Purchase_Specification.pdf

Purchase Specification Universal Fuel Control Accessory Test Stands and Process Chiller System 21 April 2015

PURCHASE SPECIFICATION

1. Scope: The purpose of this Purchase Specification is to provide three (3) Universal Fuel

Control Accessory Test Stands, one (1) central workstation, accessory modules, and one (1) closed loop facility chilled water system with all equipment, fixtures, software, manuals, and accessories as described herein. The test equipment shall fulfill all operational testing requirements outlined in the applicable Air Force test instructions provided. The Contractor shall provide all equipment, adaptors, tools, supplies, labor, and management necessary for the entire design, delivery, installation, and training. The Contractor shall also be responsible for removing the four (4) existing Fuel Accessory Test Stands and one (1) Fuel Atomizer Stand and one (1) process chiller system. The Government will conduct periodic design reviews to ensure compliance with the purchase specification and will be the final approving authority for the test system design. Unlimited rights for all technical data generated as part of this effort shall be transferred to the United States Air Force upon final acceptance of the test equipment.

2. Testing Requirements: Each Universal Fuel Control Accessory Test Stand shall be capable of testing the parts listed in Table 2-1 without any external accessory modules. Each Universal Fuel Control Accessory Test Stand shall be capable of testing the parts listed in Table 2-2 and may use external accessory modules. If external accessory modules are provided, the Contractor is only required to provide (1) of each unique module. Measurement devices shall not be included on any external accessory module. Any accessory modules shall only connect/interface with the base Universal Fuel Control Accessory Test Stand. All testing shall be in accordance with the respective test instructions provided with exceptions listed in this purchase specification.

Table 2-1

Part # Description Test Instruction 100190 A-10 Torque Motor Test

A-10FuelControlTestInstruction.pdf 3882544-2 A-10 Pump Run-In & Capacity Test 3882544-2 A-10 Main Fuel Control Test 371688-101 C-130 Fuel Control -101 Test C-130FuelControl-101TestInstruction.pdf 3603100-2/-9 C-130 Fuel Control -2/-9 Test C-130FuelControl-9TestInstruction.pdf 3609150-8 C-130 Fuel Control -8 Test C-130Fuel Control-8TestInstruction.pdf

3882810-1 Ground Power Cart Fuel Control Test C-130FuelControl-1TestInstruction.pdf

367100-2/-3 F-15 Pump Break-In/Capacity Test F-15FuelControlTestInstruction.pdf 367100-2/-3 F-15 Main Fuel Control Test 365626-4 F-15 Fuel Filter Assembly Test F-15FuelFilterTestInstruction.pdf 104030-3 F-16 Pump Test F-16FuelPumpTestInstruction.pdf 160034-400 F-16 Main Fuel Control Test F-16FuelControlTestInstruction.pdf 698395-7 C-5 Pump Run-In/Capacity Test

C-5FuelControlTestInstruction.pdf 698395-7 C-5 High Pressure Relief Valve Test 698395-7 C-5 Main Fuel Control Test

Table 1-2

394284-6 C-5 Fuel Flow Divider Valve Assembly Test C-5FlowDividerTestInstruction.pdf

3883157-2 C-17 Fuel Control, CS (Continued Service) Test (OCM) C-17FuelControlTestInstruction.pdf

3883157-2 C-17 Fuel Control, Over Haul Test

3883154-1 C-17 Differential Pressure Indicator FCU Test

C-17FuelAccessoriesTestInstruction.pdf 3876049-4 C-17 Solenoid Valve FCU Test 3883215-3 C-17 Torque Motor FCU Test

3882482-2 C-17 Pressure Relief Valve FCU Test

3882481-1 C-17 ByPass Valve FCU Test 3883156-2 C-17 Flow Divider Test C-17FlowDividerTestInstruction.pdf 3886167-3 C-17 IGV (Inlet Guide Vane) Test C-17IGVTestInstruction.pdf AV16B1519D E3 Motor Operated Gate Valve Test E-3TestInstruction.pdf 3883664-7D F-22 Green Run Test F-22TestInstruction.pdf 3883664-7D Fuel Control F-22 APU Test 161810-5 KC-135 Pump Test KC-135TestInstruction.pdf 161676-203 Fuel Control KC-135 Test

Part # Description Test Instruction 3830061-2 A10 Fuel Nozzle Assembly A-10AtomizerTestInstruction.pdf

