Attachment_16_A-S_Transition_Plan.pdf

03-1547-TMP-SP&I

ALCM Laboratory Test Program Logistics Support & Engineering Services

Transition Management

Site Preparation & Installation Plan

CDRL A037

DI-MGMT-80033A

Prepared by:

Aerospace Engineering Spectrum LTD 1307 West 2550 South

Ogden, UT 844401-3239

Submitted to:

AFNWC/NDMPL

Attn: Ms Zealetta Barton

7330 Sentry Blvd Tinker Air Force Base, OK 73145-8901

Date Submitted:

22 October 2018

Table of Contents

1.0 SCOPE

2.0 BACKGROUND

3.0 SITE PREP REQUIREMENTS & INSTALLATION PLAN

3.1 Present Day ALCM A&S Facility at ESTI

3.1.1 Warehouse

3.1.2 MTS-8E/Environmental Test Laboratory (Lab 1)

3.1.3 MTS-8/NWSS Test Laboratory (Lab 2)

3.1.4 Lockers/Shelving Storage

3.1.5 Staging Area/Work Benches

3.1.6 Operator/Technician Desk Area

3.1.7 Miscellaneous

3.1.8 Floor Layout

3.2 Present Facility Power/Utility Configuration

3.2.1 Facility Power

3.2.2 Heating and Air Conditioning

3.3 ALCM A&S Laboratory Stand-Down

3.3.1 Pre-Transition Testing and Data Archive

3.3.2 Stand-Down Environmental Equipment

3.3.3 Stand-Down Special Test Equipment

3.3.4 Ancillary Equipment

3.3.5 ALCM Components

3.3.6 Test Station Spares

3.3.7 ALCM Data Analysis Workstation, A&S Database, and Manual

3.4 Shipment

3.4.1 Air Ride Van Considerations

3.4.2 Special Tracking/Handling Considerations

3.4.3 Common Carrier Ground Transportation Considerations

3.4.4 Clearing Wide Area Workflow (Transfer of GFE)

3.5 Gaining Facility Installation Preparation Tasks

3.5.1 General Floor Layout Requirements/Constraints

3.5.2 Specific Facility Requirements

3.6 ALCM A&S Laboratory Reconstitution

3.6.1 Environmental Equipment

3.6.2 Special Test Equipment

3.6.3 Ancillary Equipment

3.6.4 ALCM Components

3.6.5 Test Station Spares

3.6.6 Validation/Verification of Test Capability/Compatibility

3.6.7 Correlation of A&S Test Results

3.6.8 ALCM Data Analysis Workstation

3.6.9 Documenting In-coming GFE in Wide Area Workflow

4.0 Un-Mitigated Issues

4.1 Software Development Environments

4.2 On-going Engineering Support for the ALCM Lab Test and SLEP Programs

List of Figures

Figure 1: ALCM A&S Test Complex at ESTI Figure 2: Warehouse Area Floor Layout Figure 3: Laboratory 1 (MTS-8E/Environmental Test Lab) Floor Layout Figure 4: Laboratory 2 (MTS-8 NWSS Test Lab) Floor Layout Figure 5: MTS 8 Controller I/O

List of Tables

Table 1: Major ALCM A&S Test Complex Components Table 2: OEM Data List Table 3: ALCM A&S Test Facility ITAs Table 4: Physical Characteristics, Weight Table 5: Physical Characteristics, Dimensions Table 6: Physical Characteristics, Floor Space Requirements Table 7: Physical Characteristics, Weight and Mobility Table 8: Equipment Facility Power Requirements Table 9: Equipment Operating Environments Table 10: Facility Air Requirements Table 11: MTS-8 I/O Interconnect Map Table 12: ALCM A&S Complex Instrument Calibration Requirements

1.0 SCOPE

This Site Preparation Requirements and Installation Plan has been developed to augment the contingent transfer of the ALCM A&S Test Complex from ESTIs present facility in San Antonio, TX to an alternative Contractor’s facility or a Government facility. The plan has been developed to account for the equipment requirements as well as the facility and shop floor requirements/configurations at ESTI’s facility. This plan should be used as a guide to assure that the gaining facility is readied for the receipt and installation of all ALCM A&S Test Complex test hardware and support equipment and to subsequently attempt to complete a successful reconstitution effort.

2.0 BACKGROUND

In the event that that the ALCM A&S Test Complex is moved to a new facility, some very specific contract actions must be initiated to augment the transition of the ALCM A&S test samples/assets, GFE/GFP, A&S test equipment, A&S data base, A&S technical data, applicable software, and ancillary items belonging to the Government in association with the ALCM A&S Test Program. The plan outlines the ALCM A&S Test Complex facility located at ESTI as well as the particulars associated with the various test consoles, environmental chambers, and test adapters. It then outlines the requirements for packing, shipping, receiving the test complex equipment, and finally, it details the steps required for reconstitution of the test complex and capability at an alternate location.

3.0 SITE PREP REQUIREMENTS & INSTALLATION PLAN

This installation plan has been developed per DI-MGMT-80033A and documents the present facility requirements of the ALCM A&S Test Complex for reference so that it can be moved and integrated into a facility outside of its present location at ESTI.

3.1 Present Day ALCM A&S Facility at ESTI

The following sections detail the facilities used at ESTI to accommodate the ALCM A&S Program support tasks. The support structure and many of the special tools and support equipment are not Government Furnished Equipment/Materials and will not be included in any shipment of the test complex. Only those items specifically designated on the current contract GFE list will be released in accordance with proper direction from the USAF Contracting Officer. A simplified overview of the ALCM A&S Test Complex facility at ESTI is shown in the following Figure.

Figure 1: ALCM A&S Test Complex at ESTI

Lab 1 Lab 2

Warehouse

Dock

3.1.1 Warehouse

Warehouse operations must consider all aspects of the test complex re-location task as well as annual test support requirements. The warehouse at ESTI is not temperature or humidity controlled. Refer to section 3.1.8 for the floor layout of the warehouse area.

