F16_EHSV_PS_April2014_Final.pdf

PERFORMANCE SPECIFICATION (PS) FOR

F16 EHSV/ISA TEST STANDS

309 COMMODITIES MAINTENANCE SQUADRON ENGINEERING (CMXG/ENH)

4/10/2014

Table of Contents

1. DESCRIPTION OF SUPPLY / SCOPE

1.1. BASIC SUPPLY / BASIC DESIGN REQUIREMENTS

1.2. SAFETY DESIGN REQUIREMENTS

1.3. HYDRAULIC DESIGN REQUIREMENTS

1.4. ELECTRICAL DESIGN REQUIREMENTS

1.5. COMPUTER HARDWARE / SOFTWARE DESIGN REQUIREMENTS

1.6. ADDITIONAL EQUIPMENT

1.7. IDENTIFICATION

1.8. UTILITIES

2. TECHNICAL DATA DELIVERABLES

2.1. CALIBRATION

2.2. TECHNICAL MANUALS

2.3. TECHNICAL DATA PACKAGE

2.4. ACCEPTANCE TEST PROCEDURES AND REPORT

2.5. SOFTWARE

2.6. MSDS

2.7. ITEM UNIQUE IDENTIFICATION (IUID)

3. GOVERNMENT FURNISHED EQUIPMENT (GFE)

4. PERFORMANCE

5. GENERAL INFORMATION

APPENDIX A

APPENDIX C

1. DESCRIPTION OF SUPPLY / SCOPE

This Purchase Specification (PS) is for the purchase of three (3), with an option to purchase one (1) additional, Automatic Hydraulic Test Stands to test the Integrated Servo Actuator for the F-16 Flight Controls. These stands test the Servo Actuators, attached to the Main Hydraulic Flight Control, per TOs 9H2-4-238-8-1 for the Horizontal Tail/Flaperon Servo Actuator Assembly, and 9H2-4-240-8-1 for the Rudder Servo Actuator Assembly.

Hencefore the Automatic Hydraulic Test Stands to test servo valves for the F-16 Integrated Servo Actuator will be referred to as the EHSV/ISA Test Stands.

The task under this PS entails the design, manufacture, qualification, delivery and installation of three (3), with an option for one (1) additional, production test systems and test capability for the F-16 Units Under Test (UUT) Servo Valves listed in Table 1. The Technical Orders (T.O.) for the test stand and each UUT will be provided to the winning contractor upon completion of the selection process. The contractor shall review and understand the defined test criterion which involves installing the UUT onto the test stand fixtures and cycling the unit to the defined criteria. The contractor shall provide a technical package as defined herein.

1.1. BASIC SUPPLY / BASIC DESIGN REQUIREMENTS

The contractor shall provide all management, tools, supplies, equipment, and labor necessary to design, build, test, deliver, and install three (3), with an option for one (1) additional, EHSV/ISA Hydraulic Test Stands. The contractor shall provide associated technical data, software, tooling, material, and training as specified herein.

The Test Stands shall be designed to test assets per their respective governing technical data as described in Table 1. Additional design requirements or constraints are further outlined herein.

Table 1 – Asset Tested by Test Stand Nomenclature Part

Number NSN T.O. Governing Technical

Data Servo Valve Assembly

975138-9 1650-01-084-

9H2-4-238- 8-1

9H2-4-240- 8-1

TP-666 (Abex Corp, Aerospace Division)

PS 975138* (NWL

Control Systems)

TS-72216-06*

1.1.1. The test stand shall have the capability to run in semi-automatic (operator has option to add data and continue testing) and manual mode (operator steps through each major operation).

1.1.2. If there is failure during an asset test the test stand shall stop and define the error. The operator will be given the option to terminate the test, run diagnostics or continue testing.

Any portion of the test can be chosen to be rerun.

1.1.3. The EHSV/ISA Test Stands and all components shall be new and of the manufacturer's current production models. To the extent possible the EHSV/ISA Test Stands shall incorporate Commercial-Off-The-Shelf (COTS) components and software.

1.1.4. Components requiring scheduled maintenance or calibration shall be easily accessible for adjustment, repair, or replacement.

1.1.5. All mechanisms requiring lubrication including gears, slide ways, and bearings (except sealed-for-life type) shall be provided with means for lubrication. All oil holes, grease fittings, and filler caps shall be easily accessible.

1.1.6. The EHSV/ISA Test Stands shall be constructed so that when it is installed and connected to power it shall be ready for operation. The EHSV/ISA Test Stand shall be capable of withstanding all pressures and forces encountered during operation to its maximum rating and capacity without permanent distortion. This includes the capability to continually run testing at a pressure of 4500 pounds per square inch (psi) and proof testing at 6000 psi.

1.1.7. All calibration shall occur without shipment of EHSV/ISA Test Stands components to another facility and meet Air Force Metrology and Calibration (AFMETCAL) requirements as referred in section 2.1 of PS. The calibration procedure shall be written, tested and approved by the government PMEL authority prior to delivery of the test stands to the government facility. CDRL# A004/TM-86-01N and A001/DID DI-QCIC- 80278B.

1.1.8. All EHSV/ISA Test Stands components shall be protected from or able to withstand hydraulic fluids, oils, or cooling water.

1.1.9. Test times on the new EHSV/ISA Test Stands for all UUTs shall be of minim duration

1.1.10. The foot print of the new EHSV ISA Test Stands shall be no larger than the existing stands of 84”L x 48” W x 64” H.

1.1.11. If the stand or fixture shades any portion of the UUT, auxiliary lighting shall be provided to project adequate lighting on the test area for the operator during testing.

1.1.12. All acceptance test records and test plots shall be stored by serial number in the EHSV

ISA Test Stand’s computer.

1.2. SAFETY DESIGN REQUIREMENTS

The EHSV/ISA Test Stands shall meet the following safety requirements:

1.2.1. The EHSV/ISA Test Stands shall include emergency shut-off switches which dissipate all stored energy readily accessible to operator.