75076-7/-32 C-130 Fuel Atomizer Assembly C-130Atomizer75076TestInstruction.pdf

899981-2 C-130 Fuel Atomizer Assembly C-130Atomizer899981TestInstruction.pdf

3601193-4 C-130 Combustion Chamber Fuel

Atomizer Assembly C-130Atomizer3601193TestInstruction.pdf

364986-10/-12/- 14/-15/-16/-24/-

F-15 Fuel Atomizer Assembly F-15AtomizerTestInstruction.pdf

5901086 (aka 160012-100) F-16 Fuel Manifold Assembly

F-16AtomizerTestInstruction.pdf 169046-2 or 27910-9 F-16 Start Nozzle

899178-11 C-5 Axial Fuel Manifold Assembly-11

C-5AtomizerTestInstruction.pdf

899178-12 C-5 Axial Fuel Manifold Assembly-12

3601520-2 C-5 Axial Nozzle

892405-1 C-5 Tangential Fuel Manifold

Assembly 698347-1 C-5 Tangential Nozzle

172336-100 KC-135 Fuel Manifold Assembly KC-135AtomizerTestInstruction.pdf

160238-400 KC-135 Fuel Start Nozzle (Assembly)

3. Test Equipment Requirements

3.1 General Test Equipment Requirements

3.1.1 The dimensions of each Universal Fuel Control Accessory Test Stand shall not exceed 120” wide by 70” deep by 108” high. The test stands must fit through doors 70” wide by 95” tall.

3.1.2 The Contractor shall provide one (1) kit including all required adaptors, fixtures, fittings, cables, etc. per each part number listed in Table 2-1 and Table 2-2 required for testing, excluding any items listed in Appendix B.

Storage containers shall be supplied to store hookup kits and shall have space for the applicable items listed in Appendix B. Kits shall be numbered and include a laminated inventory list of included components.

3.1.3 Drawings for any adapters or fixtures developed by the contractor shall be included in the drawing package.

3.1.4 All test stand interfaces shall be permanently labeled.

3.1.5 The test stands shall have isolation valves and fittings capable of steady adjustable flow to allow the calibration technician to install a master flow meter in series with the test stand flow meters for the purposes of calibration. The test stands shall be capable of providing enough flow to calibrate the entire range of the test stand flow-meters without the use of an external pump or a unit under test.

3.1.6 Hoses shall only be used where a flexible connection is required (i.e.

connections from test stand to unit under test). The hose pressure rating shall be greater than the system operating pressure. The test stands shall include a set of production drawings for the hoses in the drawing package.

The hoses shall be tagged with the hose number (to match the schematic), rated pressure, date of manufacture, and kit number. Both ends of the hose shall be labeled to easily identify proper connection points.

3.1.7 Each test stand shall be equipped with a minimum 20-gallon calibration fluid reservoir. The required calibration fluid is MIL-PRF-7024C Type II.

The reservoir shall have a low level alarm. The test stand software shall prevent starting a test if a low level condition is detected.

3.1.8 The test stands shall have a duplex 120 Volts Alternating Current (VAC) outlet plug for powering calibration equipment.

3.1.9 The test stand shall have a lockable main power switch, control power switch, and emergency stop button.

3.1.9.1 The control power switch shall provide power to the computer, data acquisition, measurement instrumentation, lights, and external 120 VAC calibration equipment. The control power switch shall be independent of the main power switch in order to provide program access without powering the rest of the stand.

3.1.9.2 The main power switch shall provide power to everything not powered through the control power switch.

3.1.9.3 The emergency stop button shall immediately establish a safe condition for the test operator, test stand, and for the unit under test, but not disable items powered by the control power switch.

3.1.10 Test stand controls shall default to the safest condition in the event of an emergency stop or power outage.

3.1.11 Plumbing shall be clearly labeled and marked with flow arrows to match drawings.

3.1.12 Calibration ports and access points shall be labeled to match drawings/manuals.

3.1.13 All wiring shall be labeled on both ends to match the electrical schematic.

Multi-stranded wire shall be ferrule ended.

3.1.14 Each test stand shall have a label plate installed showing the test stand nomenclature, part number, National Stock Number (NSN) (provided by Air Force), serial number, company name & address, company cage code (if applicable), power requirements (volts/amps/phase), the contract number, and the date of the contract award (month and year).

