SOW_REVISED_3D CT Scanner_TAFB_7 Jan 2021.pdf

Statement of Work (SOW) MXDTAC-1 3D CT Scanner – Tinker AFB

H1WM04

Version Date: 7 January 2020

3D CT Scanner Statement of Work (SOW)

1. Scope – This purchase description details the requirements for furnishing, shipping, installing, and verification/calibration of a commercially available 3 Dimensional Computed Tomography Scanner (3D CT

Scanner) for metal parts. The CT scanner shall accomplish inspections via 3D CT & 2D X-ray scans using both micro and macro magnifications. The Contractor shall provide all labor, tools, equipment, materials, parts, personal protective equipment (PPE), transportation and any other incidentals to travel to Tinker AFB OK.

Offloading and placement of the 3D CT Scanner will be assisted by Tinker AFB personnel with the guidance, planning and direction of Contractor technical personnel.

2. Applications – Scan applications include various aerospace alloys from magnesium castings to nickel based super alloys. Part sizes, materials, geometry, and complexity will vary based on requirements. The requesting laboratory is dedicated to performing first article qualifications, failure analyses, non-conforming material reviews, reverse engineering and prototype material characterization, and production support.

Metallic parts - with sections up to 3 inches thick on jet engine disks and other aircraft structures - made from magnesium to nickel based superalloys, would be examples of inspection candidates. The CT Scanner shall be utilized to inspect and measure surface and subsurface features of parts/assemblies without cutting or condemning the asset.

3. General Requirements:

3.1. Design – The CT Scanner shall be one of the manufacturer’s current production models and shall be new and unused.

3.2. Measuring System – The CT Scanner shall process data using standard and/or metric units, automatically converting between two units of measurement.

3.3. Construction – All parts and materials used in the construction of the CT Scanner shall be new. The quality of construction shall be provided to meet the strength, rigidity and wear resistance characteristics necessary to meet the standards for accuracy, performance and safety specified herein. All parts and mechanisms requiring adjustment, replacement or servicing shall be readily accessible. The CT Scanner shall be turnkey so that when installed and connected to the proper utilities it shall be ready for use.

3.4. Maintenance – Parts lists/drawings, circuit diagrams and electrical/electronic schematics shall be provided for both preventative and limited remedial maintenance and troubleshooting.

3.5. Lubrication – All parts of the CT Scanner requiring continuous lubrication shall be automatically lubricated by a system that will ensure adequate lubrication of parts. Parts or mechanisms requiring periodic lubrication shall be provided with adequate means for grease or oil lubrication. Systems using recirculated oil shall be equipped with a replaceable or washable filter element. Each oil reservoir shall have an oil level gauge. Automatic processes of lubrication shall have a warning device to indicate when lube oil is low or empty.

3.6. System identification labels/plates – The system shall be identified with corrosion-resistant metal identification plates that are printed in English using plain bold-face letters. They shall be legible and permanent. Plate/label will, at minimum, contain Manufacturer’s Name, Manufacturer’s Model, Manufacturer’s Serial Number, Power Input (volts, total full load amps, phase, frequency), and Date of

Manufacture.

3.7. Safety and Health: The safety requirements and safety steps for the system must meet the requirements of T.O 33B-1-1: Technical Manual: Nondestructive Inspection Methods, Basic Theory that includes, but is not limited to, that which is listed below:

3.7.1. “A radiation protection survey of all new shielded X-ray installations, or new equipment in existing installations, SHALL be made by a fully qualified Health Physicist, Bioenvironmental

Engineer, Nuclear Medicine Science Officer, or qualified Radiological Health Technician before the installation is placed into routine operation. The installation SHALL be inspected to verify adequacy of shielding, radiation protective devices and operational procedures.”

3.7.2. “Interlock System. The visible and audible warning beacons/signals SHALL be tied to an interlock system. The interlock system SHALL be placed on each door to interrupt power to the control box/tube head, stopping the irradiation process, when unauthorized/unintended access is attempted.”

