Statement_of_Work.pdf

STATEMENT OF WORK (SOW)

FOR

GOVERNOR TEST STAND

MODERNIZATION

MODEL GTS-2

BUILDING 2210

Oklahoma City Air Logistics Center Tinker Air Force Base

Prepared by

David Prado

76 CMXG/MXDEC

8 July 2019

Governor Test Stand Modernization Statement of Work

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CONTENTS

Section/Para ................................................................................................................. Page

1 Scope of Work

1.1 Scope

1.2 Background

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 Dimensional System

3.3 Measuring/Indicating Devices

3.4 Safety and Health

3.5 Cautions–Warning Plates

3.6 Noise Levels

3.7 Chemicals

3.8 Prohibited Materials

3.9 Environmental Protection

3.10 Other Environmental Compliance

3.11 Instruction Plates

3.12 Nameplate

3.13 Construction

3.14 Castings and Forgings

3.15 Welding, brazing and soldering

3.16 Surface Finish

3.17 Gears

3.18 Painting

3.19 Screw Threads

3.20 Interchangeability

3.21 Maintainability

3.22 Lubrication

3.23 Utilities and Maintenance Access

3.24 Modernization Plan

3.25 General Test Stand Configuration and Performance Requirements

3.26 Reliability Centered Maintenance

4 Quality Assurance Provisions

4.1 Responsibility for Inspections

4.2 Responsibility for Compliance

4.3 Environmental Conditions

4.4 Examination

4.5 Design Reviews

4.6 Final Acceptance

4.7 Tests

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4.8 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 Correlation Test Report

5.7 Acceptance Test Report

5.8 Documentation

6 Training/Familiarization

6.1 Operator

6.2 Electrical/Mechanical

6.3 Calibration

6.4 Software/Process Engineers

7 Special Provisions

7.1 Government Occupancy of Facilities & Responsibilities

7.2 Government Installation Access

7.3 Working Hours

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

7.5 Housekeeping

7.6 Tool Control and Accountability

7.7 Field Verify

8 Proposal by Contractor 9 Other Written Submittals

9.1 Required Submittals

10 Government Furnished Property and Services

10.1 Government Property

10.2 Government Services

APPENDICES

Appendix A: Equipment List

Appendix B: Reliability Centered Maintenance and Vibration Severity Chart

Appendix C: Safety Specifications

Appendix D: Glossary and Definitions

Appendix E: Environmental

Appendix F: Certification Test Plan Appendix G: Governor Test Stand Technical Manual: Operation and Maintenance Instructions Appendix H: Drawings-Basis of Design and Component Locations Appendix I: UUT & Sub-component Test Specifications (Available Upon Request) Appendix J: Design Guidelines 450

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SCOPE OF WORK:

1.1 Scope: The Contractor shall modify one (1) model GTS–2 Governor Test stand that is used to test the governors from the Constant Speed Drives (CSD) and Integrated Drive Generators (IDG). Contractor shall modernize hydraulic line drawings and console layout similar to the existing B-52 governor test stand, OC4665, while utilizing new commercial-off-the-shelf (COTS) drive belt motor, A/C motor and prime motor along with a variable frequency drive and COTS parts. Modernization shall consist of electrical and control system upgrade, repair or replace mechanical systems, and functional testing. The modified test stand shall meet all of the performance specifications listed in the Statement of Work (SOW) and the most current version of governor technical orders (T.O.s). The governor test stand shall be modified to be capable of testing the following governors: B-52H, B-1B, E-3A, E-8, KC- 135R, A-10, F-15E, F-15A/D, F-16A/B, F-16C/D, and KC-135E as required and as per their relevant T.O.s. Final modernization plan shall be approved by Government Point of Contact (POC). The Contractor shall supply all engineering, labor, materials, parts, tools, equipment, supplies, transportation, software, and incidentals necessary to modify the test stand and system equipment. The Contractor shall also, provide training in the operation, maintenance, and calibration of the test systems. This training and equipment shall be used to perform post overhaul acceptance testing for all required CSD governors. The government shall supply the CSD governors for the acceptance testing. All work associated with this contract shall have no impact on production in B2210. The testing facility for the governor test stand is located in Bldg. 2210, cell 2, at the Oklahoma City Air Logistics Center (OC-ALC), Tinker Air Force Base, Oklahoma.