1.2.2. The test stands shall be designed for and capable of accepting energy isolating devices

(Lockout/Tagout devices) in accordance with (IAW) 29 CFR 1910.147.

1.2.3. The EHSV/ISA Test Stands shall include safety interlocks, over-travel limit stops, and warning devices to protect the machine, controls, and operator from damage.

1.2.4. The EHSV/ISA Test Stands shall include shockproof controls to protect operator from mechanical and electrical hazards.

1.2.5. The EHSV/ISA Test Stands shall incorporate easily deployable shielding necessary to protect operator from high pressure fluids yet allow visibility of the UUT. The shield must be moveable to allow access to the test area.

1.2.6. The EHSV/ISA Test Stands shall provide appropriate guarding to cover all belts, gears, electric motors, pinch points, and any other mechanical moving parts.

1.2.7. The EHSV/ISA Test Stands shall secure any necessary air and hydraulic lines. Hard lined plumbing shall be used to connect to USAF hydraulic sources.

1.2.8. The noise level of the EHSV/ISA Test Stands shall not exceed 82 decibel (dB) at the operator’s position during testing.

1.2.9. The manufacturer shall furnish a corrosion-resistant plate securely attached to a visible location with safety cautions and warningsto be observed by the operator. The plate shall be permanently marked. Caution plates are required in any area of the test stand where potential hazards exist to the operator or mechanic.

1.3. HYDRAULIC DESIGN REQUIREMENTS

The EHSV/ISA Test Stands shall meet the following hydraulic requirements:

1.3.1. The new equipment shall connect to the existing hydraulic manifold pressure system existing in Building 503B.

1.3.1.1. The EHSV/ISA Hydraulic Test Stands shall be connected to the 3500 psi high flow, the 4500 low flow.

1.3.1.2. The return line shall connect into the facility return line with a minimum pressure of 100 psi.

1.3.1.3. EHSV/ISA Hydraulic Test Stand shall have the capability of running at 4500 psi and proof testing at 6000 psi, throughout a normal nine (9) hour workday, five (5) days a week.

1.3.1.4. Hydraulic lines shall be hard plumbed into the government manifold using appropriate sized AN 37 degree flared fittings and an adapter plate that conforms to the existing manifolds.

1.3.1.5. A large volume 10micron (µ) canister type replaceable oil filter element shall be connected to all manifold hydraulic oil intakes and outputs. The filter system shall have an indicator to show when the time to replace the filter element is approaching.

1.3.2. All hydraulic seals and components shall be compatible with MIL-H-83282 hydraulic oil.

1.3.3. Temperature sensors shall be included on hydraulic input lines which have an accuracy of

+/- 5º in the range of 75º to 125ºF.

1.3.4. Instrumentation (flow meters, pressure gages, etc) and additional range accuracy / requirements need to be sufficient to carry out testing as outlined in the T.O.s. and Automated Test Procedures (ATPs).

1.3.5. All hose connectors from the UUT to the stand shall be quick-disconnect type and located in an orderly, ergonomically desirable setup. They shall be designed with various styles that will prevent connection to the wrong port on the stand.

1.3.6. A drip pan feature shall be provided or built into the stand to capture minor hydraulic fluid leaks and spills.

1.3.7. The test stand shall have a stainless steel sink that drains into a 5 gallon minimum reservoir that returns filtered oil back into the return line at 100 to 300 psi. The sink area shall be large enough to capture oil from the entire UUT and fixture.

1.3.8. Instrumentation - All analog instrumentation shall be precision quality and have minimum 4 ½ inch diameter face plate and ±1% of span accuracy for the higher pressure gages and minimum 2 ½ inch diameter ±2 ½% of span accuracy for the lower pressure gauges. They shall be plumbed in an orderly fashion to be easily viewed with connectors accessible for calibration. Valves shall be plumbed in to allow isolation of the pressure gages from the rest of the test stand during calibration. Manufacturer documentation to the government shall include gauge specifications, warranty information and Original Equipment Manufacturer (OEM).

1.3.9. Valves and Plumbing

1.3.9.1. Valves and plumbing shall be stainless steel and sufficient capability to carry pressure and volume requirements defined in the UUT T.O. specifications.

1.3.9.2. All plumbing shall be located in an orderly fashion and be readily accessible for maintenance and service.

1.3.9.3. The EHSV/ISA Hydraulic Test Stands shall have the necessary calibration ports and associated valving to allow for easy access to perform calibration at test stand.

1.4. ELECTRICAL DESIGN REQUIREMENTS

1.4.1. The EHSV/ISA Hydraulic Test Stands shall contain a low-energy, capacitive discharge magnet charger with a user controlled SRC firing device that discharges the energy into the magnetizing fixture.

1.4.1.1. Max energy level is 250 Joules.

1.4.1.2. Minimum cycle time is 5 seconds.

1.4.1.3. Maximum voltage is 800 V regulated from 0-800 V,

1.4.1.4. Voltage resolution +1% of max V

1.4.1.5. Voltage accuracy +5%

1.4.1.6. Pulse shape Aperiodic (magnetization

1.4.2. The EHSV/ISA Hydraulic Test Stands shall contain a low-energy, capacitive discharge magnet conditioner with a conditioning fixture.

1.4.2.1. Energy level is 20 Joules.

1.4.2.2. The pulse wave shape is a decaying sine wave.

1.4.2.3. The conditioners shall have a coarse and fine condition level adjustment.

1.4.3. The EHSV/ISA Hydraulic Test Stands shall contain a hipot tester with the following minimum capabilities:

1.4.3.1. Dielectric Withstand Test Mode:

1.4.3.1.1. Output Rating: 5k V @ 20 mA AC & 10 mA DC.

1.4.3.1.2. Output Adjustment: 0 – 5 k V AC & DC, 10 volts/step.

1.4.3.1.3. Output Adjustment: 0 – 20.00 mA AC & 10 mA DC, 0.01 mA/step.

1.4.3.2. Insulation Resistance Test Mode:

1.4.3.2.1. Output Voltage Range: 100 – 1000 Volts, 1 volt/step.

1.4.3.2.2. Voltage Metering: 3% Digits, 0.00 – 1.00 kV, 2 ranges.

1.4.3.2.3. Accuracy ± (2% of reading + 1 count).

1.4.3.3. Resistance Metering: 3 Digits, 9.99 Gµ full Scale.

1.4.3.4. Resistance Metering: 100 – 499 V ±5% of reading + 2 counts).

1.4.3.5. Resistance Metering: 500 – 1000 V ±(10% of reading +2 counts).

1.4.4. Inbound Test - The EHSV/ISA Hydraulic Test Stands shall have the capability to perform inbound testing on the UUTs using the OEM data package.

