T38_F5 Test Stand Purchase Specifications 5Jan2011.pdf

PURCHASE SPECIFICATIONS

OO-ALC, 309 CMXG

HILL AFB, UT 84056

PROJECT NUMBER: 10-032

REVISED: 5 JAN 2011

WRITTEN BY: BRIAN MOSS

T-38/F-5 STEER DAMPER TEST STAND PURCHASE SPECIFICATIONS

TABLE OF CONTENTS

1.0 SCOPE ……………………………………………………………………………………………………………………… 2

2.0 APPLICABLE DOCUMENTS ………………………………………………………………………………………… 2

2.1 General Publications …………………………………………………………………………………………………. 2

2.2 USAF Publications ……………………………………………………………………………………………………... 3

2.3 Order of Precedence …………………………………………………………………………………………………. 3

3.0 DESIGN REQUIREMENTS……………………………………………………………………………………………..4

3.1 General Design …………………………………………………………………………………………………………. 4

3.2 Hydraulic System Design …………………………………………………………………………………………… 4

3.3 Electrical System Design ……………………………………………………………………………………………. 5

3.4 Software Design ………………………………………………………………………………………………………… 5

3.5 Operator Interface …………………………………………………………………………………………………….. 6

3.6 Test Requirements …………………………………………………………………………………………………….. 7

3.7 Tooling ……………………………………………………………………………………………………………………… 9

3.8 Other Deliverables …………………………………………………………………………………………………….. 9

4.0 IDENTIFICATION & MARKING ……………………………………………………………………………………. 11

5.0 AFTER CONTRACT AWARD ………………………………………………………………………………………… 12

6.0 VERIFICATION & VALIDATION …………………………………………………………………………………… 13

7.0 ADDITIONAL INFORMATION ……………………………………………………………………………………… 16

7.1 Safety ………………………………………………………………………………………………………………………. 16

7.2 Environmental Controls …………………………………………………………………………………………….. 17

7.3 Security …………………………………………………………………………………………………………………….. 17

7.4 Access to Facilities ……………………………………………………………………………………………………. 17

7.5 Hours of Operation …………………………………………………………………………………………………… 17

7.6 Government Furnished Equipment …………………………………………………………………………... 18

1.0 SCOPE

This purchase specification (PS) is for a new test stand that will replace the current T-38 / F-

5 Steer Damper Test Stand. The new test stand shall be capable of testing both the T-38

Steer Damper Assembly (NSN #: 1620-00-117-7326LE) and F-5 Steer Damper Assembly (NSN

#: 1620-01-139-6672) configurations to ensure the units meet field performance criteria.

The test stand shall be designed at minimum to have the same capabilities and accuracy as the current T-38 / F-5 Steering Actuator Test Stand originally manufactured by Loud

Engineering (Part Number: 5085L000-501).

The United States Air Force (USAF) prefers all new test stand components. USAF may choose not to accept the use of existing or refurbished material/ parts. The use of existing or refurbished material/ parts must be specified in the proposal response to the solicitation.

If existing or refurbished material/ parts is specified the proposal must identify the material/ part and must also include the price for using new material/ parts. USAF has the right to choose which type of material/ parts best meets the needs of the government.

All programs, data rights, source and executable code, test procedures, calibration, embedded firmware, self test capabilities, etc… developed under this contract shall become property of the USAF. The USAF shall have the right to use all other programs, data, and code delivered under this contract. The contractor shall provide licenses for all applicable programs delivered under this contract.

2.0 APPLICABLE DOCUMENTS

The test stand described in this request for proposal shall be designed and manufactured in accordance with this PS and the documents referenced herein. The latest version of each document shall be the one applicable.

In the event of a conflict between the text of this PS and the references sited herein, the text of this PS shall take precedence. Nothing in this PS shall supersede applicable laws and regulations unless a specific exemption has been obtained and documentation has been provided to both parties.