1.2 Background: The governor test stand is a self-contained console that includes a variable speed drive system, a hydraulic system with pressure and temperature regulation, and mounting provisions for adapter kits designed for various governors. The test stand also includes controls and indicators for tests, along with provisions for testing and adjusting governors with magnetic bias. The controls and indicators for governors under test are mounted on the control and indicator panels of the governor test stand. Governors to be tested are mounted on the test stand through the adapter mounting pad. The governor test stand described in this document is intended for use in the overhaul maintenance of the Constant Speed Drives (CSD) and Integrated Drive Generators (IDG) in the Aerospace Repair Industry. A full list of terms and definitions are listed in Appendix D.

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

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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

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 http://www.osha.gov/ http://www.ihs.com/

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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 edition

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 edition

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 governor test stand modernization shall use new and unused (not a prototype) parts and shall be based upon the existing design of the governor test stand currently in use at Tinker AFB, Building 2210, Constant Speed Drive Test Facility. Governor test stand particulars are noted below:

3.1.1 Governor stand construction, layout and modifications shall be based upon existing design of governor stand currently in use at Tinker AFB, Building 2210, Constant Speed Drive Test Facility.

3.1.2 Original governor test stand design drawings are the property of the USAF and relevant sheets are attached in Appendix H. These design drawings shall form the basis of design and modification of the governor stand. Complete manufacturing drawings shall not be required for the modernization of the test stand. Any exceptions are noted below. Intent of Appendix H is as follows:

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

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3.1.2.1 Provide a baseline for required layout of stand consoles and panels (i.e., location of regulators, valves, bleed ports, connection ports and all other items denoted in Appendix H), drawers, doors and required coatings.

3.1.2.2 Denote general location of major components including pumps, motors, pressure transducers and tanks.

3.1.2.3 Provide a level of detail for required panel electrical connectors and their mating connectors for Unit Under Test (UUT) cables.

3.1.3 The modified governor test stand shall be a completely standalone unit, fully capable of successfully testing every UUT IAW their respective T.O.s.

3.1.4 Testing requirements for all UUTs and subcomponents are detailed in the test stand Technical Orders and UUT Technical Order Test Section, provided in Appendix I.

Contractor shall verify latest Technical Order in use prior to software development.

3.1.5 The governor test stand shall only operate with MIL-PRF-7808L Grade 3 synthetic turbine engine oil. This requirement supersedes the T.O. requirements of using the old MIL-L-7808 synthetic turbine engine oil.

3.1.6 Time to test requirement for each known good UUT, as tested by a certified Tinker mechanic, shall not exceed one (1) hour.

3.1.7 Prior to commencement of initial on site work, a pre-job safety meeting shall be conducted with the Contractor, to include but not limited to 76 CMXG Engineering, 76 CMXG Safety, and 76 CMXG Production.

3.1.7.1 A pre-construction job review shall be conducted with Contractor prior to modification of any equipment.

3.1.7.2 A control piston assembly shall be incorporated in the hydraulic system, see Appendix H, for testing the B-52H governor on the modified governor test stand.

New shutoff valves shall be installed for the control piston as Programmable Logic Controller (PLC) solenoid valves. Control piston assembly will be provided by the government to the contractor.

3.1.8 The Contractor shall develop and implement the testing capability to perform the B-1 pressure switch actuation point check during the governor test to meet the pressure switch test requirement IAW the most current version of T.O. 9H6-3-45-3.

3.1.9 Design shall include provisions for connecting test stand calibration equipment and be similar to existing test stand configurations.

3.1.10 Appendix G contains a list of items requiring calibration. These items, exactly as listed, shall be provided and incorporated into the stand design. If calibration procedures change, the Contractor shall be responsible for writing and providing updated calibration procedures to the government.

3.1.11 All governor test stand components shall be available as commercial-off-the-shelf (COTS) items.

3.1.12 The Data Acquisition (DAQ) system shall utilize LabVIEW, 2018 or newer, to develop a test program to communicate with Siemens S7 PLC controller.

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

3.1.14 Test variables shall be indicated one of three ways: red if out-of-limits (OOL)-high, green if in limits, and yellow if OOL-low. Black shall be the foreground color for the text and numerical displays.

3.1.15 The screen display shall be defined by the testing requirements for all UUTs. The display screen shall be able to display all the monitored parameters for governor testing organized in logical groups. The display default for the parameter display sizes shall be large enough to be seen by the operator and inspector.