1.5. COMPUTER HARDWARE / SOFTWARE DESIGN REQUIREMENTS

The software described in this specification shall be used in the performance of the tests specified in paragraph 1.1 Table 1.

1.5.1. All software shall be open source, meaning the Government shall have the capability and rights to make future changes to the component test software as needed.

1.5.2. The software shall be the latest released (stable) version of a windows based commercial application package commonly used for data acquisition, instrument control, and industrial automation.

1.5.3. The EHSV/ISA Test Stands software shall contain all utilities, drivers, libraries, and applications necessary to develop and run EHSV/ISA Test Stands Operational Test Program Set (OTPS) and associated Test Program Set(s) (TPS).

1.5.4. The EHSV/ISA Test Stands software shall be configured so that self-test and calibration software may be installed and run separately from the run EHSV/ISA Test Stands OTPS and associated TPS.

1.5.5. The EHSV/ISA Test Stands software shall be configured so that each TPS developed for a particular UUT may be installed and run separately the OTPS and other TPS. The contractor shall provide the source and executable codes for the EHSV ISA Test Stand OTPS and UUT TPS.

1.5.6. The contractor shall design self-test software sufficiently to ensure correct operation and identification/isolation of faulty components of the test set.

1.5.7. Each OTPS and TPS shall display a Computer Program Identification Number (CPIN) assigned by the Government. CDRL# A008/DI-MISC-81454B

1.5.8. Computer hardware shall be commercial grade equipment

1.5.8.1. The monitor shall be at least a 19” diagonal commercial grade liquid crystal touch-screen.

1.5.8.2. The printer shall be a black and white laser type.

1.5.8.3. The keyboard and cursor control shall be commercial grade impervious to hydraulic liquid infiltration. They shall have a surface to sit and maneuver on.

A standard mouse pad, minimum of 7”x 8” will be provided.

1.5.8.4. All cabling shall be USB2 type. All computer systems shall have USB interface capability. A modem connector shall be available.

1.5.8.5. The computer shall include read/write DVD capability

1.6. ADDITIONAL EQUIPMENT

Any unique or special tooling/equipment required for installation, operation, maintenance or calibration of the EHSV/ISA Test Stands shall be provided by the contractor. They shall have a shadowed storage location in or on the test stand.

1.6.1. All hoses shall have a dog tag firmly attached with wire to indicate the following:

a. Manufacture (MFG):

b. Part Number (PN):

c. Operating Pressure (OP) PRESSURE:

d. Assembly Date (ASSY DATE):

e. CURE DATE:

1.7. IDENTIFICATION

All markings on identification plates shall be permanent and legible on a contrasting non-glare background.

1.7.1. A lubrication chart or plate shall be permanently and securely attached to the EHSV/ISA Test Stands. The following information shall be furnished on the chart or plate:

1.7.1.1. Points of application

1.7.1.2. Service interval

1.7.1.3. Type and viscosity of lubricant

1.7.2. A Corrosion-resistant nameplate shall be securely attached to the EHSV/ISA Test Stands.

The nameplate shall contain the information listed below:

a. Noun

b. Manufacturer’s name

c. Manufacturer’s serial number

d. Manufacturer’s model number

e. Main drive motor horsepower

f. Power input (volts total amperage phases frequency)

g. Contract number or order number

h. Date of manufacture (day month and year)

1.8. UTILITIES

Government utilities are rated as follows

1.8.1. Facilities electrical power: 120 Volts Alternating Current (VAC), 20 ampere (Amp), 60 Hertz (Hz) for each stand or 480 VAC, 3 phase, 60 Hz.

1.8.2. Facilities air: 100 psi

1.8.3. Facilities hydraulic supply: 3,500 psi High Flow, 4,500 psi Low Flow, High Flow Return

2. TECHNICAL DATA DELIVERABLES

The contractor shall provide a technical data package as stated in Table 2 and further explained below:

Table 2 – Technical Data Deliverables for EHSV/ISA Test Stands Deliverable CDRL# DID PS Reference

Calibration Measurements and Requirements Summary

(CMRS)

A001

DI-QCIC-80278B

2.1.1 and 2.1.3

Calibration Certification A002 DI-QCIC-80798B 2.1.2 Product Drawings and

Associated Lists A003 DI-SESS-81000D/T 2.3.1 and 4.3

Technical Manuals A004 TM-86-01N 2.2 and 4.3 Operational Test Program Set

(OTPS) Acceptance Test Procedures (ATPs)

A005 DI-ATTS-80282B 2.4 and 4.3

Operational Test Program Set (OTPS) Acceptance Test

Report (ATR) A006 DI-ATTS-80283B 2.4, 4.3 and 4.4

Computer Software Product A007 DI-IPSC-81488 2.5 and 4.3 Automated Computer Program Identification

Number (ACPIN) Data and Control Record

A008 DI-MISC-81454B 1.5, 2.5 and 4.3

Item Unique Identification (IUID) Marking Plan A009 DI-MGMT-81803 2.7

Unique Identification (IUID) Marking Activity and Verification Report

A010 DI-MGMT-81804 2.7

Material Safety Data Sheets

(MSDS) A011 FED-STD-313D 2.6

Progress, Status, and Management Report A012 DI-MGMT-80277 4.5

Conference Agenda A013 DI-ADMN-81249A 2.3 and 4.5 Conference Minutes A014 DI-ADMN-81250A/T 2.3 and 4.5