The following details are provided to document the solutions available at ESTI to meet the warehouse operational needs.

3.1.1.1 Loading Dock/Exterior Overhead Door

The loading dock provides convenient off/on loading of commercial transport vans that are required for movement of the environmental chambers. Palletized shipments of annual test assets are also loaded and off loaded using the dock. An overhead door provides the necessary facility access for the large equipment items, shipping containers and palletized units.

The overhead door to the exterior of the building is 10’ 2” wide and 12’ 1” tall and opens to the loading dock which is 12’ wide and extends out 10’ 10” from the building. The loading dock drops of approximately 1 inch from the warehouse floor level and is 32” in height from the parking lot.

3.1.1.2 Forklift Truck

A propane powered forklift truck is used to on load and/or off load larger shipments (i.e., environmental chambers). The forklift weighs 8,704 lbs and is approximately 3’ 6” wide, 7’ 1” tall with tines lowered to the floor, and has a length of 11’ 10 ” including tines which are 4’ in length. This unit has a lift capacity of 4,225 lbs.

3.1.1.3 Pallet Jacks

A set of common pallet jacks are used for movements of most palletized units.

3.1.1.4 Portable Hoist

A portable hoist is available to augment packaging, unpacking, and positioning of chambers, ancillary equipment controllers/conditioners, and the 1,800 pound Avex Shock Machine. The hoist is 9’ 4” wide, 5’ 5” deep, and is 10’ 10” tall. The load/lift capacity of the hoist is 4000 lbs.

3.1.1.5 ESTI Proprietary Handling Fixture (Avex Shock Machine transport utility)

An ESTI designed transport utility is used for moving and/or positioning the Avex Shock Machine within the test facility.

3.1.1.6 Floor Space for Packaging and Crating Operations

An open floor space of roughly 20’ by 20’ is used for packaging and crating operations. This area will also be necessary as a staging area in preparation for shipments.

3.1.1.7 Shelving for Storage

Storage racks are configured in the warehouse for long term retention of the shipping containers for all of the dedicated and contingency spare ALCM avionics components provided for use the A&S Program. The shelving is 24” deep, 16’ 3” long, and 7’ tall and includes four equally spaced shelves (including the top of the rack).

3.1.1.8 Overhead Door to Test Laboratory

An insulated overhead door provides access between the warehouse and the environmental test laboratory where the majority of the environmental chambers reside. The overhead door is 10’ wide and 11’ 10” tall.

3.1.1.9 Personnel Access Doors

Multiple access doors are employed as entry/emergency exits as required between work areas and external landings.

3.1.1.10 Standard Electronics Shop Hand Tools and Instruments

Tool carts are included in the warehouse and/or test labs as required for control of all common hand tools and portable instruments used in UUT preparation for test, test diagnostics, and troubleshooting tasks. The tools include such items as wrenches, pliers, screw-drivers, socket drivers, carpenters’ rules, micrometers, thread gauges, wire strippers and torque wrenches.

Portable instruments include power supplies, oscilloscopes, and digital multi-meters.

3.1.1.11 Air Compressor & Compressor Dryer

An industrial shop air compressor is located in the warehouse and compressed air is routed to areas within the facility to include both Lab 1 and Lab 2 as required for common shop use and as stipulated in various test scenarios. The air compressor in use is an Ingersoll Rand Type 30 unit.

Co-located with the air compressor is a Quincy QRHT-25 Compressor/Air Dryer to extract moisture and provide filtered air to all down-stream regulators. QRHT Series Total Air System High Temperature Dryers integrate five different components that perform separate functions.

An air-cooled after-cooler, refrigerated dryer, moisture separator, Zero Loss drain, and coalescing filter — these five components work in harmony to ensure clean dry, filtered compressed air.

3.1.2 MTS-8E/Environmental Test Laboratory (Lab 1)

In the present facility, Environmental Test Laboratory 1 (Lab 1) was created by sectioning off a portion of the facility warehouse and building in a pre-planned layout for the environmental chambers, storage lockers, work benches and test equipment required to implement the environmental tests associated with the Cruise Missile A&S Program. Dedicated air conditioning units and air handlers were installed to assure adequate cooling to off-set the heat generated by the environment equipment and maintain temperature controls for the special test equipment in the lab.

Lab 1 is configured to house the large environmental chambers used for long-term storage of dedicated assets as well as a Thermotron Agree Style Chamber and test suite which is used to provide simultaneous application of temperature and vibration environments for various ALCM A&S component tests. Three standalone temperature/humidity controlled chambers are in use for long term storage of A&S Program “dedicated assets and contingency spares.” These chambers provide temperature and humidity controls in isothermal room conditions that emulate operating base conditions. These chambers run 24 hours a day throughout the year.

An AGREE Style Chamber/control station is also located in Lab 1. This unit provides the simultaneous application of controlled vibration and temperature test environments to a unit under test. The MTS-8E test station is co-located with the Agree chamber to provide the test capability of specific ALCM components that have limited interface cable length stipulations due to effects of injected noise, cross talk interference, and capacitive loading of longer test cables.

Static tests (i.e. non-environmental tests) requiring use of the MTS-8E are conducted in Lab 1 as a result of the need to co-locate the MTS-8E with the Agree Chamber.

Refer to section 3.1.8 for the floor layout of this Lab.

3.1.3 MTS-8/NWSS Test Laboratory (Lab 2)

The Test Laboratory (Lab 2) is configured to conduct A&S static tests and some low level environmental tests of various Nuclear Weapon Sub-System components. The MTS-8 is located in Lab 2 and is the test platform used for these tests. The MTS-8 is located adjacent to the wall that co-joins Lab 1 and Lab 2, as the test platform is also used in conjunction with the Agree Chamber for some tests that require controlled vibration and temperature test environments. A cable transition port is provides through the wall access for the test interface cables between the MTS-8 and the units under test.