2.1 GENERAL PUBLICATIONS

OSHA 2206 - Occupational Safety and Health Standards for General Industry (29 CFR 1910), (Application for copies should be addressed to the Superintendent of Documents, Government Printing Office, Washington DC 20402-0001)

NEMA ICS 1 & 4 – Enclosures for Industrial Controls and Systems, (Application for copies can be made at: http://www.nema.org)

NFPA 79 – Electrical Standards for Industrial Machinery, (Application for copies should be addressed to the National Fire Protection Association, ATTN: Support Services, 11 Tracy

Drive, Avon, MA 02322)

ISO 4413:1998 – Hydraulic Fluid Power, General Rules Relating to Systems (Application for copies can be made at: http://www.iso.org/iso/iso_catalogue.htm)

NFPA T2.24.1 R1 - Hydraulic Fluid Power, Systems Standard for Stationary Industrial

Machinery; Supplement to ISO 4413:1998 (Application for copies can be made at:

http://www.nfpa.com/Standards/Standards_Overview.asp)

MIL-PRF-83282 – Specifications for Synthetic Hydrocarbon-Based Hydraulic Fluids

(Applications for standard can be made at: http://www.everyspec.com)

ANSI Y32.10 – Fluid Power Graphic Symbols (Applications for standard can be made at:

http://www.ansi.org/)

40 CFR 302 - Designation, Reportable, Quantities, AND Notification (Applications for standard can be made at: http://www.gpoaccess.gov/)

2.2 UNITED STATES AIR FORCE PUBLICATIONS

The Contractor shall obtain the forms and publications expressly required to perform the work in this contract via internet at: www.e-publishing.af.mil. In the event that a form or publication is not available online, program manager or responsible engineer will provide the form, instruction, or publication to the Contractor upon written request (e-mail is acceptable). In the event that laws, regulations, Technical Orders, Air Force Instructions, Air Force Material Command Instructions change during the term of this contract, the Contractor is required to comply as such changes come into effect.

Hill AFB Instruction 91-302………………...... Control of Hazardous Energy

T.O. 9H2-3-54-3 …………… Overhaul Instructions, T-38 Aircraft, Steer Damper Assembly

T.O. 4SA3-42-3 ………………. Overhaul Instructions, Nose Wheel Steering Actuator, Part No.

5035L000-1

3.0 DESIGN REQUIREMENTS

This section defines the design requirements for the new test stand

3.1 GENERAL DESIGN

3.1.1 The test stand shall be portable; meaning it can be disconnected from electrical power and a separate hydraulic source, wheeled over to another location, and reconnected all by one operator.

3.1.2 It is to be no larger than 5.5’ high x 3’ wide x 3’ deep

3.1.3 There shall be no peripheral equipment in addition to the test stand.

3.1.4 The test stand shall be constructed so that when it is connected to power and turned on it shall be ready for operation.

3.1.5 The structure shall be capable of withstanding all forces encountered during operation of the test stand to its maximum rating and capacity without permanent distortion.

3.1.6 All parts subject to wear or fatigue failure shall be easily accessible for adjustment, replacement, and repair. All other components requiring scheduled maintenance or calibration shall be easily accessible for adjustment, replacement, and repair.

3.1.7 All components shall be protected from or able to withstand hydraulic fluid.

3.2 HYDRAULIC SYSTEM DESIGN

3.2.1 The hydraulic system will be externally supplied with hydraulic fluid conforming to

MIL-PRF-83282 at temperatures between 40° to 120° F.

3.2.2 The main pressure and return lines are to be easily accessible and are to be connected to the external hydraulic supply with flexible hosing not longer than 3 feet.

3.2.3 The test stand’s hydraulic system shall have its own filtration system which meets

AS4059 Class 7 A-F cleanliness rating.

3.2.4 The test stand’s hydraulic system shall be able to regulate the supply pressure.

3.2.5 The test stand’s hydraulic system shall be able to measure flow from 0.3 – 3 gpm continuously.

3.2.6 All hydraulic lines and components shall be rated to have a minimum operating pressure of 4500 psig and burst pressure of 7500 psig.

3.2.7 The test stand shall be able to measure fluid temperature on the supply side.

3.3 ELECTRICAL SYSTEM DESIGN

3.3.1 All electrical equipment for the test stand shall conform to the applicable requirements noted in sections 2.1 – 2.2 of this PS.