2.1. CALIBRATION

DEFINITION: Calibration is a comparison between equipment items, one of which is a measurement standard of known accuracy, to detect, correlate, adjust and report any variation in the accuracy of the other item(s):

2.1.1. Calibration quality standard and traceability - With CMRS: The Contractor shall ensure the developed system is capable of being calibrated and its calibration is verified IAW AFMETCAL requirements. Calibration and measurement traceability shall be identified and documented IAW MIL-STD-1839D. MIL-HDBK-1839C will be used for interpretive guidance to clarify requirements invoked by MIL-STD-1839D. The Contractor shall provide a means to perform calibration to meet these requirements. The Contractor shall provide, with each EHSV/ISA Hydraulic Test Stand, all proprietary/unique software and peculiar/special hardware required to perform calibration and calibration verification. The Contractor shall develop and deliver a system calibration procedure verifying system performance to the performance specification contained within the Governing Technical Data defined in Table 1. The Contractor shall deliver the Calibration Measurement Requirements Summary (CMRS) IAW CDRL#

A001/DID DI-QCIC-80278B.

2.1.2. The contractor shall calibrate and certify per NIST standards the upgraded stands at the contractor facility before delivery and again after delivery as outlined in Table 4 under section 4 of this PS. The contractor shall provide calibration certification IAW CDRL# A002/DID DI-QCIC-80798B with delivery of test stands.

2.1.3. The Contractor shall provide a Calibration TPS and ITA(s) as required. The Calibration TPS shall verify that, as a minimum, the functions and parameters required to support the UUT requirements are documented in the CMRS, IAW CDRL# A001/DID DI-QCIC- 80278B, and are within specified tolerance. The Contractor shall develop and deliver a system calibration T.O., in accordance with Data Item Description TM86-01 (Technical Manual Contract Requirements) and Contract Data Requirements List (DD Form 1423).

2.1.4. Calibration ITA: The EHSV/ISA Test Stands shall have a calibration ITA to connect to external standards (such as PATEC) for calibration/verification. The calibration ITA shall include all cables, adapters, etc, necessary to perform a calibration/verification at the UUT interface. The calibration ITA may be combined with the self-test ITA.

2.1.5. The contractor shall calibrate the upgraded stands at the contractor facility before delivery. After delivery as outlined in Table 4 of this PS, contractor shall calibrate and certify per NIST standards the upgraded EHSV/ISA Test Stands.

2.2. TECHNICAL MANUALS

The contractor shall provide a technical manual for operation, maintenance, and calibration IAW CDRL# A004/TM-86-01N. CDRL# A004 is governed by TM-86-01N, tailored for the EHSV ISA Test Stands. Some of the requirements identified in these documents are emphasized below:

2.2.1. The contractor shall provide the government with an updated version of existing TOs (9H2-4-238-8-1 and 9H2-4-240-8-1) to include pictures and documentation required to incorporate the new EHSV/ISA Hydraulic Test Stands into the UUT test process. These updates shall include the EHSV/ISA Hydraulic Test Stands test parameters and pass / fail criteria for all tests performed.

2.2.2. The government shall be given unlimited rights for all business rules (tailoring and application methods and procedures as is common in T.O. management.)

2.2.3. If some source data is copyrighted or contains proprietary data offeror may propose limited rights, but as a minimum, manuals shall be provided with Government Purpose Rights (GPR). CDRL# A004/TM-86-01N

2.2.4. The contractor shall provide written backup and recovery procedures for system software.

The contractor shall also provide procedures on data acquisition hardware setup, including Field Programmable Gate Array (FPGA) programming necessary for system operation, be included. CDRL# A004/TM-86-01N

2.3. TECHNICAL DATA PACKAGE

2.3.1. Engineering Data: The contractor shall develop, produce, maintain, and deliver a Technical Data Package (TDP) that accurately depicts the final product. The TDP shall represent the approved, tested, and accepted configuration of the defined delivered item(s). TDP data includes, but is not limited to, Computer Aided Design (CAD) data, CAD models, model based definition data sets, Gerber data and Master Bill of Materials (BOM). The TDP shall provide the necessary design, engineering, manufacturing, testing and quality assurance requirements information necessary to enable the procurement or manufacture of an interchangeable item that duplicates the physical and performance characteristics of the original product without additional design engineering effort or recourse to the original design activity or any third party. All engineering product definition data created as a result of this contract shall be considered a part of the TDP. The TDP shall be delivered in accordance with Air Force Product Data Specification drawing 9579776 (CAGE 98752) and CDRL# A003/DI-SESS-81000D/T Product Drawings and Associated Lists.

2.3.2. Engineering Data Guidance Conference: The contractor shall support and co-chair a Guidance Conference with AFLCMC/EZGEM for engineering data within 60 days after contract award. The Conference shall be convened at a site and on a date agreed upon by the Government contracting officer and the contractor. The contractor shall prepare an agenda and record the minutes of the Guidance Conference. The contractor shall address, discuss, and provide status on the following: CDRL #A013 DI-ADMN-81249A;

CDRL #A014 DI-ADMN-81250A/T

2.3.2.1. Understanding of all CDRL requirements, applicable DIDs, specifications and standards.

2.3.2.2. TDP review requirements and schedules.

2.3.2.3. TDP delivery requirements and schedules.

2.3.2.4. Contractor's drafting practices/procedures/TDP drawing formats/CAD programs.

2.3.2.5. The contractor's quality assurance procedures relating to TDP documents, including quality control of subcontractor and vendor data.

2.3.2.6. The role of subcontractors and vendors who may deliver TDP documents under this contract.

2.3.2.7. The contractor's configuration management system, including methods for releasing documents, approving documents, and incorporating changes into documents.

2.3.2.8. Digital Technical Data Package (TDP) deliverables.

Note: Guidance Conference may be held in conjunction with other meetings or conferences.