3.7.3. “Warning Beacons. Rotating or flashing strobe-type visible warning beacons SHALL be used at all entrances to the enclosure.” Radiation enclosure, interlock, and warning lights to meet all state and federal x-ray safety regulations.

3.8. Mercury Restriction –No mercury components may be added to the CT Scanner. Trace amounts of mercury naturally occurring in the granite slabs are acceptable as long as no additional mercury is added.

3.9. Asbestos Restriction – Asbestos and materials containing asbestos will not be used on or in the CT

Scanner and are strictly forbidden.

3.10. Ozone Depleting Substances - All Class 1 ozone depleting substances (ODSs) are strictly forbidden.

3.11. Environmental Protection – Under the operating, service, transportation and storage conditions described herein, the CT Scanner will not emit materials or radiation hazardous to the operator or ecological system as prohibited by Federal, State or Local statutes in effect at the time of installation.

4. 3D CT Scanner – The CT Scanner shall consist of an X-ray source or an X-ray generator from a single or from multiple sources for macro and micro CT capabilities. Also, it shall consist of an X-ray focus controller, a digital detector, a sample table, and an automated specimen/part manipulation system to provide movement (of one or all) of the detector, X-ray source, or the sample during scanning so that optimal scanning positions can be obtained for complex geometries.

4.1. Scanning Capability:

4.1.1. The CT scanner shall have fully automated computed tomography (3D) at low and high magnification

4.1.2. CT scanner will provide real-time 2D imaging:

4.1.2.1. Live image video capture

4.1.2.2. Still image capture

4.1.2.3. Frame averaging

4.1.3. The CT scanner shall be capable of performing CT volume reconstruction for 3D inspection.

4.1.4. The CT Scanner shall be capable of performing 2D CT slice reconstruction and 2D inspection from

3D scans.

4.1.5. The CT Scanner shall be capable of performing overall and local (small region within a volume) CT volume reconstruction for 3D inspections.

4.1.6. The CT Scanner shall be capable of performing 3D internal and external surface scanning.

4.1.7. System will be capable of automatic geometry corrections for reconstruction errors.

4.1.8. The CT Scanner shall utilize geometry tools (software or hardware) to determine system geometry for reconstruction of CT scans.

4.2. Enclosure – The CT Scanner will be encased in a radiation-proof cabinet. Radiation proofing on the cabinet shall be adequate such that the standard operation would NOT require the operator to wear a dosimeter per APA and OCIA guidelines.

4.2.1. Max footprint for system – 25 foot by 12.5 foot area (312.5 square feet), with a maximum allowable height of 13.5 feet. The system must fit within the 312.5 square foot area and shall include all external ancillary equipment, system accessories and part loading mechanisms; the enclosure alone shall not occupy the whole 25 foot by 12.5 foot area. Within the 312.5 square foot area, thirty-six (36) inches of space in front of the electrical access panel will be required, and a minimum of 18 inches of space will be required around the perimeter of the enclosure for maintenance access. In the room that will house the CT Scanner, there will be a maximum of 15 foot height clearance for installation purposes.

4.2.1.1. Due to limited entry and access restrictions, if the radiation enclosure shipping crate is larger than the dimensions listed in 9.1.2, the enclosure MUST be delivered disassembled and reassembled on site. This must be included in the quotation provided if necessary.

4.2.1.2. A detailed description of the dimensions of the cabinet will be needed at least 60 days in advance to perform an analysis of the movements to get the system into the correct locations.

4.2.2. Weight Capacity and Loading Capacity of Specimen Table – The sample table must be able to hold a component weight of up to 400 pounds without interfering with/or compromising the general operation of the scanning apparatus while loaded.

4.2.3. Stage size - The CT Scanner must be able to accommodate a part to fit in a working volume of 60 inches by 60 inches by 60 inches. For clarification, the volume is required for part articulation and/or awkward configurations.

4.2.4. Remote Sample Actuation – The CT Scanner cabinet shall have a means to provide electrical, pneumatic, and hydraulic utility connections to samples for the purpose of operation/actuation of the sample during operation of the CT scanner. Proper use of these ports or connecters, for this purpose, shall not compromise the radiation shielding of the cabinet.