3.3.2 Shockproof controls to protect the operator from electrical hazards shall be provided. Any power conditioners, surge protectors, or other devices necessary to protect electrical components shall be installed.

3.3.3 There shall be two readily accessible safety disconnect switches (E Stops) which dissipates all stored energy and does not power down computer.

3.3.4 The test stand shall draw all of its power from a single circuit having a fused safety disconnect switch. Preference is for 100-120 VAC, 60 Hz power supply, but 208 VAC, 60 Hz power supply is available.

3.3.5 The test stand’s electrical system shall withstand a line voltage fluctuation of +/-

10% with no damage to the test stand or its related components.

3.3.6 All sensors or measurement instrumentation shall interface with software. The operator shall also be able to check the input and output shaft position to a physical reference on the test stand.

3.3.7 Section 7.1 of T.O. 4SA3-42-3 requires that all input parameters in end item testing are to be within +/- 2% of specified pressure, flow, force, torque, and voltage. All sensors and measurement instrumentation used in the new test stand shall meet this requirement.

3.4 SOFTWARE DESIGN

3.4.1 The software shall use LabVIEW 2010 as its programming solution.

3.4.2 The software shall be designed and implemented by individuals who have attained the LabVIEW Developer or LabVIEW Architect Certification from National

Instruments.

3.4.3 The operating system shall be Windows 7 Professional 32 bit or better.

3.4.4 The software shall have capability to accept new Virtual Instruments (VIs) or programming changes to meet future requirements.

3.4.5 Each test procedure shall be programmed so that the operator will be able to search and select each test independently, upon which the correct front panel will be displayed and all the necessary parameters automatically set.

3.4.6 Software shall have capability of running a ‘system test’ to show that all inputs and outputs are receiving and producing accurate data compared to programmed set points in a go / no go style.

3.4.7 Operator shall not have the ability to change unit under test (UUT) test results.

3.4.8 All items requiring calibration through the software shall be contained in a separate

VI that is password protected.

3.4.9 Software shall have capability to save test data and plots, internally and externally, including identification data, test date, test results, etc…

3.4.10 Software shall have data mining capabilities, meaning data is saved and stored in a manner that is easy to analyze and compare results over time.

3.4.11 Software shall have capability to print test reports to any network or USB printer in a standardized form.

3.5 OPERATOR INTERFACE

3.5.1 The test stand shall be ergonomically friendly and designed to be operated by one user.

3.5.2 The test stand shall not be reconfigured physically between testing an F-5 steer damper unit and a T-38 steer damper unit.

3.5.3 The test stand shall have a touch screen interface with the operator.

3.5.4 Computer screen shall be industrial grade, 19” minimum, touch screen, non-glare, scratch resistant, and able to withstand hydraulic fluid.

3.5.5 The computer screen shall be capable of being turned off or locked out so the operator can wipe the screen without accidentally sending inputs or shutting down the test program.

3.6 TEST REQUIREMENTS

Technical Order publications 4SA3-42-3 and 9H2-3-54-3, specifically chapter 7, are to serve as general guidelines for the testing procedures the new test stand will carry out. Only the test requirements specified in this PS shall be required of the new test stand to follow.

Table I is only a partial summary of the test requirements listed in this section.

3.6.1 Operational Test: the test stand shall adhere to requirements specified in T.O. 4SA3-

42-3 section 7.3.1, excluding paragraph a, for both the T-38 and F-5 steer damper configurations.

3.6.2 Breakout Force Test: the test stand shall adhere to requirements specified in T.O.

4SA3-42-3 sections 7.3.2.d – 7.3.2.g for F-5 steer damper configuration. The process shall be the same for testing the T-38 steer damper configuration except the test stand shall adhere to requirements specified in T.O. 9H2-3-54-3 sections 7.6.4.b &

7.6.4.f.

3.6.3 Leakage & Operation: the test stand shall adhere to requirements specified in T.O.

4SA3-42-3 section 7.3.5, except that the input shaft most only be cycled 5 times instead of 25 times as specified in paragraph b, for both the T-38 and F-5 steer damper configurations.