3.1.15 The manufacturer shall furnish corrosion-resistant caution plates secured to the system in a visible location with all important cautions to be observed by the operator. The plate shall be permanently marked. If more than one plate is required to alert the operator and/or maintenance personnel in one or more areas, caution plates shall be furnished and installed identifying potential hazards to human safety such as high voltage, pressure, and temperature.

3.1.16 Item Unique Identification (IUID) Requirements: Universal Fuel Control

Accessory Test Stands shall contain Unique Identification (UID) marking IAW MIL-STD-130M. 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 shall maintain the IUID tags (markings) IAW MIL-STD-130N, dated 17 December 2007, contract clauses, DFARS (252.211-7003, 252.211-7007), and the Contractor's IUID Marking Plan. The Contractor shall report using the IUID registry, located on the internet at http://www.acq.osd.mil/dpap/pdi/uid/data_submission_information.html.

The Contractor is responsible for identifying new candidate parts for inclusion in the IUID program.

3.1.17 Detachable cables shall be identified with a part number to match the electrical schematic. Both ends of the cable shall be labeled to easily identify proper connection points. Production drawings of the cables shall be included in the drawing package.

3.2 Unique Requirements for Table 2-1 Tests

3.2.1 Each test stand shall have a shatter resistant clear enclosure to protect the test operator from rotating components and high pressure systems while testing. Any non-transparent trim shall not exceed 2” width in order to maximize operator view of the unit under test.

3.2.2 The enclosure shall have a minimum light level of 93 lumen per square foot

(1,000 lux) to allow proper visual inspection.

3.2.3 The operator shall be able to open the enclosure in order to make adjustments on the unit under test during testing operations. The open door shall not interfere with the operator’s ability to access the test stand computer or emergency stop system.

3.2.4 The operator shall not have to turn their head more than 45° from the test stand monitors in order to view the unit under test from a seated position.

3.2.5 Each test stand shall have a stainless steel funneled or sloped drip pan to collect fluid from the units under test and discharge it into the facility calibration fluid gravity drain. Each drip pan shall have screen or filter covering the drain to collect debris.

3.2.6 Where the option to use a back pressure curve instead of an atomizer simulator is provided in the Test Instructions, the contractor shall use the back pressure curve instead of the atomizer simulator. Please note extra back pressure simulating Compressor Discharge Pressure (CDP) is often added in addition to the back pressure curve at intermediate test steps.

3.3 Unique Requirements for Table 2-2 Tests

3.3.1 The Contractor may provide up to three (3) detachable accessory modules to accomplish the testing requirements of Table 2-2. If detachable accessory modules are not provided, each of the three test stands must have built-in capability of testing the items listed in Table 2-2.

3.3.1.1 If provided, each accessory module shall have four (4) swivel casters with a minimum wheel thickness of 1.25”. At least two (2) of the casters shall have wheel locks.

3.3.1.2 If provided, the maximum footprint of each accessory module shall not exceed 36” wide by 36” deep by 84” tall.

3.3.2 Single element atomizers and nozzles shall not be enclosed. Spray mist shall be collected via a backdraft system. The backdraft system shall safely collect atomized fluid so that the exposure rate 12 inches from the spray does not exceed 50 parts per million.

3.3.3 Single element atomizer and nozzle spray patterns shall be illuminated with an adjustable fiber optic light with variable intensity that can protrude into the center of the spay cone.

3.3.4 The test stand shall have adequate dampening to maintain an inlet pressure within ±1 psi of the set point while at steady state condition.

3.3.5 The line supplying fluid inlet pressure to the unit under test shall have a method for purging the hose and unit under test with shop air upon completion of test.

3.3.6 The Contractor shall provide a repeatable means for taking spray pattern angular measurements when required by the applicable test instruction. Any measurement system shall be approved by AFMETCAL.

3.4 Central Work Station

3.4.1 Each of the test stands shall have its own computer that is networked to a central work station. The central work station shall be used for all software development and program storage. Upon startup, each test stand shall download the latest iteration of test program sets (unit under test files) from the central workstation. If the central work station is offline, the test stand shall use the last acquired test software.

3.4.2 The central work station computer shall be able to access the hard drives of each test stand to transfer files.

3.4.3 The central workstation computer shall have a mirrored hard drive for backup.

3.4.4 The central workstation shall include a color laser jet printer, HP CP4025dn or equal to print test results. Test results should be able to be printed from each of the stand computers and the central workstation computer.

3.4.5 The central workstation computer, monitors, and printer shall be mounted in a stand-alone structure that does not exceed 40” wide by 30” deep by 84” tall.