Refer to section 3.1.8 for the floor layout of this Lab.

3.1.4 Lockers/Shelving Storage

A set of storage lockers and various shelf units are used for ambient storage of various ALCM components and critical equipment spares that are in place as GFE. These assets are required to provide long term support of the ALCM A&S test complex test stations (namely, the MTS-8 and MTS-8E), as well as the Service STAR test complex Test Station (or SSTS) located at Hill AFB, UT.

Refer to section 3.1.8 for the floor layout diagrams that reflect the locations of the lockers and shelves.

3.1.5 Staging Area/Work Benches

Sufficient area should be allotted to meet the needs for staging areas and workflow requirements.

Work benches of various sizes are arranged as needed in Lab 1 and Lab 2 to meet these needs.

Refer to section 3.1.8 for the floor layout diagrams that reflect the locations of the staging areas and work benches.

3.1.6 Operator/Technician Desk Area

Test operators are provided workstations for use in daily operations to include direct test related tasks (i.e., tabulating test failures, documenting photos taken, preparation of shipping labels, etc) as well as overhead tasks (i.e., daily accounting of time and attendance, lunch/break rest area, storage of personal items such as jackets, hats, etc). Personal workstation computers are provided as necessary.

Refer to section 3.1.8 for the floor layout diagrams that reflect the locations of the desk locations.

3.1.7 Miscellaneous

3.1.7.1 Book Shelves for Reference Material

Commercial manuals delivered with many of the common pieces of support equipment used in the design, manufacture, and long term support of the test complex are stored on shelving located in the test labs.

Refer to section 3.1.8 for the floor layout diagrams that reflect the locations of the book shelves.

3.1.7.2 Engineering Support Work Station

A software utility was specifically designed to provide a semi-automated means of conducting the linear regression analysis required after all annual ALCM A&S test results and Service STAR test results have been appended to the various component data bases. The software utility has been named the ALCM A&S Data Analysis Program. Sufficient workspace and a workstation with a personal computer is required to provide a platform for hosting the software utility and perform the necessary data archive and annual regression analyses.

The location and size requirements for the workstation should be based on best practice ergonomics.

3.1.8 Floor Layout

The present facility includes concrete floors, which are untreated and without tile or other resurfacing. The floor in Lab 1 is painted with standard garage floor paint locally purchased while Lab 2 includes tile overlays on the concrete base.

The following diagrams show the existing floor layouts at ESTIs ALCM A&S test facility.

Figure 2: Warehouse Area Floor Layout

Figure 3: Laboratory 1 (MTS-8E/Environmental Test Lab) Floor Layout

Figure 4: Laboratory 2 (MTS-8 NWSS Test Lab) Floor Layout

Table 1: Major ALCM A&S Test Complex Components

3.2 Present Facility Power/Utility Configuration

The utility configurations for the existing ALCM A&S Test Complex are described in the following sections. Since the warehouse and both Laboratories have some shared space with other company business areas, an effort has been made to separately allocate the requirements when deemed necessary.

3.2.1 Facility Power

Facility power is provided as defined in the following sections.

3.2.1.1 Warehouse Power

Standard 120VAC, 15 Amp service outlets are included throughout the warehouse for convenience in day-to-day warehouse operations. Power tools to include band saws, circular saws, drills, nail guns and vacuums are used for packaging and crating operations. In addition a dedicated space is allocated in the warehouse for the facility air compressor and compressor/air dryer. The air compressor is configured with a dedicated 230 VAC 60 Hz, single phase, 60 Amp service from facility power. The compressor/air dryer is supplied with 120 VAC single phase, 60 Hz power from a standard 20 Amp outlet.

A&S Equipment Designation Manufacturer Mfgr P/N

Oven 2 Thermotron Model SM-8-C Oven 4 Cincinnati Sub Zero ZPHS-32-2-2-H/AC Oven 5 Cincinnati Sub Zero MCBHS-1.2-.33-.33H/AC

AGREE Chamber Thermotron F-12-CHV-5-5 Shaker Controller System Thermotron DS-2000-911-12M

Shaker Controller Thermotron (system component) Shaker Thermotron (system component)

Shaker Cooling Blower Thermotron (system component)

MTS-8 ESTI 03-1039-0000

MTS-8E ESTI 03-1449-0100

Shock Machine AVEX/ESTI 03-1162-0950

Helium Leak Detector ESTI 03-1162-0300 Force Displacement Test Fixture ESTI 03-1162-0800

3.2.1.2 Lab 1 Equipment Power Requirements

Standard 120VAC, 15 amp service outlets are included throughout Lab 1 for convenience in day-to-day lab operations. Failure isolation and troubleshooting tasks often require the use of portable laptops, bench-top power supplies, multi-meters, capacitance meters, oscilloscopes, etc.

during routine activities. Power requirements for the major equipment items in Lab 1 are as follows:

Oven 2, 230 VAC, 30A, 1-Phase, 60 Hz (NWSS Isothermal Storage)

Agree Style Chamber, 208V, 80A, 3-Phase, 60Hz (Oven 3)

Shaker Controller, 208VAC, 70A, 3-Phase, 60 Hz

Oven 4, 208VAC, 70A, 1-Phase, 60Hz (GMFC Isothermal Storage)

Oven 5, 120VAC, 15A, 1-Phase, 60Hz (Small Cincinnati Sub-Zero not presently in use)

Oven 5 Water Pump, 120VAC, 15A, 1-Phase, 60Hz

MTS-8E, 120VAC, 20A, 60Hz

GMFC Cooling Fixture, 120VAC, 10A, 60Hz

3.2.1.3 Lab 2 Equipment Power Requirements

Standard 120VAC, 15 amp service outlets are included throughout Lab 1 for convenience in day-to-day lab operations. Failure isolation and troubleshooting tasks often require the use of portable laptops bench-top power supplies, multi-meters, capacitance meters, oscilloscopes, etc.

during routine activities. Power requirements for the major equipment items in Lab 2 are as follows:

MTS-8 Test Station, 120VAC, 20A, 60Hz

Dillon Stress/Strain Test Machine, 120VAC, 20A, 60Hz

Modified Avex Shock Machine, 120VAC, 1A, 60 Hz

Helium Leak Detector System 120VAC, 20A, 60Hz

3.2.2 Heating and Air Conditioning

There is no specific equipment air flow/temperature monitoring requirements for the A&S Test complex. There are some limited range of operation requirements for temperature and humidity that are satisfied via use of standard room air conditioning systems that are duct channeled for even air flow application. Heating and air conditioning is provided as defined in the following sections.

