Analysis which has been verified by a professional, disinterested third party. The Safety Analysis shall match Design Guideline (Appendix A), Section 450. The Contractor shall provide one (1) each hard copy and one (1) each electronic copy of the Cause and Effect Matrix and Test Stand Safety Analysis. The electronic copy via email or CD-ROM shall be in Acrobat Adobe version 9 or higher. The Cause and Effect Matrix and the Test Stand Safety Analysis shall be provided to the Government POC as part of the Critical Design Review.

4.6. Design Reviews: Design Review shall not supersede the SOW unless a specific exception has been obtained.

4.6.1. 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 (calculation, drawings), software and hardware 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 Contractor shall be responsible for taking minutes during the on-site meeting and shall provide one (1) electronic copy via email or CD-ROM to the Government POC NLT seven (7) calendar days after the meeting date.

4.6.2. 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

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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, software and hardware specifications, certificates, reports and test plans as well as 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 Contractor shall be responsible for taking minutes during the on-site meeting and shall provide one (1) electronic copy via email or CD-ROM to the Government POC NLT seven (7) calendar days after the meeting date.

4.6.3. 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 Building 3902 or Building 3907, Tinker Air Force Base. 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, software and hardware specifications, certificates and reports, as well as 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 Contractor shall be responsible for taking minutes including action items during the meeting and shall provide one (1) electronic copy via email or CD-ROM to the Government POC NLT seven (7) calendar days after the meeting date.

4.7. Test Readiness Review: The Contractor shall have a Test Readiness Review (TRR) which 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.

Test Plan: The Contractor shall describe how to meet all testing requirements specified in Technical Orders (Appendix I).