4.2.5. Safe and Ergonomic Loading – The CT scanner system will be supplied with an automated loading system to facilitate ergonomic loading of large and heavy samples. The loading table must be less than 30 inches tall and be able to extend out of the chamber for part loading/positioning and retract for scanning. The automated loading system will be integrated within CT scanner system, and fully supported for maintenance by the Contractor. Walk-in enclosures with other means of load assist mechanisms (such as gantry system or robot arm) for safe loading of parts onto the scanning stage will be acceptable as long as scan volume is not inhibited and it does not extend out of the available footprint for the system.

4.2.6. Interior lighting: LED based lighting must be sufficient to illuminate entire enclose interior.

4.3. System Component Specifications – The following section details minimum specifications:

4.3.1. X-ray Tube Configuration – X-ray tube configuration must be met with one or more X-ray tubes

(may be interchangeable). The X-ray tube and detector should be adjustable to provide a larger working volume for large parts. System should be capable of supplying 225 KV and 450 KV X-ray

(Dual head) power source.

4.3.1.1. 225 kV microfocus source tube

4.3.1.1.1. <10 micron focal spot

4.3.1.1.2. Adjustable energy: variable up to 225 KV

4.3.1.2. 450 kV microfocus source tube

4.3.1.2.1. <500 micron focal spot capability

4.3.1.2.2. Adjustable energy: variable up to 450 KV

4.3.1.3. Automatic tube switching if multiple tubes are used. (No hardware or electrical disconnects required)

4.3.2. Detector:

4.3.2.1. Type: Flat panel digital detector

4.3.2.2. Minimum imaging window: 16 inch x 16 inch array

4.3.2.3. Maximum detector pixel size: 200 micron

4.3.2.4. Minimum Resolution: 16 bit

4.3.2.5. Minimum frame rate: 15 FPS @ full resolution

4.3.2.6. Gadox scintillator screen

4.3.2.7. Sensitivity: Ultra High

4.3.3. System Motion – System motion shall provide at least 6-axes of motion that allows:

4.3.3.1. Tube/Source vertical travel - minimum 60 inches

4.3.3.2. Part manipulation

4.3.3.2.1. Minimum Thirty-six (36) inches of horizontal travel (front to back)

4.3.3.2.2. Minimum tilt of +/-20 degrees

4.3.3.3. 360 degrees rotation, continuous with minimum 0.1 degree resolution. The distance between the source and detector must be variable to accommodate various part sizes and geometries.

4.3.3.4. Focal distance (Source Tube to Detector)

4.3.3.4.1. 450kV minimum 80 inch maximum spacing

4.3.3.4.2. 225kV minimum 80 inch maximum spacing

4.3.4. Manipulator control – Complete control and monitoring of all manipulation axes and X-ray tube/detector.

4.3.4.1. Automated control of all axes for CT imaging

4.3.4.2. Manual control of all axes for component positioning during setup and real-time 2D imaging

4.3.4.3. Manual control of manipulator to position component stage for ease of loading and unloading parts

4.3.4.4. Manual control of all motorized axes shall be provided utilizing push-button control or joystick operation. Axes positions shall be displayed on a monitor.

4.4. CT Scanner Control Computer – The following minimum hardware and software capabilities/functions will be required (items may be exact or equivalent to; verification of equivalency is required):