3.1.16 The footprint size of the existing governor test stand shall remain the same size. The UUT adapter areas shall in no way be altered.

3.1.17 Test stand shall recycle contaminated oil used during test by circulating through an 8-micron filtering system to capture and remove particulates before being captured and returned to the oil reservoir. The filtering system shall be outfitted with removable/replaceable filters screens (see Appendix H).

3.1.18 Test stand shall incorporate a safety-glass cover around UUT test area, to shield operator from oil spray. Cover must be easily retracted laterally to allow full access to UUT.

3.1.19 The governor test stand shall remain modular in design.

3.1.20 Modifications to the test stand shall meet all requirements listed in Appendix I, UUTs and subcomponents Technical Orders and are available to the Contractor upon request, as well as other requirement stated in this SOW.

3.1.21 The Contractor shall provide all components that are missing from the test stand that are required by the modernized design.

3.1.22 The 76 CMXG Manuals for Operation & Maintenance and Illustrated Parts Breakdown (IPB) shall be updated on completed changes.

3.1.23 Electrical, hydraulic, and mechanical level 3 drawings for modifications made during the modernization of the governor test stand shall be updated and provided to the government in AutoCAD 2015 or newer .dwg format.

3.1.24 Contractor shall be present for initial calibration of the test stand and shall remain present until calibration of the stand is complete. Calibration support shall be provided and be responsible for resolving any calibration issues that may arise from the modifications above within 10 days of identification.

3.1.25 The Contractor shall attend, or conference call, monthly collaboration meetings with Government POC, including but not limited to 76 CMXG Engineering and 76 CMXG Production, for the purpose of specifying progress to date, any changes to estimated completion date and sharing information to ensure accurate completion of all major milestones to meet performance requirements.

3.1.26 Training Sessions, as referenced in Section 6, shall be provided to include: a minimum of 60 hours total of on-site familiarization and training with the operators on all

SOW-2019-Governor Test Stand Page 9 operations, Maintenance Session for mechanical maintenance and electrical familiarization, Calibration Session with PMEL personnel, and Software/Engineering Session for an overview of maintenance, computer system and test software.

3.1.27 Correlational acceptance testing shall include a comparison run for each type of UUT:

B-52H, B-1B, E-3A, E-8, KC-135R, A-10, F-15E, F-15A/D, F-16A/B, F-16C/D, and KC-135E. The results for each run shall be comparable to the most current version of their respected T.O.s. Contractor shall successfully run Correlation Testing as detailed in Appendix F. Contractor shall be present for all Correlation Testing to record all data and to produce Correlation Test Reports.

3.1.28 Prior to acceptance, test stand and subcomponents shall be cleaned to adhere to Cleaning guidelines as defined in T.O. Cleanliness of the test stand is important to satisfactory operation and to promoting a longer life for test stand equipment and components.

3.2 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).

3.3 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 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.

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

3.5 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 marked on the plates.

3.6 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 governor test stand unit as measured on the “A” weighted scale of a standard Type II sound level meter.

3.7 Chemicals: The Contractor shall not transport, ship or use any chemical, material or substance used in the performance of this SOW on Tinker AFB prior written approval is provided by 72 ABW/CEIE, Natural Infrastructure Management (Environmental Compliance). The Contractor shall furnish to the Government POC a list of all chemicals used in conjunction with the modernization of the equipment, and their Safety Data Sheets (SDS) with a completed OC-ALC Form 152, SDS Information Sheet, ten (10) calendar days after contract award date. The government reserves the right to reject use of any chemicals

SOW-2019-Governor Test Stand Page 10 and request alternative(s) be proposed for completion of the modernization. Proper use, storage and removal of any chemical required during modernization of test stand shall be coordinated with the Tinker Unit Environmental Coordinator (UEC). UEC info will be made available to Contractor by Government POC, as needed. Contractor shall remove all unused chemicals from Tinker AFB. Contractor shall comply with all chemical and environmental requirements as stipulated in Appendix E.

3.8 Prohibited Materials:

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

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

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

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

3.8.5 Ozone Depleting Chemicals (ODC) Restrictions: Class I ozone depleting substances in accordance with (IAW) 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.

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

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

3.11 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-7808L Grade 3 synthetic turbine engine oil and suffer no degradation when subjected to it.