3.2.2.1 Warehouse Heating and Air Conditioning

The warehouse area is not provided with heating and air conditioning.

3.2.2.2 Lab 1 Heating and Air Conditioning

The simultaneous use of the various elements of Government provided GFE (ovens, test equipment and AGREE Chamber) along with the ESTI owned environmental equipment drives a need for implementing a dual based air conditioner and air handler system. The air handlers are mounted above the false ceiling while the air conditioner units are ground level/outdoor devices.

The air conditioners are 7-1/2 ton units that provide cooling feature only. Each compressor power supply is specified as 208/230, 3phase, 60 Hz. Each air conditioners current capacity is

20.7 Amps and a 60 Amp maximum fuse size is recommended by the manufacturer for each unit.

3.2.2.3 Lab 2 Heating and Air Conditioning

A single air conditioner and air handling unit provides sufficient temperature control for Lab 2.

The air handler is mounted above the false ceiling while the air conditioner is a ground level/outdoor device. The air conditioner is a 4 ton unit that provides cooling feature only. The compressor power supply is specified as 208/230, 3phase, 60 Hz. The air conditioner current capacity is 38.1 Amps and a 40 Amp maximum fuse size is recommended by the manufacturer for each air conditioner.

3.2.1 Overhead Lighting

Overhead lighting is provided as defined in the following sections.

3.2.3.1 Warehouse Overhead Lighting

The warehouse includes overhead florescent lighting. The ceiling is approximately 20’ tall and the lighting is mounted just below the ceiling. This light configuration includes 8 sets of dual 8 foot long bulbs for a total of 16 bulbs.

3.2.3.2 Lab 1 Overhead Lighting

The lighting in Lab 1 includes overhead florescent lighting. The false ceiling is approximately 15’ tall and the lighting is mounted at the ceiling tile level. This light configuration includes 12 light assemblies which each hold four 4-foot long lamps.

3.2.3.3 Lab 2 Overhead Lighting

The lighting in Lab 2 includes overhead florescent lighting. The false ceiling is approximately 9’ tall and the lighting is mounted at the ceiling tile level. This light configuration includes 6 light assemblies which each hold four 4-foot long lamps.

3.2.2 Shop Compressed Air

An industrial shop air compressor is located in the warehouse and compressed air is routed to both Lab 1 and Lab 2 as required for common shop use and as stipulated in various test scenarios. The air compressor in use is described as an Ingersoll Rand Type 30 unit. The Type 30 air compressor is widely used in commercial applications and various models have evolved over the past 75 years. The ESTI-owned compressor/tank has a maximum pressure of 175 psi and a flow rating of 14.3 CFM @ 90 psi.

The following sections detail the test scenarios requiring compressed air.

3.2.4.1 Lab 1, Thermotron AGREE Style Chamber

The Thermotron AGREE Style Chamber is used for environmental test on various components in the ALCM A&S Program. The chamber requires compressed air for adjusting the feet to level the Shaker Table before use. The established requirement is 70-90 psig filtered air and 125 psig is provided at the regulator for this application.

3.2.4.2 Lab 2, Impact Sensor Shock Machine

A modified Benchmark/Avex shock machine is used for dynamic testing of the ALCM Impact Sensor Assembly. The shock machine requires compressed air for inflating the shock absorption feet as well the programmable compressed air driven shock head. The requirement for shop level compressed air for the Avex Shock Machine is 104-114 psig filtered.

3.2.4.3 Lab 2, Rotary Switch Pin-Pull Fixture

A pneumatically driven cylinder provides the means of dynamically removing the Rotary Switch Detent Pin & Lanyard assembly to allow for switch timing tests within the unit under test. The compressed air requirement for cylinder actuation is 120 psig filtered.

3.2.4.4 Lab 2, Helium Leak Detector System

The helium leak detector test system includes compressed air driven solenoid valves to control vent flow and vacuum channel configurations during leak tests. The compressed air requirement for this system is 100-115 psig filtered air.

3.2.4.5 Standard/Miscellaneous Use Shop Air

General purpose compressed air outlets are also provided in the warehouse and labs for convenience in performing tasks such as compressed air drying or compressed air cleaning as a normal course of operations. All standard shop air is provided via 125 psig air regulators and hoses.

3.2.3 Nitrogen/Helium Gas Supply

A specified Nitrogen/Helium gas mixture supply is required for all ALCM A&S Program component Leak Tests. This is satisfied via locating a dedicated gas tank with regulator valves and interface hoses and fittings in near proximity to the Leak Test Fixture in Lab 2. The gas tank used (a rented unit) has a volume of 212.6 cubic feet and a tank pressure of 2000 psig when full. The tank contents is composed of 95% nitrogen and 5% helium, and the tank is regulated down to a pressure of about 18 psig as applied to the Leak Test Fixture.

Refer to section 3.1.8 for the floor layout diagrams that reflect the location of the gas tank.

3.3 ALCM A&S Laboratory Stand-Down

There are seven major elements considered for a logical/systematic approach to executing a stand-down of the existing A&S test complex and each is delineated in the following sections.