2.3.3. In-Process Review (IPR) of the TDP: The contractor shall host, support, and co-chair an IPR of the engineering drawings and associated lists and other documentation to be included in the TDP. The IPR shall be conducted only after the contractor's quality assurance personnel have completely reviewed the data and determined that data are of sufficient quality that Government time will be effectively utilized during the review.

IPR may be scheduled when data has reached the 50% percent completion point and shall be held, when possible, in conjunction with other reviews (i.e., PDR, CDR). The contractor shall notify AFLCMC/EZGEM a minimum of 30 days prior to the anticipated date of completion point. The IPR shall focus on the contractor's progress in the preparation of the TDP. The contractor shall support and provide the necessary resources, i.e., meeting agenda, conference room, applicable data, minutes, and appropriate personnel available to answer any questions to perform the IPR effectively.

The contractor shall correct all discrepancies identified in the IPR. All subcontractor/vendor data shall be made available for review. If the quantity of subcontractor/vendor data is of sufficient magnitude, the Government may schedule a separate IPR at the subcontractor's/vendor's facility. CDRL #A013 DI-ADMN-81249A;

CDRL #A014 DI-ADMN-81250A/T

2.3.4. Relationship of Contractor with Subcontractors/Vendors: The contractor shall levy on sub-contractors and sub-vendors the same requirements for Technical Data Packages (TDPs) as are levied on them by this contract. This requirement shall apply at all tiers of sub-contractor/vendor levels associated with the program.

2.3.5. Engineering Data Updates and Revisions: The contractor shall (and shall cause subcontractors and vendors to) update and maintain engineering data for the item(s) designed/ developed/modified/produced and funded by this contract for the life of this contract and shall incorporate all changes in accordance with the following:

2.3.5.1. All engineering changes shall be incorporated into the applicable engineering data within 90 days after engineering release/Air Force concurrence or at intervals of five changes, whichever occurs first, except a change involving safety, which shall be incorporated immediately.

2.3.5.2. All engineering changes shall be incorporated into the applicable engineering data prior to delivery of data for review.

2.3.5.3. All engineering changes shall be incorporated into the applicable engineering data prior to delivery of final media.

2.3.5.4. Revisions to existing engineering drawings/models and associated lists and other documentation to be included in the TDP for which the contractor is the current design activity shall result in the delivery of the entire revised document and associated data file. For example, when a portion of a document is revised the entire document shall be delivered.

2.4. ACCEPTANCE TEST PROCEDURES AND REPORT

The contractor shall submit OTPS, ATPs and Acceptance Test Report (ATR) for the EHSV/ISA Hydraulic Test Stands and for each UUT. The government will review and approve the Acceptance Test Procedure.

2.4.1. The contractor and the government will perform the testing in accordance with the approved Acceptance Test Procedure for the acceptance of the EHSV/ISA Hydraulic Test Stands and UUT’s (at contractor’s facility). A Functional Configuration Audit (FCA) and Physical Configuration Audit (PCA) along with T.O. Verification shall be held in conjunction with the acceptance activities. IAW CDRLs # A005/DI-ATTS-80282B and

A006/DI-ATTS-80283B.

2.4.2. The ATR will document OTPS results and test results of the EHSV/ISA Hydraulic Test Stands and five (5) UUTs each for the Rudder and the Horizontal Tail/Flaperon Servo Actuator Assemblies, randomly chosen by the government from available assets and shall be tested per the respective TO(s). The test result will be compared to those on one of the existing stands and data compared for consistency.

2.4.3. The OTPS ATP shall be provided as outlined in Table 3 under section 4.3 of PS before factory acceptance testing occurs. The OTPS and associated results shall be included in the ATR.

2.5. SOFTWARE

The contractor shall submit computer software IAW CDRL# A007 DI-IPSC-81488/ and

A008/DI-MISC-81454B.

2.5.1. The contractor shall provide licensing for all software used to develop the EHSV/ISA Test Stands programming and run system programs for the EHSV/ISA Test Stands.

2.5.2. The contractor shall comply with TO 00-5-16 when implementing or revising any software code in the EHSV/ISA Test Stands. Any such changes shall be accompanied with properly labeled media identified by a new or revised CPIN, visible in the software program itself, assigned by the government.

2.5.3. The software shall separate any code or programming specific to any Unit Under Test (UUT) in its own executable application from the OTPS executable.

2.5.4. The contractor shall deliver all software used in, on, or in support of the Test Stand including data, documentation and licenses. The contactor shall provide the software application and client access licenses for all software used in, on, or in support of the test set. The contractor shall deliver source code on all software, including any translators, operating systems, runtime, and development environment software. The source code shall include instructions describing the process of recreating the executable object files.

2.6. MSDS

The contractor shall submit Material Safety Data Sheets IAW CDRL# A011/FED-STD- 313D for any chemicals or oils required for the test stand.

2.7. ITEM UNIQUE IDENTIFICATION (IUID)

EHSV/ISA Hydraulic Test Stands shall contain Unique Identification (UID) marking IAW MIL-STD-130N and DI-MGMT-81803. The Contractor shall have a thorough understanding of IUID marking requirements, marking equipment, databases and their interfaces, engineering evaluation requirements, verification, and data and configuration management relating to IUID marking. The Contractor will report using the IUID registry, located on the internet at http://www.acq.osd.mil/dpap/pdi/uid/data_submission_information.html IAW DI- MGMT-81804. The contractor shall provide for IUID IAW CDRL# A009/DI-MGMT- 81803 and CDRL# A010 DI-MGMT81804.

3. GOVERNMENT FURNISHED EQUIPMENT (GFE)

The government will provide five (5) each of servicable equipment outlined in Table 4 based on appropriate loan / lease agreements consistent with FAR clause 52.245-1 Government Property.

Table 3: GFE

Nomenclature P/N NSN Number of available units for Contractor’s use

Servo Actuator Assembly

975138-9 1650-01-084-7203-1570 5 each

The following further defines government requirements in regards to loaned property:

3.1. The contractor shall be responsible for all return shipping costs of GFE and shall be held liable for Freight On Board (FOB) destination.