3.12 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-7808L Grade 3 synthetic turbine engine oil and shall suffer no degradation when subjected to it. Lettering shall be a minimum of 18 point font.

3.12.1 Nomenclature of the Machine

3.12.2 Manufacturer’s Name and Address

3.12.3 Manufacturer’s Model Number

3.12.4 Manufacturer’s Serial Number

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3.12.5 Date of Manufacture

3.12.6 Contract Number

3.12.7 Services Requirements – All service requirements to be included.

3.13 Construction: The governor test stand shall be constructed of parts that are new, without defects, commercial-off-the-shelf (COTS), and free of repairs. Quality of materials used in construction shall be equivalent to or superior to those used in construction of existing governor test stand located in B2210. Metals shall be of corrosion resistant materials unless suitably protected to resist corrosion. The machine construction shall include all components, parts, and features necessary to meet the performance requirements specified herein. All parts subject to damage from environmental hazards shall be sealed or otherwise protected. The machine shall be capable of withstanding all forces encountered during operation of the machine at its maximum rating and capacity without distortion or failure.

Welding, plugging, or filling with solder or paste shall not be employed as repair or reclamation measures for defective parts. All screws, pins, bolts and similar parts shall be installed with means of preventing loss of tightness. All parts subject to removal or adjustment, shall not be swaged, peened, staked, or otherwise permanently deformed. Test stand shall be built in compliance with Design Guideline 450 as shown in Appendix J. The final modernization design of the governor test stand shall be neat, tidy, and match existing test stand color.

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

3.15 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.

3.16 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.

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

3.18 Painting: Yellow or orange safety color-coding shall be used for designated physical hazards.

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

3.20 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. Replaced parts shall be the latest version available by the equipment supplier so that any replacement parts are available to the customer throughout the life of the equipment.

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

3.22 Lubrication: Means shall be provided to ensure 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. Contractor shall recommend a remedial maintenance schedule for servicing the lubrication system for the governor test stand.

3.23 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 even if using existing connections.

3.23.1 Utilities Interconnection: The governor test stand is currently connected to all utilities necessary for operation. Any changes to the utilities required by the modernization shall be the responsibility of the Contractor. Any damages to the facility during the modernization of the governor stand shall be the responsibility of the Contractor to remedy. Contractor shall provide and run all conduit, conductors, and all other required electrical components from utility terminals to the stand in order to make the stand fully operational electrically. All interconnections shall maintain the hazardous classifications for both inside and outside the test stand.

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

3.24 Modernization Plan: Contractor shall submit a Modernization Plan to the Government POC for review and approval. Modernization Plan shall include:

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3.24.1 Installation and design drawings for the governor test stand modifications.

3.24.2 Design drawings denotes general locations of major components including, but not limited to pumps, motors, pressure transducers, tanks, conduit sizes, conductor types and sizes, seal off locations, test stand electrical interconnect drawing and over-current protection devices and sizes.

3.24.3 The control piston assembly shall be incorporated in the hydraulic system, see Appendix H, for testing the B-52H governor on the modified governor test stand. The control piston assembly will be provided by the Government POC to the Contractor. New shutoff valves shall be installed for the control piston as PLC controlled solenoid valves.

3.24.4 Developing and implementing the testing capability to perform the B-1 pressure switch actuation point check during the governor test, while attached to the governor on the test stand to meet the pressure switch test requirement IAW the most current version of T.O. 9H6-3-45-3.

3.24.5 All subcontractor and partnership information.

3.24.6 Replacement of the Drive and Prime Motor with Variable Frequency Drive (VFD) and

Alternating Current (AC) motor.

3.24.7 Provide encoder feedback to the drive and utilize for speed indication to the PLC with adjustable gear ratio. Signal can be split or transmitted digitally over communications.

3.24.8 Replace charge/scavenger pump and motor with new standard COTS item, not modified in any way. The new pump and motor assembly shall fully fit within existing, dedicated space inside stand. New pump and motor must be equivalent to existing or better.

Contractor shall provide all hoses and fittings as necessary to connect charge and scavenge pumps to existing hydraulic circuitry. The hydraulic lines shall incorporate a charge pressure bleed and shut off valves.

3.24.9 Pump system design shall be developed to pump out a minimum of 5 gallons per minute of fluid from the bottom drip pan when it fills with oil. The pump system shall be a permanent solution to resolving excess fluid collecting in the bottom of the test stand.