3.5 Ergonomics

3.5.1 The test operator shall be able to view Table 2-1 tested assets and computer monitors at eye level from a seated position. The contractor shall provide four (4) non-permeable (non-cloth) adjustable roller chairs for each of the three (3) test accessory stands and one (1) central work station.

3.5.2 The test operator shall be able to view Table 2-2 tested assets from a standing position.

3.5.3 The design of the test stand should minimize strain on the test operator while installing and removing test assets.

3.6 Facility:

The following services are available in the facility. It shall be the responsibility of the Contractor to route any new piping, cables, conduit, etc. required from the existing facility connection points.

3.6.1 Electrical—480VAC, 3 Phase, 60 Hertz (Hz), 60 Ampere (Amp) Breakers for each test stand

3.6.2 Shop Air—100 psig, ½” tubing for each test stand

3.6.3 Air—300 psig, ½” pipe

3.6.4 Chilled Water— Existing indoor piping may be reused

3.6.5 Calibration Fluid (MIL-PRF-7024 C Type II Fluid)—1” pipe NPT, 1” drain

3.6.6 Ventilation—6” blower tubing to outside air (blower not supplied by Government)

3.7 Computers and Data Management

3.7.1 Information Assurance

3.7.1.1 The contractor shall maintain appropriate IA management and incorporate tools into system software that provide DoD-approved malware protection/prevention and tracking IAW AFI 33-138.

3.7.1.2 The contractor shall maintain a robust information assurance program that is detailed in a written Contractor’s Information Assurance Plan. The contractor shall perform a virus scan prior to all shipments addressing most current virus scanning software. A signed and dated certification from the virus scanning official that this action has been taken will be shipped with the asset. CDRL

A014/DI-MGMT-81842

3.7.1.3 The contracting officer shall be notified upon discovery of any virus or malware associated with the equipment being procured. Be aware that an IA reporting/tracking process is mandatory for subject procurement. Ensure the following:

3.7.1.3.1 Malicious Logic: In accordance with AFI 33-138, the contractor and 309 CMXG/EN shall promptly report any incident meeting the requirements as defined in paragraph

5.4, Incidents Defined, to the USAF and cooperate with USAF investigations. Affected assets shall be immediately quarantined. The Contractor shall notify the Government by telephone within 24 hours upon verification of virus. The contractor shall not perform any remedial action of affected USAF equipment without direction from Procuring Contracting Officer (PCO).

3.7.1.3.2 Malicious Logic Protection: The contractor shall ensure incoming and outgoing non-volatile storage devices, via utilization of human and technological preventative measures such as good cyber hygiene and virus scanning, are free of malicious logic. (AFMAN 33-282, 27 March 2012, pp 6.5).

3.7.1.3.3 Removable Media: The contractor shall ensure all

removable media devices (hard drives, thumb drives, CDs, etc.) are free of malicious logic before and after use (AFMAN 33-282, pp 6.5.6).

3.7.2 The central workstation and test stand computers shall have a minimum of dual-core processors, 64-bit Windows 7 (or later) as the operating system, and have a minimum of eight (8) GB RAM and one (1) TB hard drive. The computer shall have a DVD R/W drive, and at least four (4) USB ports (minimum two (2) in front). Each computer shall be equipped with two (2) minimum 19” flat screen monitors.

3.8 Software: The software package for the test stands shall be built with NI

LabVIEW and shall be capable of executing the operational tests outlined in the applicable test instructions along with the additional requirements and modifications listed below. The Contractor shall deliver all software used in, on, or in support of the Test Stands including data, documentation, and licenses. The Contractor 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 that were generated as a result of this contract. The source code shall include a text or document file with instructions describing the process of recreating the executable object files. CDRL A002/DI-

IPSC-81488

3.8.1 The Contractor shall provide self-test software sufficient to ensure correct operation and identification/isolation of faulty components of the test set.

3.8.2 A Computer Program Identification Number (CPIN) shall be embedded into the software source code to be displayed on the login screen and test reports.