4.4.1. Software Requirements:

4.4.1.1. Windows 10-based Operating System for both acquisition and processing workstations.

4.4.1.2. DICONDE data format compliant as described in ASTM E 2767

4.4.1.3. Automatic detector correction (offset, gain, missing pixels)

4.4.1.4. Spatial calibration and measurements in all axes

4.4.1.5. Pseudo colorizing and thresholding of density variations

4.4.1.6. Digital Radiography Features (2D)

4.4.1.6.1. Live/Real-time imaging, frame averaging, contrast/brightness adjustments

4.4.1.6.2. Sharpening, smoothing, edge enhancement, and other user definable filters

4.4.1.6.3. Image archival in TIF (multiple resolutions), BMP, RAW, and JPEG formats

4.4.1.6.4. Text annotation (text, arrows, shapes) on captured or live measurements

4.4.1.6.5. Profile analysis function: Line and histogram-based analysis functions for contrast adjustments

4.4.1.7. Automatic 3D and 2D scan stitching software

4.4.1.8. Video rendering of 3D scan

4.4.1.9. CT Software Features

4.4.1.9.1. Recording of projections

4.4.1.9.2. Image processing tools and projection filtering to allow cropping of multiple planes/angles (slicing)

4.4.1.9.3. 2D capturing and Graphical rendering from 3D scans

4.4.1.9.4. The CT Scanner shall utilize ring artifact suppression and non-uniform pixel response correction software.

4.4.2. Hardware:

4.4.2.1. Computer System Table/Workstations – A table or workstation for the operating system shall be provided by the supplier. Table must at a minimum approximately 48 inches wide by 30 inches deep by 29 inches tall. An appropriate full adjustable/ergonomic office task chair that is compatible with the provided desk setup will be supplied as well.

4.4.2.2. Digital Radiography Workstations (Acquisition):

4.4.2.2.1. Dual Core Processor – Speed must meet minimum acquisition requirements to provide efficient, reliable, and error free operation.

4.4.2.2.2. Minimum RAM required to run acquisition software to meet minimum acquisition requirements to provide efficient, reliable, and error free operation.

4.4.2.2.3. Minimum 4TB hard drive (or total combination of drives)

4.4.2.2.4. Blue Ray and DVD+/-RW Drive

4.4.2.2.5. USB 3.0 ports

4.4.2.2.6. Minimum 32 inch monitor (LCD/LED)

4.4.2.2.7. Wired Keyboard and Mouse

4.4.2.3. CT Reconstruction Workstation (Post-Processing):

4.4.2.3.1. Processing power must meet minimum requirements of the vendor’s reconstruction software to provide efficient, reliable, and error free rendering of 3D CT data.

4.4.2.3.2. Sufficient Video RAM for reliable performance for supporting rendering and video display of CT models.

4.4.2.3.3. RAM-Include minimum required to perform efficiently, reliably, and without impeding general performance with vendor’s reconstruction software.

4.4.2.3.4. 64-bit Windows operating system

4.4.2.3.5. Multiple monitors via Display port or HDMI type connectors

4.4.2.3.6. 24 TB min of storage for large file storage of scans.

4.4.2.3.7. Blu-Ray compatible internal optical drive

4.4.2.3.8. Two (2) 32 inch minimum, LCD/LED Monitors with cable

4.4.2.3.9. Wired Keyboard and Mouse

4.5. Utility requirements -

4.5.1. Power input: 208-240 VAC , 60 Amp, Single Phase, 50/60 Hz (480 VAC max may be considered)

5. Additional Equipment

5.1. Air Filter / Regulator – If pressurized air is required, the CT Scanner will operate using at most 100 psi shop air supply in the existing area, or provide a regulation system to step up the supply to required pressure. The supply line will include a moisture/water purge trap to prevent moisture introduction.

The contractor shall supply a means to remove contaminants and regulate the pressurized air entering into the CT Scanner.

5.2. Vibration Dampening System – The contractor shall supply (if required) any means necessary to reduce external environmental vibratory inputs/excitations not directly associated with the CT

Scanner operation, effects associated with operation in both an industrial manufacturing and airport type environment. Vibration analysis will be included if necessary in the procurement contract.

Active, passive, or combination systems with demonstrated effective system performance at a similar and the final location are acceptable.

5.3. Machine Manuals – Two (2) complete sets of technical data (or a single electronic file of all manuals) will be submitted upon contract approval prior to delivery to ensure proper shop footprint specifications and familiarity with the CT Scanner before delivery. This technical data will include items such as operating manuals, maintenance manuals, facilities requirements, parts catalogs, parts lists, wiring schematics, lubrication charts, machine accuracy, and power requirements. Applicable test results shall be written in English.

6. Electrical Equipment – The electrical system of the CT Scanner and all electrical components thereof, will conform to the requirements of NEC. All electrical equipment design and documentation is subject to final approval by the Government.