The seven major elements are as follows:

• Pre-Transition Testing

• Stand Down of Environmental Equipment

• Stand Down of Special Test Equipment

• Stand Down of Ancillary Equipment

• Preparation of ALCM Components

• Preparation of Test Station Spares

• Preparation of Data Analysis Software, A&S Database, and Documentation

3.3.1 Pre-Transition Testing and Data Archive

ESTI should be tasked to conduct a complete/successful series of every alignment test, self-test and UUT test included in the ALCM A&S Test Program (NWSS and GMFC). For each test of an ALCM component type, there should be at least two tests performed, one on each of two separate serial-numbered components. These ALCM components should be drawn from the set of A&S assets that are part of the A&S program (those in environmental storage or those used in providing pipeline spares). The test results and real-time data files should be archived for use in a comparison analysis following the test complex reconstitution at the gaining contractor’s facility.

3.3.2 Stand-Down Environmental Equipment

This section details the considerations made for preparing the Shaker Control System, various ovens and the Agree Style Chamber for packaging and shipment.

3.3.2.1 Oven 2, Thermotron SM-8-C Oven

This oven normally houses the WAD and Impact Senor NWSS components that are retained as dedicated and/or contingency spares in the A&S Program. All NWSS components should be removed and placed aside for packaging as discussed in section 3.3.4 below.

Perform Oven Shutdown procedures.

Disconnect Facility Power.

Disconnect the power cable from facility breaker.

Open the lower front door on the oven (requires 5/32” allen wrench) to gain access to the input power terminal block. Disconnect the power cable leads from L1 and L2 on the power terminal block and the bare ground wire from the ground terminal block. Remove the power cable from the oven. This is identified as the “as used” Oven 2 power cable configuration. Pack cable for shipment. Appropriately mark all shipping containers. (Note: The “as used” configuration includes approximately 12 ½ feet of 14 GA 3-wire cable along with 6 feet of flexible conduit.

The white lead is not used in this power cable. The flexible conduit is attached at the power input hole on the left side of the cabinet and runs along-side the cabinet to an installed facilities conduit line (1” OD, 39 inches long) that terminates at the dedicated circuit breaker for the oven.)

Remove and package the three shelves mark shelve locations and remove and bag shelve clips for later re-installation. Appropriately mark all shipping containers.

Remove and package the water circulation tank. Appropriately mark all shipping containers.

Remove and package the demineralization filters. Appropriately mark all shipping containers.

Remove and package the Cumo water filter. Appropriately mark all shipping containers.

Palletize the chamber for transportation.

Bubble wrap the upper chamber to protect observation window and control panel during handing operations.

3.3.2.2 Oven 4, Cincinnati Sub Zero ZPHS-32-2-2-H/AC

This oven normally houses the Rotary Switch NWSS components and GMFC components that are retained as dedicated and/or contingency spares in the A&S Program. All NWSS and GFMC components should be removed and placed aside for packaging as discussed in section 3.3.4 below.

Perform Oven Shutdown procedures.

Disconnect Facility Power.

Disconnect the power cable from facility breaker.

The power cable extends from the chamber chassis to the facility power circuit breaker and includes a 5 foot long 1 ¾ inch OD flexible conduit which terminates at the facility breaker. The power cable is internally routed in such a manner that it cannot easily be disconnected for shipment. The power cable should be coiled and secured to the side of the chamber for packing and shipment.

Remove and package the base plate and shelf. Remove and package the 2 shelf brackets after annotating the location of brackets for later reinstallation. Appropriately mark all shipping containers.

Disconnect the power cable for the circulating pump at the power terminal block inside the rear chamber door. Disconnect the water inlet hose at the chamber cabinet. Disconnect the water overflow hose at the chamber cabinet. Remove and package the water tank. Appropriately mark all shipping containers.

Palletize the chamber for transportation.

Bubble wrap the chamber to protect observation window and control panel during handing operations.

3.3.2.3 Oven 5, Cincinnati Sub Zero Microclimate MCBHS-1.2-.33-.33H/AC

This unit is not presently in service.

Remove and package the chamber shelf. Remove and package the shelf brackets. Appropriately mark all shipping containers.

Disconnect the ancillary water tank and package the tank. Appropriately mark all shipping containers.

Secure the power cable to the main chamber body.

Palletize the chamber for transportation.

Bubble wrap the upper chamber to protect observation window during handing operations.

3.3.2.4 Shaker Controller for Thermotron DS-2000-911-12M System

Obtain assistance from Thermotron to oversee/conduct this section of the stand-down procedure.

Perform controller shut down procedure.

Disconnect Facility Power.

Disconnect the power cable from facility breaker

Disconnect the facility power cable from the shaker controller. (Note: The “as used” power cable configuration includes a ground wire and 3 power conductors that are approximately 30 feet of 4 GA wire. The cable leads along with 11 feet of flexible conduit and attaching hardware comprise the power cable. The flex conduit is connected at the controller console chassis on the top surface (forward right) and the power leads extend into the console for interconnection. The flex conduit is then routed to the rear of the console and down to a rigid conduit interface that runs along the floor and up to the wall mounted facility breaker. The flexible conduit (1-7/16” OD) mates to a rigid conduit (1-7/8” OD) and allows the power cable to be routed to the facility breaker. The rigid conduit is approximately 16 ½ feet long and is not part of the controller power cable, as it is an installed facility fixture as is the facility breaker.) Disconnect the flex conduit from the rigid conduit and extract the power cable leads. Package power cable and flex conduit. Appropriately mark all shipping containers.

Obtain Thermotron assistance in disconnecting all interface cables that span between the shaker controller, the shaker, and the blower unit. Package all interface cables. Appropriately mark all shipping containers.

If not yet accomplished disconnect LAN communications interface cables that interconnect the Shaker controller, MTS-8, MTS-8E and network computer. These are ESTI facilities items and will not be shipped.