The design must be approved by the Government POC in writing before the Contractor shall implement/install this design.

3.24.10Test sink drain shall be connected to the scavenge line and add an inlet strainer to the scavenge pump.

3.24.11Modernization Plan shall be submitted to the Government POC a minimum of Fourteen calendar (14) days prior to initial work on test stand. Stand shall not be modified until written approval of plan has been received by Contractor from the Government POC.

The government shall have 7 calendar days to review the Modernization Plan and initiate contact with Contractor to discuss/review/resolve any issues. Following resolution, Contractor shall have 7 calendar days to resubmit revised Modernization Plan to Government POC for review and approval.

3.25 General Governor Test Stand Configuration and Performance Requirements: The governor test stand shall generally be configured, calibrated and tested as noted below:

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3.25.1 General Configuration. Governor stand construction and layout shall be based upon design of existing governor stand currently in use at Tinker AFB, B2210, Constant Speed Drive Test Facility. See Appendix H for general test stand configuration and Appendix G for list of required calibrated items.

3.25.1.1 Governor test stand subcomponents, controllers and cards shall have at least one

(1) secondary, independent manufacturer as identified by Contractor that provides a COTS functional replacement.

3.25.2 Governor Test Stand Controlled Area: The surrounding area located within governor test stand footprint, floor to ceiling shall be 300,000 Class rated as defined in T.O. 00- 25-203, available upon request. This project shall in no way compromise these existing ratings.

3.25.3 Governor Test Stand Electrical Items: All electrical/electronic components located within or outside the governor test stand area, detailed in immediately preceding paragraph shall meet or exceed the minimum requirements defined by NFPA 70 Article 500 and shall be mounted in an enclosure(s). Enclosure(s) interior shall only be accessible from outside the Governor Test Stand envelope.

3.25.4 PC and PLC Control System: Control system as originally designed is obsolete and no longer available. Consequently, governor test stand shall be controlled using a PC/PLC configuration as noted below:

3.25.4.1 PLC shall be Siemens S7 architecture and controlled using LabVIEW, no earlier than 2018, no substitutes accepted.

3.25.4.2 New Computer System

3.25.4.2.1 Latest Air Force approved Windows Enterprise version

3.25.4.2.2 CPU: Quad Core i7 (minimum)

3.25.4.2.3 RAID array based with a minimum of 1TB SSDs

3.25.4.2.4 8GB SDRAM (minimum)

3.25.4.2.5 Detachable, standard 101 key computer keyboard and mouse

3.25.4.2.6 USB mass storage device ports

3.25.4.3 Minimum 15” color flat screen (touch screen) HMI. Replacement shall be equivalent or better to existing monitor Xycom 5015T.

3.25.4.4 No custom proprietary software shall be used.

3.25.4.5 LAN connection capability to existing LAN system allowing full interface with and backup capability of governor test stand PC and PLC.

3.25.4.6 Hardware shall be chosen, where feasible, that has error handling capabilities and be tied back through LabVIEW for pre-test verification of operation.

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

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3.25.4.7.1 Operator level: allows access for testing of UUTs alone. Software changes and access to calibration data are NOT allowed at this level

3.25.4.7.2 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

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

3.25.5 Governor 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 governor test stand.

3.25.6 Governor Test Stand Anchoring: If governor test stand is required to be anchored to the slab, anchors shall be no longer than three and three-quarter inches (3.75”) in length.

All holes required to be drilled into the slab shall be no more than four inches (4”) deep.

Any damage to the existing vapor barrier due to holes deeper than those allowed shall be fully repaired by the Contractor. Repair method and final repair shall be reviewed and approved by Tinker AFB Civil Engineering.

3.25.7 Governor Test Stand Preliminary/Final Calibration: Calibration process shall be delivered by Contractor for review at Intermediate Design Review. Review comments will be delivered via the Government POC back to Contractor within 14 calendar days.

Contractor shall fully incorporate comments as necessary and resubmit revised procedure prior to Critical Design Review for review.