3.6.4 Steer Rate with no load test: the test stand shall adhere to requirements specified in

T.O. 4SA3-42-3 section 7.3.3.c – 7.3.3.h for the F-5 steer damper configuration. The process shall be the same for testing the T-38 steer damper configuration except the test stand shall adhere to requirements specified in T.O. 9H2-3-54-3 sections

7.6.5.m, 7.6.5.r, and 7.6.5.s. Additionally the new test stand’s software shall plot the output shaft’s position over time during the test.

3.6.5 Steer Rate with load test: the test stand shall adhere to requirements specified in

T.O. 4SA3-42-3 section 7.3.4, excluding paragraph a, for the F-5 steer damper configuration. The process shall be the same for testing the T-38 steer damper configuration except the test stand shall adhere to requirements specified in T.O.

9H2-3-54-3 sections 7.6.3.r – 7.6.3.t, 7.6.4.d – 7.6.4.e, and 7.6.4.k. The torque applied to the output shaft of the T-38 steer damper configuration during this test shall be 1800 in-lbs instead of 3000 in-lbs as applied to the F-5 steer damper output shaft. Additionally the new test stand shall plot both the torque applied to the output shaft and its position over time during the test.

3.6.6 Damping Test: the test stand shall adhere to the intent of the requirements specified in T.O. 4SA3-42-3 section 7.3.6. The process shall be the same for testing the T-38 steer damper configuration except the test stand shall adhere to the intent of the requirements specified in T.O. 9H2-3-54-3 sections 7.4.1, 7.5.1, & 7.5.2.

TABLE I

Test Unit T.O. Reference Acceptable Result

Breakout Force Test F-5 4SA3-42-3 sections 7.3.2.d

– 7.3.2.g

@ 2800 psig 16.5 in-lbs either direction

Breakout Force Test T-38 T.O. 9H2-3-54-3 sections 7.6.4.b & 7.6.4.f.

@ 2800 psig 30 in-lbs either direction

Steer Rate w/no load F-5 T.O. 4SA3-42-3 section 7.3.3.c – 7.3.3.h

@ 2800 psig 1.5 – 2.75 seconds to move output shaft 0° to 40° in either direction

Steer Rate w/no load T-38 T.O. 9H2-3-54-3 sections 7.6.5.m, 7.6.5.r, and 7.6.5.s

@ 2800 psig 4-5 seconds to move output shaft 0° to (40° 10’ - 42° 10’) in clockwise direction, and 4-5 seconds to move output shaft 0° to (44° 10’ - 46° 10’) in counterclockwise direction.

Both times to be within .75 seconds of each other

Steer Rate w/load F-5 T.O. 4SA3-42-3 section 7.3.4, excluding paragraph a

@ 2800 psig 2.5 – 5.5 seconds to move output shaft, with 3000 in-lbs applied to the output shaft throughout rotation, 0° to 40° in either direction

Steer Rate w/load T-38 T.O. 9H2-3-54-3 sections 7.6.3.r – 7.6.3.t, 7.6.4.d – 7.6.4.e, and 7.6.5.k

@ 2800 psig < 13 seconds to move output shaft, with 1800 in-lbs applied to the output shaft throughout rotation, 0° to (45.5°-47.5°) clockwise & 0° to (50°-52°) counterclockwise

Damping Test F-5 T.O. 4SA3-42-3 section 7.3.6

@ 2800 psig, solenoid de-energized, @ 25 cps damping coefficient of 150 in-lbs per rad/sec

Damping Test T-38 T.O. 9H2-3-54-3 sections 7.4.1, 7.5.1, & 7.5.2

@ 2800 psig, solenoid de-energized, @ 25 cps damping coefficient of 150 in-lbs per rad/sec

3.7 TOOLING

The contractor shall be responsible to furnish all tools and equipment required to set up the test stand and perform the tests specified in this PS. These tools shall also be provided to

USAF. The technical data needed to fabricate these tools shall be included in the technical manuals provided, see 3.8.2.c of this PS.

3.8 OTHER DELIVERABLES

These items listed in Table II shall to be delivered to the USAF project manager before acceptance of the test stand. The USAF project manager shall submit written notice for each item listed that it is acceptable before payment of contract.