If not yet accomplished, disconnect the accelerometer and microdot BNC cable from the shaker and extract the accelerometer and cablefrom the chamber. Disconnect the accelerometer from the microdot BNC cable. Disconnect the opposite end of the microdot cable from the junction box. Package the accelerometer and microdot cable for shipment. Appropriately mark all shipping containers.

If not yet accomplished, disconnect the 8-channel accelerometer interface instrument (CN196927) box-from-J1 on shaker controller break out box P/N 1089471 (at the rear of the shaker controller). Package the instrument box and interface cable for shipment. Appropriately mark all shipping containers.

Remove controller monitor, keyboard, mouse, and printer. Package all controller accessories for shipment. Appropriately mark all shipping containers.

Palletize the controller for transportation.

Bubble wrap the upper chamber to protect observation window during handing operations.

3.3.2.5 Shaker Cooling Blower, Thermotron System Component

Obtain assistance from Thermotron to oversee/conduct this section of the stand-down procedure.

Assure all facility power to shaker controller is disconnected.

If not yet accomplished, disconnect 6” diameter flex duct that spans between the blower and Agree Chamber. Package flex duct and attaching hardware for shipment. Appropriately mark all shipping containers.

If not yet accomplished, obtain Thermotron assistance in disconnecting all interface cables that span between the shaker controller, the shaker, and the blower unit. Package all interface cables.

Appropriately mark all shipping containers.

Palletize the blower for shipment.

3.3.2.6 Shaker, Thermotron System Component

Obtain assistance from Thermotron to oversee/conduct this section of the stand-down procedure.

Assure all facility power to shaker controller has been disconnected.

If not yet accomplished, disconnect the accelerometer and microdot BNC cable from the shaker and extract the accelerometer and cablefrom the chamber. Disconnect the accelerometer from the microdot BNC cable. Disconnect the opposite end of the microdot cable from the junction box. Package the accelerometer and microdot cable for shipment. Appropriately mark all shipping containers.

If not yet accomplished, disconnect the 8-channel accelerometer interface instrument (CN196927) box-from-J1 on shaker controller break out box P/N 1089471 (at the rear of the shaker controller). Package the instrument box and interface cable for shipment. Appropriately mark all shipping containers.

If not yet accomplished, obtain Thermotron assistance in disconnecting all interface cables that span between the shaker controller, the shaker, and the blower unit. Package all interface cables.

Appropriately mark all shipping containers.

Disconnect the air hose at the shaker

Extract shaker from Agree Chamber.

Remove the L-Bracket from the shaker head and package bracket and securing bolts for shipment. Appropriately mark all shipping containers.

Verify the armature support and three isolator regulators are set to 0 psi. Set the air isolation pressure/exhaust switch to “Exhaust”.

Use overhead lifting device to assist in palletizing the shaker for transport.

3.3.2.7 AGREE Style Chamber, Thermotron F-12-CHV-5-5

Obtain assistance from Thermotron to oversee/conduct this section of the stand-down procedure.

Disconnect Facility Power.

Disconnect the facility power cable from the Agree chamber. (Note: The “as used” power cable configuration includes a ground wire and 3 power conductors that are approximately 30 feet of 4 GA wire. The cable leads along with 8 feet of flexible conduit and attaching hardware comprise the power cable. The flex conduit is connected at the chamber console chassis on the top surface (rear left) and the power leads extend into the console for interconnection. The flex conduit is then routed to the rear of the console and down to a rigid conduit interface that runs along the floor and up to the wall mounted facility breaker. The flexible conduit (1-7/16” OD) mates to a rigid conduit (1-7/8” OD) and allows the power cable to be routed to the facility breaker. The rigid conduit is approximately 9 ½ feet long and is not part of the controller power cable, as it is an installed facility fixture as is the facility breaker.) Disconnect the flex conduit from the rigid conduit and extract the power cable leads. Package power cable and flex conduit. Appropriately mark all shipping containers.

If not yet accomplished, obtain Thermotron assistance in disconnecting all interface cables that span between the shaker controller, the shaker, and the blower unit. Package all interface cables.

Appropriately mark all shipping containers.

Disconnect any GPIB interface connection at the special external Thermotron Instrument translator used for GPIB-to-serial communications between the MTS-8/MTS-8E and the Agree controller. Disconnect the instrument leads within the Agree Chamber control panel. Remove the instrument leads and package instrument for shipment. Appropriately mark all shipping containers.

Disconnect and stow facility air hose from the chamber.

If not yet accomplished, disconnect 6” diameter flex duct that spans between the blower and Agree Chamber. Package flex duct and attaching hardware for shipment. Appropriately mark all shipping containers.

Disconnect and remove the chamber monitor from the chamber controller. Package the monitor for shipment. Appropriately mark all shipping containers.

Use overhead lifting device to assist in palletizing the Agree chamber for transport.

3.3.2.8 Helium Leak Detector System, ESTI P/N 03-1162-0300

Disconnect the MTS-8 interface test cable from the test stand.

Disconnect facility power from leak detector.

Disconnect Helium/Nitrogen supply lines from leak detector.

Disconnect facility air from leak detector.

Package the acrylic bell jar and protective shield for shipment using materials suitable for level of protection needed to prevent damage to acrylic components. Appropriately mark all shipping containers.

Disconnect the vacuum fittings that secure the vacuum tubing to the Varian Vacuum Pump and remove the pump from the test fixture. Drain the service oil from the pump by temporarily opening fill cap and exhaust cap on top of unit and then opening drain valve located on back of unit. Do not leave caps and/or plug open for any longer than necessary to drain oil. Crate the pump for shipment with appropriate “THIS END UP” markings on the crate sides to preserve pump integrity during shipping. Appropriately mark all shipping containers.

Disconnect the vacuum fittings and tubes that secure the leak detector to the test stand. Pack all loose vacuum fittings and vacuum tubes.

Remove the leak detector from the test stand.