3.2. The contractor shall be responsible to return all GFE to the government by the return date accepted in loan / lease agreements. Failure to do so represents a contract failure and will be noted as such in contract performance evaluation. If necessary, loan time extensions of GFE can be negotiated by the contractor with the government before the applicable return date.

http://www.acq.osd.mil/dpap/pdi/uid/data_submission_information.html

4. PERFORMANCE

There shall be a series of meetings to coincide with milestones in this effort. Table 4 below specifies the meeting type and/or location, and milestone achievements associated with the meeting. With the exception of the kick-off meeting, the contractor shall provide any drawings, documents and slide presentations at least 7 days prior to any scheduled meeting. The effort shall not progress beyond a milestone until both the government and contractor agree the milestone achievements have been accomplished. Additional information about these meetings and milestone achievements are listed in this section.

The contractor shall provide a Gantt like chart showing all major operations and performance milestones tracking program progress. The contractor shall immediately report, apart from status reports, to the 309 CMXG/ENH, major deviations from the schedule, including updates on any activity and/or deliverable which will not be achieved as scheduled, citing the cause, contributing factors, impacts, and resolutions to get back on schedule.

Table 4: Performance Milestones

Milestone Meeting Location

Milestone Achievements Timeline

Initial Stage / Kick-off

Hill AFB 1. Completed Engineering Data Guidance conference.

2. Baseline project schedule / timeline

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

4. Agenda, Notes, Presentation and Participants List shall be submitted to the government at least 5 working days prior to scheduled meeting

21 calendar days from contract award

Preliminary Design Review

(PDR)

TBD – no cost to contractor

1. Initial Bill of Materials; to include all sensors, instrumentation, power supplies, and basic construction material to be used in EHSV/ISA Test Stands design.

2. Initial CMRS Summary IAW CDRL# A001/DI-

QCIC-80278B.

3. Initial GUI reviewed

4. Agenda, Notes, Presentation and Participants List shall be submitted to the government at least 5 working days prior to scheduled meeting

80 calendar days from contract award

Critical Design Review

(CDR)

TBD – no cost to contractor

1. A fully completed or updated CAD design of the EHSV/ISA Test Stands

2. A finalized Bill of Materials

3. Government acceptance of final CMRS IAW

CDRL# A001/DI-QCIC-80278B

4. Agenda, Notes, Presentation and Participants List shall be submitted to the government at least 5 working days prior to scheduled meeting

140 calendar days from contract award

In-Process- Review

(IPR)

TBD – no cost to contractor

1. A fully completed or updated CAD design of the EHSV/ISA Test Stands

2. Initial submission of technical manual and receipt of government review IAW CDRL# A004/TM-86-01N.

3. Government acceptance of final OTPS IAW CDRL#

200 calendar days from contract award

A005/DI-ATTS-80282B.

4. Submission of software IAW CDRL# A008/DI-

MISC-81454B.

5. Government acceptance of material safety data IAW

CDRL# A011/ FED-STD-313D.

Factory Acceptance Testing

(FAT)

Contractor’s facility

1. PMEL verification of EHSV/ISA Test Stands IAW section 2.1 of PS at contractor facility.

2. Completion of Physical Configuration Audit and Functional Configuration Audit IAW section 4.3 of

PS.

3. Successful completion of required test data acquisition for ATR submission IAW CDRL#

A006/DI-ATTS-80283B.

4. Submission of software IAW CDRL# A007/ DI- IPSC-81488 and CDRL# A008/DI-MISC-81454B.

5. Submission of technical manual IAW CDRL#

A004/TM-86-01N

260 calendar days from contract award

Delivery and Verification

Hill AFB 1. Delivery and installation of EHSV/ISA Test Stands.

2. Submission of component calibration certificates IAW

CDRL# A002/DI-QCIC-80798B

3. Completion of training as outlined in section 5.1 of PS

4. AFMETCAL / PMEL certification and acceptance of

EHSV/ISA Test Stands IAW CDRL# A002/DI-QCIC- 80798B.

5. Submission of Product Drawings and Associated Lists

IAW CDRL# A003/ DI-SESS-81000D/T.

6. Successful completion of required test data acquisition ATR submission IAW CDRL# A006/DI-ATTS-80283

350 calendar days from contract award

4.1. The initial stage meeting shall incorporate an Engineering Data Guidance Conference to ensure contractor understands all PS requirements, CDRL requirements, applicable Data Item Descriptions, and government standards. The initial stage meeting shall provide a thorough overview of all delivery requirements and schedules. Required GFP paperwork and policy will also be reviewed.

4.2. The PDR, CDR, and IPR shall be held at a Contractor’s facility, Hill AFB, or via teleconference. The Project Manager will coordinate the actual date, time, and location of the reviews with the contractor. Preference will be given to have meetings via telecom with notes, data and PowerPoint presentations being forwarded at least 5 working days prior to the meeting.

4.2.1. The IPR may require several discussions as the government shares its review of the submitted data’s compliance with CDRL and PS requirements.

4.3. Factory Acceptance Testing/Physical Configuration Audit will occur at contractor’s off-base facility of choice. The following applies to factory acceptance testing:

4.3.1. The EHSV/ISA Test Stands calibration shall be verified by an AFMETCAL or PMEL representative as outlined in section 2.1 and 2.2 of this PS.

4.3.2. The Physical Configuration Audit (PCA) shall ensure that the technical data provided reflects the “as built” configuration to the EHSV/ISA Test Stands, such as schematics and illustrated parts lists in the technical manuals and drawing package. A product baseline will be established upon completion of and government acceptance of the PCA. A complete preliminary copy of the technical data package IAW CDRL# A004/TM-86- 10N, A005/DIATTS80282, A007/DI-IPSC-81488, A008/DI-MISC-81454B, and CDRL# A003/ DI-SESS-81000D/T shall be delivered 15 days prior to PCA.