TABLE II

Item Deliverable CDRL # DID PS Section

1 COTS Manuals A001 DI-TMSS-80527B 3.8.2

2 CMRS A002 DI-QCIC-80278B 3.8.2

3 Software, data, code A003 DI-IPSC-81488 3.8.4

4 Verification Test Report A004 DI-NDTI-80809B 6.0

3.8.1 The contractor shall provide a two year warranty covering hardware parts, software, and labor on the test stand. Warranty is to begin once USAF has accepted the test stand.

3.8.2 The contractor shall supply and deliver with the test stand three original copies each of

“as built” standard manuals containing all necessary instructions for operation, calibration, maintenance, and repair of the test stand. The contractor shall generate the

COTS Manuals in accordance with Contract Data Requirements List number (CDRL#)

A001/D1-TMSS-80527B. The technical manual shall include, as a minimum, all of the following information:

a. General description of the equipment

b. Setup instructions

c. List of special tooling / fixtures with necessary technical data to fabricate them

d. List of hazards and warnings as applicable

e. Calibration procedures meeting Air Force Metrology and Calibration (AFMETCAL) requirements. The contractor shall generate the Calibration and Measurements

Requirements Summary (CMRS) in accordance with CDRL# A002/DI-QCIC-80278B.

f. Test procedures for the test stand to meet test requirements outlined in section 3.6 of this PS. The procedures should be written in a format similar to section 7 in T.O.

4SA3-42-3 to allow USAF to replace the entire section with new documentation

g. COTS manuals for every component applicable

h. Preventative maintenance schedule and lubrication instructions

i. Any necessary Material Safety Data Sheets (MSDS) for lubricants used

j. Trouble shooting techniques

k. Mechanical diagrams for the test stand

l. Hydraulic schematic drawn according to ANSI Y32.10 standards

m. Electrical wiring diagrams drawn according to NFPA standards and that contain average electronic characteristic waveform and voltage readings at pre-selected points throughout the system

n. Cable schematic diagrams including connector type, wire gage, shielding, etc.

o. Illustrated parts breakdown (IPB) with Bill of Materials to include list of vendors and vendors’ part numbers for all components shown on system diagrams

3.8.3 All documentation of electrical, hydraulic, and mechanical systems shall be illustrated using symbols provided by the ANSI standards organization. A table of symbols shall be included with the documentation and any non-standard symbols shall also be defined on the sheet(s) where they appear. American standard units of measurement shall be used in all written documentation.

3.8.4 The contractor shall provide 3 original copies of all source and executable code as described in section 3.4 of this PS. A level of code should be provided that would allow

USAF to change parameters if necessary, troubleshoot and repair, reprogram for a new workload, change GUI, etc… A copy and license of LabVIEW 2010 with the development package necessary to build the test stand program code shall also be supplied. The contractor shall submit the software and code in accordance with CDRL# A003/DI-IPSC-

81488.

3.8.5 The contractor shall provide all training and training materials as specified for each of the skills identified in Table III below. USAF shall only be responsible for the costs associated with food, transportation, and lodging for government employees that attend the training. The contractor shall provide a qualified technician(s) to complete the listed training that is knowledgeable in all operations of the system. This training and orientation shall be provided at the beginning of Operational Testing and Evaluation referenced in Table IV at Hill AFB, UT.

TABLE III

Training Scope Minimum # of USAF personnel to be Trained

Hours of Training to be provided to USAF personnel

Test Stand Operation 2 40

Test Stand Maintenance / Calibration

4 40

Test Stand Software / Programming

2 16

4.0 IDENTIFICATION & MARKING

All markings on the plates shall be permanent and legible on a contrasting non-glare background. See clause 252.211-7003, Item Identification and Valuation. The following identification plates outlined in sections 4.1 through 4.3 of this PS are required if applicable.