Bubble wrap and crate the leak detector for shipment assuring that the unit cannot move within the crate. Annotate outside of shipping container with “THIS END UP” markings on the crate sides to preserve leak detector integrity during shipping. Appropriately mark all shipping containers.

Disconnect the package the UUT interface fitting, vacuum tube and machined surface interface fittings. Appropriately mark all shipping containers.

Bubble wrap the test stand to protect the exposed gages, glass access doors and machined surface.

Crate the leak detector stand using suitable materials to protect the tight tolerance-machined stainless steel surface of the test stand. Damage to the surface may jeopardize future use due to unacceptable surface damage contributing to equipment interface leaks during tests.

Appropriately mark all shipping containers.

3.3.2.9 Dillon/ESTI Force Gauge Test Stand, P/N 03-1162-0800

If not yet accomplished, disconnect the communications interface cables from the test stand.

Remove the Force Gauge and Travel Gauge from the test stand. Package the gauges for shipment. Appropriately mark all shipping containers.

Remove the Rotary Switch mounting hardware from the base of the test stand. Package the mounting hardware for shipment. Appropriately mark all shipping containers.

Bubble wrap and crate the force gauge test stand using suitable materials to protect the drive chain and control panel.

3.3.2.10 AVEX/ESTI Impact Sensor Shock Machine, P/N 03-1162-0950

If not yet accomplished, remove the accelerometer from the unit under test shock head and disconnect the micro-dot cable from the accelerometer. Appropriately mark all shipping containers.

If not yet accomplished, disconnect the Impact Sensor ITA cable leg P2 from the side of the shock machine. Relocate the ITA cable leg to an area near the ITA.

Disconnect facility power from the shock machine.

Prepare the shock machine for local transport.

Disconnect facility air from the shock machine.

Assure that air has been bled off the shock machine inflatable feet.

Transport the shock machine to the warehouse for final packing and shipment. Appropriately mark all shipping containers.

3.3.2.11 OEM Data

Insure all OEM documentation for the environmental chambers (manuals, drawings, lists, etc.)

are assembled as a library for convenience in packaging, handling and tracking. Hard bound copies of the following manuals/excerpts will be included in the transfer.

Table 2: OEM Data List

3.3.3 Stand-Down Special Test Equipment

3.3.3.1 MTS-8 Test Station

Power down test station and disconnect facility power.

Disconnect Facility Power cable from custom designed power distribution chassis in the MTS-8 test station. Pack power cable for shipment. Appropriately mark all shipping containers.

ESTI Unit Mfgr P/N Document Notes

Oven 2 Model SM-8-C Thermotron Standard Products Instruction Manual, Revised 5/98 Provides Options, Installation, Operation, Preventive Maintenance and Parts List & Drawings

Oven 4 ZPHS-32-2-2-H/AC Installation Operation Manitenance Manual, ZP Series

56120 REV A, 05/2004

Provides Installation, Operation, Preventive Maintenance and Parts List & Drawings

Oven 5 MCBHS-1.2-.33-.33H/AC Installation Operation Manitenance Manual, MicroClime Series (unknown date)

Provides Installation, Operation, Preventive Maintenance and Parts List & Drawings

AGREE Chamber F-12-CHV-5-5 Thermotron Envrionmental Chamber

Instruction Manual Revised March 13, 1999

Provides Installation, Operation, Preventive Maintenance and Parts List & Drawings

Shaker Controller System DS-2000-911-12M Thermotron Electrodynamic Vibration Testing System

DS-1000 & 2000 Series Models Instruction Manual, Revised October 8, 1999

Provides Installation, Operation, Preventive Maintenance and Parts List & Drawings

Avex Shock Machine Model SM 105-MP AVEX/Benchmark Electronics Operation Manual

Provides Installation, Operation, Preventive Maintenance and Parts List

Varian Leak Detector Model 979 Series

Helium Mass Spectrometer Leak Detector

Varian Vacuum Technologies Operations Manual

Manual No 699909979, Rev K, Sept 2003 Provides Operation and Maintenance Instructions

Dillon Force Gauge Dillon TC2 Various Excerpts

No single manual available. Multiple excertps from various sources pieced together to accumulate sufficient background for software implementation and use.

MTS-8 Test Station 03-1039-0000 MTS-8 Tets Station User's manual Operation instructions for WAD, Roraty Switch and Impacvt Sensor A&S tests.

MTS-8E Test Station 03-1449-0000 MTS-8E Tets Station User's manual Operation instructions for GMFC and GMFCSRU tests.

OEM Data

Disconnect externally routed GPIB and RS-232 serial bus communication cables from inside the test station and destination interface connectors found at the test station controller, leak detector, Dillon test stand, force gage on Dillon test stand, Digimatic Model 572 Series Height Scale on Dillon test stand, and Endevco 2775B accelerometer amplifier. Pack all associated MTS-8 controller communication interface cables for shipment. Appropriately mark all shipping containers.

Disconnect Microdot Cable from the rear of the Endevco Charge Amplifier in the test station and relocate the cable to the vicinity of the shock machine.

Secure loose cables in the rear compartment of the test station using tie down straps for protection during shipping.

If not yet accomplished disconnect LAN communications interface cable from the test station controller. This is an ESTI facilities item and will not be shipped.

Disconnect the printer from the test station controller. A dedicated printer was not included as part of the MTS-8 design. This printer is an ESTI facilities item which will not be shipped.

Disconnect Monitor, Keyboard, Mouse and controller power cable from Controller. Pack the test station controller and peripherals for shipment. Appropriately mark all shipping containers.

Remove any ITAs that may be installed on test station receiver

Protect receiver interface from damage, contamination, etc., by installing protective cover.

MTS-8 should be palletized, bubble wrapped and crated for handling protection.

3.3.3.2 MTS-8E Test Station

Power down test station and disconnect facility power

Disconnect Facility Power cable from Eaton Power Distribution Unit in the test station and pack power cable. Appropriately mark all shipping containers.