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

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

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

3.25.7.1.3 As Left values for each item calibrated

3.25.7.1.4 Any alignments or adjustments performed during calibration

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

3.25.7.2.1 Review and perform entire calibration process step-by-step on the governor test stand with PMEL personnel present

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

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

3.25.7.2.4 Once the calibration procedure is finalized, revised and resubmitted by Contractor, PMEL will formally calibrate the governor test stand. Contractor shall have appropriate personnel present during the entire Final Calibration process. Limitations on the calibration are not acceptable and any limitations noted by PMEL shall be fully resolved by Contractor.

3.25.8 Governor Test Stand IVV and As-Built Drawing Review: Prior to government calibration, contractor shall provide the latest data package to the government. The government will verify the accuracy of all As-Built drawings, to include but not limited to Illustrated Parts Breakdown (IPB) and all drawings associated with the project.

Following review, the Government shall list all deficiencies noted and submit list to Contractor for correction. All deficiencies shall be corrected by Contractor prior to final As-Built drawing submittals. Once finalized, the Government shall submit a signed and dated document noting that As-Built drawings are 100 percent accurate. Please note that Level 3 drawings as per MIL-STD-31000B are required. Document shall include a detailed list of As-Builts including drawing name, date, and rev level of each drawing.

3.25.8.1 Contractor shall also hire an independent Consultant to verify the accuracy of all As-Built drawings, COM data and all other submitted documentation required as a part of this contract. Following review, Consultant shall list all deficiencies noted and submit list to Contractor for correction. All deficiencies shall be corrected by Contractor prior to final documentation submittals unless otherwise approved by 76 CMXG/ENC Engineering. Once finalized, Consultant shall submit a signed and dated document noting that As-Built drawings, COM data and all other submitted documentation are 100 percent accurate. Please note that Level 3 drawings as per MIL-STD-31000B are required. Document shall include a detailed list of As-Builts listed in section 5.5.3.

3.25.9 Software: The Contractor shall develop a Test Executive as well as individual UUT Computer Software Configuration Items (CSCIs) so that they can have separate configuration management at the completion of the contract. The software shall be developed utilizing LabVIEW’s object oriented design such that there is an Executive piece that calls independent pieces for each UUT. The software shall perform data acquisition, conversion, limit, and alarm checking, data logging, real time calculations, control loop updates, initiate data saves and computations.

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3.25.9.1 Executive Software: Contractor shall develop executive software that is common to all UUT types tested. The Executive Software shall run on the latest Air Force approved Windows OS platform. Occasionally, a Windows OS may freeze or lock up when a software program performs an illegal operation, or it may include an Interrupt Request line (IRQ) conflict, incompatible device driver, virus, etc. To prevent such problems, all software updates to OS, device drivers, or anti-virus software or the addition of hardware shall be performed by an authorized software maintainer. A password protected Administrative level shall be used to limit user access to executive software including drives, read/write access, and OS privileges in order to prevent transfer of viruses or unwanted data. However, if it is suspected that a host computer is infected with a computer virus, a qualified user shall be able to initiate a system scan. In the event of Windows OS lock ups, a manual E-stop switch shall allow the operator to bring the UUT to a safe condition.

3.25.9.2 Unit Under Test (UUT) Software: Before executing the test for the governors, the software shall capture and archive the UUT specifications such as, but not limited to: weapon system and Individual Tracking Number (ITN), UUT serial number, governor test stand’s On-Condition (OC) number, date and time. 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 (IAW) the target test equipment style requirements. The main test menu shall display a list each individual TPs, matching the most current version of T.O. requirements, prompting the operator to select which semi-automated test to run in as well as prompting the operator afterwards to acknowledge that the selected test has completed. Once individual test section is complete, the display shall read, “Operator must confirm test IAW T.O.” and the operator will then confirm the action on the test screen. All tests points shall be programmed and carried out IAW the most current version of UUT T.O.s including applicable AF Form 202s. After testing of the governors, the software shall capture and archive the UUT failure modes from a government provided list of standard failures modes. The operator shall be able to select the corresponding failure mode from a dropdown menu. The generated test report shall include the identified failure mode and a comments section to allow the operator to digitally input comments. 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.

3.25.9.2.1 The software shall use a data acquisition (DAQ) system for capturing data throughout the testing of each UUT. During testing of the governor, data shall be written to the hard drive in the new computer system at regular intervals.

The DAQ system shall meet a minimum sampling rate of 1 sample per second.