4.1 A lubrication chart or plate permanently and securely attached to the test stand supplying the following information:

a. points of application

b. service interval

c. type and viscosity of lubricant

4.2 NAMEPLATE - A corrosion resistant nameplate securely attached to the test stand, that can be removed, containing the information below:

a. Noun

b. Manufacturer’s model number

c. Manufacturer’s serial number

d. National Stock Number (NSN)

e. Power input (volts, phases, frequency, total amperage)

f. Manufacturer’s name and address

g. Contract number

h. Date of manufacture (month and year)

i. a 1” x 1” blank space

4.3 CAUTION PLATE - A corrosion resistant caution plate securely attached to test stand in a visible location with important cautions to be noted by operator. All caution plate markings shall be visible from at least 5 ft away. Caution plates are required in any area of the test stand where potential hazards exist to the operator or mechanic.

5.0 AFTER CONTRACT AWARD

After the contract award the successful bidder shall adhere to the following to receive final acceptance of the test stand produced. Failure to meet all requirements outlined in this PS shall be grounds for the test stand’s rejection.

5.1 There shall be a series of meetings that coincide with milestones in the project. Table IV below specifies the meeting location, scheduled time, and milestone achievements.

Milestones are reached only after completion of milestone achievements to USAF satisfaction.

TABLE IV

Milestone Meeting Location

Scheduled Time

Milestone Achievements

Initial Stage / Kick-off

Contractor’s facility of contractor’s choice

3 weeks after contractor award

1. Validation of quality control system, based on ISO 9001 or contractor’s internal quality manual. The contractor will provide a quality manual for review prior to the audit

2. Baseline project schedule / timeline

3. Identification of project team members and their roles and responsibilities

Preliminary Design Review (PDR)

TBD – no travel required for contractor personnel

To occur no later than 10 weeks after contract award

1. Finalized schedule for remaining project life

2. Initial Bill of Materials; to include all sensors, instrumentation, motors, actuators, computer hardware, software, and basic construction material to be used in test stand design

3. Basic structure / algorithm of LabVIEW code for test stand

Critical Design Review (CDR)

TBD – no travel required for contractor personnel

To occur no later than 21 weeks after contract award

1. A fully completed CAD design of the test stand

2. Portions of the Technical Manual that is to be submitted at the end of OT&E referenced in this PS specifically sections 3.8.2.j – 3.8.2.n

3. Front panel window views from LabVIEW of the operator interface

Initial Operational Test and Evaluation

(IOT&E)

Contractor’s facility of contractor’s choice

IOT&E starts no later than 30 weeks after contract award

1. The completed Technical Manual as outlined in the PS in section 3.8.2. This includes the COTS Manuals in accordance with CDRL# A001/D1-TMSS-80527B, and the CMRS in accordance with

CDRL# A002/D1-QCIC-80278B

2. A brief report of the IOT&E, noting USAF satisfaction of the results, will be submitted. This report must be signed by the USAF project manager

Operational Test and Evaluation

(OT&E)

Hill AFB, UT OT&E starts no later than 39 weeks after contract award

1. Submission of all software programs as outlined in section

3.8.4 of this PS in accordance with Sequence A003/DI-IPSC-81488 (sec 5.1.5.a)

2. Submitted Verification Test Report signed by USAF manager as outlined in section 6 of this PS in accordance with Sequence A004/DI-NDTI-80809B (sec 5.1.5.b)

3. If necessary, submitted revised copies of the Technical Manual as outlined in the PS in section 3.8.2. This includes the COTS Manuals in accordance with CDRL# A001/D1-TMSS-80527B, and the CMRS in accordance with CDRL# A002/D1-QCIC-80278B (sec 5.1.5.c)

5.2 The initial stage meeting will allow for system requirements, reporting procedures, initial timelines, and contractor questions to be reviewed by both parties.

5.3 USAF shall decide whether the PDR and CDR will be in person or through other means such as a teleconference.

5.4 The IOT&E shall include a functional performance test, per section 3.6 of this PS, with government furnished components that are deemed necessary in the initial stage meeting mentioned in section 5.2 of this PS. USAF personnel shall be able to witness any IOT&E activities. The USAF project manager will sign a brief report of the IOT&E, noting USAF satisfaction with the results.