7. Contract Monitor Provisions

7.1. Quality Conformance Inspection – Quality conformance inspection shall be applied to each item prior to being offered for acceptance under the contract. Preliminary quality conformance inspection prior to shipment will be conducted at the facility chosen by the contractor. Final quality conformance inspection shall be conducted at the Government installation site, after installation, standard checkouts and after calibrations have been completed, and will consist of the examination in 7.2. and the tests in 7.3. under the supervision of Government representatives appointed by the contract administrator. The calibration data obtained in the preliminary and the final quality conformance checks shall be furnished with the machine in a standard certificate format. Failure of any item to pass any examination or test shall be cause for rejection. The 3D CT Scanner and all equipment associated with this purchase will remain the property of the contractor until all items of this quality conformance inspection have been passed and accepted by all government representatives.

7.2. Examination – The 3D CT Scanner and all associated equipment shall be examined for compliance with design, construction, materials, components, electrical equipment and workmanship requirements specified herein by the Contractor and customer.

7.3. Tests – In addition to the specific testing requirements of 3.7 and 4.0, the Contractor shall demonstrate that the 3D CT Scanner performs as required herein using accepted industry standards for testing and calibration provided these tests demonstrate all performance requirements stated in this purchase description. Failure of any test to demonstrate that the CT Scanner, related equipment and software, to meet the minimum requirements as specified herein, will be cause for rejection or delay of acceptance.

8. Certifications/Accreditations – Contractor shall have relevant industry certifications or accreditations such as ISO 9001, AS9100, or Nadcap, or equivalent(s).

9. Shipping and Installation:

9.1. The Contractor shall include all costs associated with shipping or transport to the final destination of

Tinker AFB, OK, as specified in the contract delivery schedule. Upon delivery, Tinker AFB personnel will assist with offloading the crated equipment. The equipment shall be moved to either the space allocated for the system or to a staging area until representatives of the contractor can be on site for uncrating and final installation. Prior to delivery, the Contractor shall provide to the Contracting

Officer the data as specified in 9.1.1. This data shall be in the Contractor’s format.

9.1.1. Contract information to include Contract and CLIN numbers, Contractor identification, SOW reference(s), system name/information, date of submission, and appropriate distribution statement.

9.1.1.1. Utility, temperature, and space requirements for preparation of facility.

9.1.1.2. Methods of delivery to include shipping crates, etc., and special tools/equipment required for delivery, offloading, moving, etc.

9.1.1.3. Names and pertinent information of visitors, technicians, engineers, etc., who will be visiting Tinker AFB for the installation of the system.

9.1.2. Crates and boxes must be able to fit through a 11-feet-11-inches wide by 10-feet-11-inches high roll-down door with lifting/moving equipment under the crate or container. Staging of equipment will not exceed 14 calendar days upon receipt of equipment, unless negotiated and agreed upon by the Contractor and Contracting Officer if changes from the original contract are deemed necessary.

10. Training – Upon delivery and inspection/acceptance of the CT Scanner, the Contractor shall train two (2)

Government personnel on all delivered hardware and software applications. The purpose of this training is to ensure safe and proper initial use of the system. Additional applications training shall be provided to the

Government upon request within one year of delivery. The Contractor shall provide training for two (2)

Government personnel, not to exceed 40 hours per person. This training shall be focused and advanced class-based applications training at the Contractor’s site or at the Customer’s site. The applications training, which shall consist of using and inspecting parts with the CT Scanner, shall be based on methods governed by industry standards such as the American National Standards Institute/American Society for

Nondestructive Testing (ANSI/ASNT®) CP-105 and NAS 410 and Department of Defense standards such as

T.O. 33B-1-1. In advance to conducting classroom training, the Contractor shall deliver the training course content and material to the Contracting Officer to be approved by the OC-ALC NDI Program Manager (PM).

This is required for the ALC PM to establish equivalent prerequisite for certification. The course content and material will be in the Contractor’s format.

11. System/Software Support – Contractor will provide standard commercial support to ensure proper functioning and operation of the 3D CT Scanner system.