The data collected shall include all testing parameter requirements IAW T.O.

such as, but not limited to: governor speeds, loads, frequencies, pressures, and temperatures. The data collected shall have the capability of being exported to the latest Air Force approved Microsoft Excel Enterprise version. The data from the last one hundred (100) completed governor test runs shall be captured and archived on the new computer system. The software shall have a playback

SOW-2019-Governor Test Stand Page 18 simulation function using archived data imported from the latest Air Force approved Microsoft Excel.

3.25.9.2.2 Test results from the governor test stand shall be used to generate and populate UUT test reports. Test reports shall be archived electronically in the governor test stand’s new computer system and available for easy retrieval by Operator in PDF format. Test results in PDF format shall also be capable of being printed out in hard copy for every UUT and the required test point. The test reports and governor test results shall be searchable by, but not limited to:

weapon system and Individual Tracking Number, CSD serial number, governor test stand’s On-Condition number, date and time, and failure modes.

The test reports and results shall 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.

3.25.9.3 Computer Printer: The contractor will provide a HP LaserJet Pro 200 printer for the governor test stand, so that every UUT test reports and required test point can be printed from the test stand.

3.25.9.3.1 Verify all UUT test reports can be printed using the Government furnished printer and that test reports are complete and accurate.

3.25.9.4 Electrical System: The machine shall be capable of running using the existing power supply source.

3.25.9.5 Extended Spares Kit: The Contractor shall provide a list of suggested extended spare parts, with manufacturer's lead times and expected service life, for the system.

The list shall identify the part name, the Contractor’s part number, the manufacturer's name and address, the manufacturer's part number if different from the Contractor's part number, the part cost, and the number required per system or quantity recommended for spare parts. The list shall be prioritized from the most used/needed to the least used/needed items, taking into account which items are most susceptible to damage and wear and the mean time between failures, if established, for replaceable parts. The list shall include both individual items and kitted parts with unit pricing for each item or kit. The listing shall include those parts needed for maintenance of the governor test stand for the first and second year of operation, assuming 2500 hours of actual run time in the year.

3.25.9.5.1 The contractor shall provide one (1) complete spare parts kit for the items listed as being the most susceptible to damage and wear or having a lead time of more than 30 days.

3.26 Reliability Centered Maintenance (RCM)

3.26.1 RCM Acceptance Testing with Baseline Data: Baseline data is condition monitoring information that is representative of equipment in a new and / or properly operating condition. The baseline data is the foundation of the predictive trending analysis required to forecast equipment condition. Baselining, including Equipment Health Checkout, is detailed in Appendix B and will be completed by personnel from 76 MXSG/MXDEQ. This effort shall be performed following Final Calibration of the

SOW-2019-Governor Test Stand Page 19 governor test stand and prior to commencement of Correlation Testing and shall be attended by a Contractor’s technical representative. Additional information requested in Appendix B shall be provided to the Government POC for distribution.

3.26.2 Vibration Baseline Testing: Contractor shall complete a vibration baseline for each motor, motor/drive and pump/motor combination. All data shall be taken in accordance with ISO10816-3 and acceptable vibration levels are as per the “New machine condition” range detailed in the ISO 10816-3 Vibration Severity Chart (see Appendix B). This data shall form the vibration baseline for each motor and pump/motor combination, provided all data is in Good Condition or better, as per ISO10816-3.

Vibrations that are unacceptable as per the ISO 10816-3 Vibration Severity Chart, New Machine Condition shall be remediated prior to install. Vibration data shall be submitted to Government POC for review prior to modification of stand.

3.26.2.1 Following Final Calibration of the governor test stand at Tinker AFB and prior to Correlation Testing, all motor and pump/motor vibrations will 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 ISO 10816-3 Vibration Severity Chart shall be remediated by Contractor, at no cost to the government. Following successful remediation, a final vibration report noting all components/combinations tested, Root Mean Squared (RMS) and “Derived Peak” vibration data in inches per second (ips) as read at Tinker by Contractor and by 76 MXSG/MXDEQ shall be completed by Contractor and submitted to the Government POC for review. Report shall also include class of motor, motor/drive and pump/motor combination tested and zonal results, all as per ISO10816-3.

3.26.3 Audible Noise Test: The equipment shall be evaluated prior to calibration and post correlation in such a manner as to determine compliance with Noise Levels in Section

3. For each measurement, the microphone shall be located on a straight line which is perpendicular to the surface/corner being measured at the specified distance of…