4.3.3. The Functional Configuration Audit (FCA) shall ensure the EHSV/ISA Test Stands perform acceptably as outlined in the OTPS ATP submitted IAW CDRL# A004 at IPR.

It shall also ensure that government furnished field acceptable equipment, as confirmed by supplied test results, successfully pass testing and the data is recorded as necessary for the ATR submitted IAW CDRL# A006. Testing during the FCA shall be performed by a Hill AFB mechanic.

4.3.4. The draft ATR shall be submitted to and accepted by the government IAW CDRL#

A006/DI-ATTS-80283B.

4.3.5. The USAF Systems Engineer assigned to the EHSV/ISA Test Stands must approve successful completion of PCA and FCA.

4.3.6. If necessary revisions to the technical manuals result from PCA and FCA they shall be submitted before conclusion of factory acceptance testing.

4.3.7. The software and associated CPINs shall be submitted and accepted in government systems before conclusion of factory acceptance testing. CDRL A008/DI-MISC- 81454B

4.3.8. Fault Insertion: As part of the acceptance testing, the contractor shall insert non-destructive faults into the test system for self-test verification. The testing shall include a Fault Candidate List (FCL) for the Test Set and any Test Set Adapters. The FCL shall consist of 25 faults for the console and 10 faults for any test adapters. Each FCL shall describe how they will be inserted and what the anticipated outcome is. Destructive faults shall not be included on the FCL. The FCL will be provided in contractor format.

4.4. Delivery and Verification shall occur at Hill AFB and includes the following:

4.4.1. The contractor shall ship, off-load, install, and test the EHSV/ISA Test Stands at Hill AFB, Utah.

4.4.1.1. The project manager and contract administrator shall be furnished an estimated delivery date for the EHSV/ISA Test Stands at least 30 days prior to actual delivery.

4.4.1.2. The contractor shall instruct the carrier that the EHSV/ISA Test Stands shall be off-loaded only under the supervision of a representative of the contractor. All shipping and packing materials will be removed from the work area and properly disposed of by the contractor.

4.4.1.3. The EHSV/ISA Test Stands shall remain the property of the contractor until all of the contractual obligations are accepted by the government.

4.4.1.4. All costs associated with the manufacture, shipping, installation, testing and preparation of the EHSV/ISA Test Stands for final acceptance at Hill AFB shall be the responsibility of the contractor.

4.4.1.5. The contractor shall be responsible to furnish all special tools, equipment, and labor required to install the EHSV/ISA Test Stands and perform the tests specified in this specification.

4.4.2. The contractor shall provide training as outlined in section 5.1 of this PS before final verification begins.

4.4.3. The contractor shall assist PMEL technicians to ensure system calibration at Hill AFB as outlined in section 2.2.1 of this PS before verifying the EHSV/ISA Test Stands performance at Hill.

4.4.4. A portion of the ATR shall reaffirm the EHSV/ISA Test Stands performance at Hill before a final ATR is submitted and accepted by the government IAW CDRL# A006/DI-

ATTS-80283B.

4.5. Monthly Progress, Status, and Management Report

4.5.1. A status report in contractor format with current contractor program status, including schedule, problems, cost overruns and action items, shall be delivered monthly. CDRL#

A012/DI-MGMT-80277.

4.5.2. Conference agendas shall be delivered, in contractor format, no less than 5 working days prior to scheduled conferences or meetings, CDRL# A013/DI-ADMN-81249A.

4.5.3. Conference Minutes shall be delivered, in contractor format, no more than 5 working days after conference or meeting completion, CDRL# A014/DI-ADMN-81250A.

5. GENERAL INFORMATION

5.1. TRAINING

The contractor shall provide training of 6 hours minimum for two people for Hydraulic, Software, Calibration and Mechanical maintenance. The training shall take place at the Hill AFB unless otherwise accepted by the government.

The contractor shall provide a qualified technician(s) to complete the above training who is knowledgeable in all operations of the EHSV/ISA Test Stands. This technician shall provide training to the operator(s) concerning proper operation of the EHSV/ISA Test Stands components. This orientation shall be provided after satisfactory completion of all inspections, tests, examination and checks required in this Purchase Specification, but before final acceptance of the EHSV/ISA Test Stands

5.2. PARTS AND SUPPORT WARRANTY

The contractor shall provide a manufacturer’s standard one year warranty on all parts, labor, and services for the stand. Warranty is to begin after full contract acceptance and payment.

5.3. SECURITY REQUIREMENTS

5.3.1. ACCESS TO FACILITIES AND PROPERTY: The Government Representative will assist with security and access requirements. To obtain access to Hill AFB, each employee will need to have (or be escorted by a person that has) a base entrance pass.

Contractor shall provide a list to the Government Representative not less than 7 business days prior to the date access to the base is required. The list will be computer generated or typed and organized alphabetically by the visitor’s last name.

The list will include Last name, First name, Middle Initial, and Date of Birth of all guests that will need access. The Pass and Registration Office is open from 0800-1600, Monday thru Thursday and 0800 -1530 on Friday and is located in Bldg #408, 5830 F Ave, Hill AFB. Contractor employees shall be given a gate pass for access to the base and shall be escorted by a government employee at all times behind the flight line (poc coordination, license, registration and proof of insurance are required at the security registration office at the right of the entrance to the south gate).

5.4. PHYSICAL SECURITY

The contractor shall be responsible for safeguarding all government property provided for contractor use. At the close of each work period, government facilities, property, and materials shall be secured.

5.5. HOURS OF OPERATION

The contractor shall perform the services required under this contract during the following hours: Monday through Friday, 0600-1630, with the exception of Federal Holidays. Unless otherwise scheduled with site engineer, work is required to be performed in bldg.. 503 Hill AFB, UT. If a government furlough is in effect, the contractor will work with the contracting office and project manager to determine acceptable working hours.

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 Days, 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.

Altered work schedules may be in effect at the at the government facility. Arrangements will have to be made to escort the contractor at all times or limit the time the contractor can be allowed on base.