5.5 The test stand’s hydraulic supply during IOT&E shall meet the requirements of section 3.2 in this PS.

5.6 The OT&E shall include verification and validation of the test stand as outlined in section 6 of this PS. OT&E shall not commence until IOT&E is completed to USAF satisfaction. The following are also aspects of the OT&E:

5.6.1.1 The contractor administrator shall furnish the USAF project manager a delivery date for the test stand at least 30 days prior to the scheduled delivery.

5.6.1.2 The contractor shall ship, offload, set-up, and test the test stand at Hill AFB, Utah.

5.6.5.2 The test stand shall be offloaded only under the supervision of a representative of the contractor.

5.6.5.3 The test stand shall remain the property of the contractor until it is accepted by

USAF.

5.6.5.4 All costs associated with the manufacture, shipping, set-up, testing and preparation of the test stand for final acceptance at Hill AFB shall be the responsibility of the contractor.

5.6.5.5 All operational testing shall be performed by USAF personnel. Any personnel identified by either the contractor or USAF project manager shall be allowed to witness all activities related to OT&E of the test stand.

5.6.5.6 While on Hill AFB, any USAF personnel may observe contractor operations.

5.7 All travel costs associated with the meetings listed in Table III for USAF personnel shall be the responsibility of USAF.

5.8 Any deviations from this PS during any phase of development must receive authorization from the USAF contracting officer and a contract modification must be submitted for such deviations.

6.0 VERIFICATION & VALIDATION

Verification & Validation will occur during the OT&E phase of this project.

6.1 The test stand shall be calibrated prior to OT&E, and all measuring instruments shall have evidence of calibration traceable to the National Bureau of Standards.

6.2 The contractor’s presence shall only be required for the training referenced in section 3.8.5 of this PS.

6.3 All operational tests and their results shall be recorded by the USAF.

6.4 All OT&E data shall be the property of the USAF.

6.5 Table V of this PS shall be included in section 10.2.6.4.2 of DI-NDTI-80809B which is in

CDRL# A004. At least 5 units of both the T-38 Steer Damper Assembly (NSN #: 1620-00-117-

7326LE) and F-5 Steer Damper Assembly (NSN #: 1620-01-139-6672) configuration that are approved by USAF to enter the field shall be tested in accordance with Table V.

TABLE V

Test Objective Test Parameter Acceptable Result

Repeatability A field approved unit, without changing its configuration, is to be tested once per day over a 5 day period per section 3.6 of this PS

All results are with +/- 10% of the first test result (5 units of each)

Accuracy The repeatability test results are compared with the USAF field approved test result conducted on the current test stand (Part Number: 5085L000-501).

The average result of the repeatability test is within +/- 10% of the field approved test result (5 units of each)

6.6 Table VI of this PS shall be included in section 10.2.6.4.2 of DI-NDTI-80809B which is in

CDRL# A004. Only one unit of both the T-38 Steer Damper Assembly (NSN #: 1620-00-117-

7326LE) and F-5 Steer Damper Assembly (NSN #: 1620-01-139-6672) configuration shall be tested in accordance with Table VI. For each test objective the unit’s original configuration shall be kept the same for each test objective except for the internal valve change called out in the test parameter.

TABLE VI

Test Objective Test Parameter Acceptable Result

Capture UUT operational change due to changing flow characteristics

Replace, one at a time, the UUT’s internal flow valves with a flow valve tested at 205 cc/min and capture test data

The results compared with the original configuration test result show a marked difference in steer rate times.

Detect known fault of UUT with failed bypass valve

Replace the UUT’s internal bypass valve with a failed bypass valve

The results compared with the original configuration test result show symptoms of internal bypass and denote failure.

Detect known fault of UUT with failed solenoid valve

Replace the UUT’s solenoid valve with a failed solenoid valve

The results compared with the original configuration test result show marked difference in operational and damping tests denote failure.

Detect known fault of UUT over steer

Adjust UUT’s piston plug to induce known over steer

The results will show unit failure due to over steer

6.7 When the test stand meets the requirements for verification and validation the USAF project manager will sign the Verification Report that is to be submitted per CDRL# A004/DI-

NDTI-80809B.