If not yet accomplished, disconnect any GPIB interface connection at the special external Thermotron Instrument translator used for GPIB-to-serial communications between the MTS-8E and the Agree controller. Disconnect externally routed GPIB communication cable from the GPIB interface in the test station. Pack the MTS-8E GPIB-to-Thermotron Instrument interface cable for shipment. Appropriately mark all shipping containers.

If not yet accomplished disconnect LAN communications interface cable from the test station controller. This is an ESTI facilities item and will not be shipped.

Note: The MTS-8E utilizes access to a facilities printer via the LAN. A dedicated printer was not included as part of the MTS-8E design and will not be included in the shipment of this device.

Disconnect Monitor, Keyboard, Mouse from MTS-8E. Remove Monitor Keyboard and Mouse from Ergo-Arm. Remove Ergo Arm from slide rail. Package all removed hardware for shipment. Appropriately mark all shipping containers.

Secure loose cables in the rear compartment of the test station using tie down straps for protection during shipping.

Remove any ITAs that may be installed on test station receiver

Protect receiver interface from damage, contamination, etc., by installing protective cover

MTS-8E should be palletized, bubble wrapped and crated for handling protection.

3.3.4 Ancillary Equipment

Ancillary equipment used in the conduct of the ALCM A&S tests include test station Interface Test Adapters (ITAs), adapter plates used to mount test articles on the shaker, a leak isolator kit used in conjunction with the leak detector test stand, a lead melt furnace used to produce specified/molded lead pellets for Impact Sensor shock tests, an accelerometer simulator used for the impact test alignment test, as well as a Shore A hardness test fixture. Each of these items is included on the current GFE on ESTI’s contract and will be packed for shipment. Appropriate markings will be applied to shipping containers.

Other ESTI owned equipment items are used during the course of various program support tasks.

However, these items will not be shipped. These items include standard power supplies, oscilloscopes, cameras, microscopes, LCR meters and probes, DMMs.

The following Table provides of list of ALCM A&S ITAs that are included in the ALCM A&S Test Facility:

Table 3: ALCM A&S Test Facility ITAs

3.3.5 ALCM Components

The current GFE list includes all Military Spares that will be packaged for shipment to the gaining contractor. Packaging materials used to deliver the hardware to ESTI from Government stores has been retained for use in any shipping requirements. All components will be packed for shipment. Appropriate markings will be applied to shipping containers. All GFE, including any ALCM component located at ESTI, is tracked and inventoried according to the ESTI’s approved Government Property Control procedure and is detailed in the official ESTI GFE list.

3.3.6 Test Station Spares

A recently completed obsolescence study was conducted for the MTS-8, MTS-8E and SSTS test stations. A result of that study was the procurement of various critical spares that are included as GFE for use in various program support tasks. The original OEM packaging materials have been retained for use in shipping requirements. These spares will be packed for shipment. In addition, all previously procured GFE spares will be packed for shipment. Appropriate markings will be applied to shipping containers. All GFE, including all spare test station components, is tracked and inventoried according to the ESTI’s approved Government Property Control procedure and is detailed in the official ESTI GFE list.

ALCM Component ITA Name ITA P/N

WAD ITA #1 03-1039-0300

WAD ITA #2 03-1162-0400

WAD LOAD SIMULATOR 03-1039-0300-A2

Rotary Switch ITA #1 03-1249-0500 Rotary Switch ITA #2 03-1249-0700 Rotary Switch ITA #3 03-1249-0800 Rotary Switch LOAD BOX 03-1249-0500 Impact Sensor ITA #1 03-1039-0200 Impact Sensor ITA #2 03-1162-0900

GMFC ITA #1 03-1449-0200

GMFC ITA #2 03-1449-0300

GMFC ITA #3 03-1449-0400

GMFC LOAD BOX 03-1449-0220

MTS8 SELF TEST 03-1039-0100

MTS8E SELF TEST 03-1449-0500

ALCM A&S Test Facility ITAs

3.3.7 ALCM Data Analysis Workstation, A&S Database, and Manual

The Data Analysis Workstation is a Windows-based PC workstation, owned by ESTI which hosts the Data Analysis software program that was developed for use in the A&S program. Test results from all ALCM A&S testing performed since the inception of the ALCM A&S program has also been gathered and placed in an A&S database that resides on this workstation. In addition, there is a Data Analysis User’s Manual that is resident on the workstation for use in helping to operate the Data Analysis software program.

The workstation is to remain, but the Data Analysis software program, the A&S Database and the Data Analysis User’s Manual should be copied to media (CDs or DVDs), and at least two copies of all files/item should be produced. A Setup.exe program should be created and placed on the CD/DVD, using the LabView 2017 development environment, to create an appropriate installation program for the Data Analysis software and the associated LabView 2017 run-time engine. Following verified successful copies have been produced, the files can be expunged from the Data Analysis workstation. The CDs/DVDs should be placed in appropriately labeled jewel cases and packaged in shipping envelopes with bubble wrap included for shipment. The following list of files/items should be included in the shipment:

• Data Analysis.exe (installed with LabView 2017 run-time engine using Setup.exe)

• WAD DOMs.txt

• Rotary Switch DOMs.txt

• Impact Sensor DOMs.txt

• GMFC DOMs.txt

• A1DOMs.txt

• A2DOMs.txt

• A4DOMs.txt

• A5DOMs.txt

• A6DOMs.txt

• A7DOMs.txt

• A8DOMs.txt

• A9DOMs.txt

• Lvanlys.dll

• Nianlys.dll

• Output.txt

• Pathlist.txt

• All files in C:\ALCM A&S (entire A&S database)

• ALCM A&S Data Analysis Program User’s Manual.doc

3.4 Shipment

3.4.1 Air Ride Van Considerations

Based on past shipping experiences the MTS-8, MTS-8E and Agree Style Chamber Shaker Controller should be shipped via air ride van direct to the…