5.6. 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 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 Department at 777-1911. The liability for the spill or release of such substances rests solely with the contractor and its agent.

The contractor shall follow manufacturer’s guidelines and professional recommendations for control of humidity, temperature, cleanliness, and materials handling. This includes hazardous materials.

5.7. APPLICABLE SPECIFICATIONS AND STANDARDS

The EHSV/ISA Test Stands described in this request for proposal shall be designed and manufactured IAW this PS and the documents referenced herein. The latest version of each document shall be the one applicable.

TECHNICAL ORDERS: The applicable T.O.s for the items being tested are listed below (The latest revision when contract is awarded shall be used). The Contractor shall provide a current DD Form 2345 and must comply with AFI61-204 (NOTICE TO

ACCOMPANY THE DISSEMINATION OF EXPORT-CONTROLLED TECHNICAL

DATA) and verify the DD Form 2345 through the Joint Certification Program http://www.dlis.dla.mil/JCP/.

U.S DEPARTMENT OF LABOR, OCCUPATIONAL SAFETY AND HEALTH

ADMINISTRATION (OSHA)

OSHA 1994 General Industry, OSHA Safety and Health

Standards (29 CFR 1910)

SAE INTERNATIONAL

AS4059 Aerospace Fluid Power – Cleanliness

Classification for Hydraulic Fluids

NATIONAL ELECTRICAL MANUFACTURERS ASSOCIATION (NEMA)

NEMA ICS 6 Enclosures for Industrial Controls and Systems.

(1993 edition)

NEMA MG 1 Motors and Generators. (1998 edition)

NATIONAL FIRE PROTECTION ASSOCIATION (NFPA)

NFPA 79 Electrical Standard for Industrial Machinery. (2007 edition)

NATIONAL FLUID POWER ASSOCIATION

NFPA T2.24.1 R1 Hydraulic Fluid Power- Systems Standards for Stationary

Industrial Machinery Supplement to ISO 4413:

1998-Hydraulic Fluid Power-General Rules Relating to Systems to be Used in Conjunction with

ISO 4413: 1998

NFPA T2.25.1 R1 Pneumatic Fluid Power - Systems Standard for Industrial

Machinery (NFPA/T2.25.1M-1986) First Edition (1987 edition).

LOCAL INSTRUCTIONS

Hill AFB Instruction 91-302 Control of Hazardous Energy (Lockout/Tagout)

5.8. APPENDICES

A. Acronyms & Abbreviations list B.

C. SAFETY, FIRE PROTECTION AND HEALTH SPECIFICATION

APPENDIX A

ACRONYMS AND ABBREVIATIONS

Acronym/Abbreviations Definition ACPINS Automated Computer Program Identification Numbering

System AF Air Force AFI Air Force Instruction AFB Air Force Base AFMC Air Force Material Command AFMETCAL Air Force Metrology and Calibration AFTD Air Force Technical Data AFTO Air Force Technical Order ATP Acceptance Test Procedure ATR Acceptance Test Report BOM Bill of Materials CAD Computer Aided Design CDRL Contracting Data Requirements Listing CFR Code of Federal Regulations CMRS Calibration Measurement Requirements Summary CO Contracting Officer COR Contracting Officer Representative COTS Commercial off the Shelf CPIN Computer Program Identification Number DBIDS Defense Biometric Identification System DID Data Item Description DoD Department of Defense EHSV Electro Hydraulic Servo Valve FCA Functional Configuration Audit FCL Fault Candidate List FPGA Field Programmable Gate Array GFP Government Furnished Property GR Government Representative GUI Graphical User Interface HAFB Hill Air Force Base IAW In Accordance With ISA Integrated Servo Actuator ISO International Standard Organization NIST National Institute of Standards and Technology NSN National Stock Number

OEM Original Equipment Manufacturer OJT On the Job Training OPSEC Operations Security OTPS Operational Test Program Set PCA Physical Configuration Audit PMEL Precision Measurement Equipment Laboratory PS Purchase Specification PWS Performance-Based Work Statement QCP Quality Control Plan SS Service Summary SVA Servo Valve Analyzer TDP Test Data Package TO Technical Order TPS Test Program Set UID Unique Identification Number UUT Unit Under Test

APPENDIX C

SAFETY, FIRE PROTECTION AND HEALTH SPECIFICATION

INDUSTRIAL SAFETY REQUIREMENTS

OGDEN AIR LOGISTICS COMPLEX

UNITED STATES AIR FORCE

HILL AIR FORCE BASE, UTAH 84056

EHSV/ISA HYDRAULIC TEST STANDS

26 March 2013

Prepared by:

Tim Helms

OO-ALC/SE

(801) 777-9931

Control Number: TH140302

SECTION I - GENERAL REQUIREMENTS

A. Safety Program Requirements.

The contractor will implement a safety program that ensures protection of Government personnel and property. The program will consist of, as a minimum:

1. Mishap reporting, as defined in paragraph B1 below.

3. Routine and recurring surveillance to ensure the safety requirements of this contract are enforced.

4. Identification of segregated work site locations for operations that cannot be co-mingled with general industrial operations and the process for ACO approval of operations and changes at these specific sites.

5. All contractor personnel shall be trained and qualified to perform their duties safely.

6. The contractor shall include a clause in all subcontracts requiring the subcontractors to comply with the safety provisions of this contract, as applicable.

2. Per AFPAM 91-210, para 6.4, due to non-hazardous nature of work, a Safety Plan and corresponding site specific checklist is not required.

B. Mishap Notification

1. The contractor shall notify OO-ALC/SE (801-777-3972), or the Hill AFB Command Post (777-3007) after normal duty hours, and the designated Government Representative (GR), i.e., the ACO, PCO, or DCMA QAR (Quality Assurance Representative) within one (1) hour of all mishaps or incidents at or exceeding $2,000 (material + labor) in damage to DOD property entrusted by this contract, even if the government is wholly or partially reimbursed. This notification requirement shall also include physiological mishaps/incidents.