7.0 ADDITIONAL INFORMATION

7.1 SAFETY

It is the Contractor’s responsibility to maintain a safe work environment and to conform to all OSHA and HAFB safety guidelines, and to take such additional immediate precautions as the contracting officer may reasonably require for safety and mishap prevention purposes.

In the case of an accident or mishap sections 7.1.1 – 7.1.3 of this PS apply to the contractor.

7.1.1 In the event of an accident/mishap take reasonable and prudent action to establish control of the accident/mishap scene, prevent further damage to persons or property, and preserve evidence until released by the accident/mishap investigative authority through the contracting officer.

7.1.2 Record and report promptly (within one hour) to the contracting officer or authorized USAF representative, all available facts relating to each instance of damage to USAF property or injury to either Contractor or USAF personnel.

7.1.3 If the USAF elects to conduct an investigation of the accident/mishap, the

Contractor, and each applicable subcontractor, shall cooperate fully and assist

USAF personnel in the conduct of the investigation until the investigation is completed.

7.2 ENVIRONMENTAL CONTROLS

The Contractor shall be knowledgeable of and comply with all applicable Interstate, Federal, State, and Local laws, regulations and requirements regarding environmental protection. In the event environmental laws/regulations change during the term of this contract, the

Contractor is required to comply as such laws come into effect. If there is an increase or decrease in cost as a result of the change, the Contractor shall inform the Contracting

Officer pursuant to the notice requirements and negotiate a modification to the contract. If the Contractor spills or releases any substance contained in 40 CFR 302 into the environment, The Contractor or its agent shall immediately report the incident to Hill AFB

Fire Dept at 801-777-1911. The liability for the spill or release of such substances rests solely with the Contractor and its agent(s).

7.3 SECURITY

Contractor personnel shall not divulge any information regarding files, data, reports, processing activities/functions, user ID's, passwords, or other knowledge that may be gained, to anyone who is not authorized to have access to such information. Contractor personnel shall abide by all USAF rules, procedures, and standard of conduct. At the close of each work period, government facilities, property, and materials shall be secured. All requests for information shall be forwarded to the USAF project manager.

7.4 ACCESS TO FACILITIES & PROPERTY

Access to Government facilities is limited. Therefore, the contractor shall coordinate required access/usage times and dates with the USAF project manager at least fifteen (15) calendar days prior to the need date. Control of the facilities shall remain with the Government. The USAF project manager will assist contractor personnel in processing the necessary Department of Defense forms to obtain base or area badges for access to Government facilities. The contractor must return all base identification badges immediately after the installation and/or training is complete. Please see clause AFFARS 5352.242-9000.

7.5 HOURS OF OPERATION

The time frame for contractor work on Hill AFB shall be established between the contractor and USAF project manager. The time frame is subject to change based upon the needs of production. Current production hours are 0600 to 1600hrs. Recognized Holidays: The contractor is not required to provide service on the following days: New Year’s Day, Martin

Luther King Day, Presidents’ Day, Memorial Day, Independence Day, Labor Day, Columbus

Day, Veterans’ Day, Thanksgiving Day, and Christmas Day. If the holiday falls on Saturday, it is observed on Friday. If the holiday falls on a Sunday, it is observed on Monday.

7.6 GOVERNMENT FURNISHED EQUIPMENT

Government Furnished Equipment (GFE) will be provided in accordance with FAR Clause

52.245-1 and 52.245-9. The following USAF items will be supplied:

TABLE VII

Scheduled Delivery Date of GFE Required Assets Asset Condition

3 weeks after contract award 1 T38 Steer Damper assembly

1 F5 Steer Damper Assembly

Any condition acceptable

18 weeks after contract award 1 T38 Steer Damper assembly

1 F5 Steer Damper Assembly

Any needed internal valves for verification and validation as stated in section 6.0 of this PS

“A” condition asset

7.7 AMERICANIZED ENGLISH

All paperwork submitted by contractor to USAF contracting office must be in Americanized

English.

7.8 CONTACT INFO

The USAF project manager contact info is:

5738 Southgate Ave Bldg 509

Hill AFB, UT 84056

(801) 777-1091