The Government Representative will provide the CPIN number to the Contractor prior to the Critical Design Review. Prior to installation at Hill AFB, compact discs containing the software source code and executable installation discs shall be provided to the Government. The installation discs shall contain any needed drivers for proper software execution. The Contractor shall deliver a mirror image on the Test Station Operation Software. The mirror image shall include all software except for UUT Test Program Sets (TPS). The Test Station software shall include calibration software, Self-Test, (including both executable and source code), and Operating software shall be delivered on individual CD-ROMs and assigned separate Computer Program Identification Numbers (CPINs). CDRL A001/DI-MISC-81454B/T and A002/DI-IPSC-81488

3.8.3 The test program shall have three (3) levels of password protected access:

Administrator, Operator, and Calibration Technician. Each administrator, operator and calibration technician shall have their own user account. Only an administrator shall have rights to create and delete user accounts and enter any diagnostic menus. Only the administrators shall have rights to modify test limits, test durations, and alarm/alert set points. The operators shall only have rights to execute the tests. The calibration technician shall have access to the calibration and alignment functions but shall not be able to execute a test.

3.8.4 Only an administrator shall have access to the central work station computer. The central work station computer shall be used for managing user accounts.

3.8.5 During calibration, the software shall calculate based on parameter accuracy requirements whether or not an imputed calibration signal is within tolerance but shall give the calibration technician the ability to make an alignment adjustment regardless of the “as found” condition. The software shall be capable of multi-point alignment. The calibration technician shall be able to view both the raw and scaled values.

3.8.6 The main test screen shall contain all information required for the operator to monitor test parameters and test stand alarm conditions. The test program shall identify to the operator if a measured signal falls outside of test instruction requirements by changing the displayed reading color. The virtual gage names on the screen shall include the test instruction name as well as the gage label on the test stand.

3.8.7 Prior to running a test, the software shall provide step by step instructions to the operator to verify that the unit under test is properly installed/connected to the test stand.

3.8.8 The software shall have the following features:

3.8.8.1 Integrated test builder utility for the development of test program sets for each component to be tested.

3.8.8.2 Requires the following operator inputs to run: operator name, operator password, part number of unit being tested (pick from list), and serial number.

3.8.8.3 Capable of displaying status for all measurements, alarms/alerts, safety interlocks (i.e. e-stop status), communication status, etc. that would interfere with proper testing or that would create an unsafe condition. It shall display both active alarms/alerts and latched alarms and have a button for resetting latched alarms.

3.8.8.4 Ability to pre-view test reports while still actively running tests.

3.8.8.5 Access to help documents during testing.

3.8.8.6 Generates a non-editable (such as .pdf or .html) test report for each serial number tested. Final test reports shall include the CPIN number and revision, the date of last calibration, the start and stop timestamps of each test sequence, the operator’s name, the part number, the serial number, and all measurements taken during the test that correspond with test instruction requirements/limits.

3.8.8.7 The test program shall generate a non-editable (such as .html or .pdf) printable report file each time the test stand calibration is certified.

The calibration report shall include “as found” and “as left” calibration data, including gain and offset (alignment) numbers, the calibration date, and name of the calibration technician.

3.8.8.8 Integrated control loop proportional-integral-derivative (PID) controller tuning tools adjustable while running a test (available with an administrator password only). PID tuning shall be test specific and not channel specific.

3.8.8.9 Ability to integrate special calculations/graphing.

3.8.8.10 Test screen shall display minimum and maximum measurements detected during the test sequence duration. The report shall identify measurements that do not meet test instruction requirements. The test report shall also show the final disposition (pass/fail) entered by the test operator.

3.8.8.11 Operator shall be able to print the test report directly from the main test program. Final test reports shall be automatically saved to the hard-drive once all required test parameters have been obtained.

The file path shall include the part number, serial number, and date tested.

3.8.9 The software shall support the following modes of operation:

3.8.9.1 Manual: Whereby the required test conditions are achieved manually by adjusting software control values and the operator commands the computer to record the data.

3.8.9.2 Semi-Automatic: Whereby the operator steps through each test point and the test stand automatically adjusts the computer controlled parameters to achieve the desired conditions. The operator commands the computer to record the data.

3.8.9.3 Automatic: Whereby the computer automatically advances through the test points, sets the conditions, and records the data. If the data is out of limits, the operator is prompted to take action.

4. Documentation: The Contractor shall provide the following documentation related to the test equipment:

4.1 Operation and Maintenance Manual: See attached TMCR for Technical Manual requirements. CDRL A003/TM-86-01N and A009/TM-86-01N

4.2 Drawing Package: The Contractor shall develop, produce, maintain and deliver a

Technical Data Package (TDP) that accurately depicts the final product. The final TDP shall represent the approved, tested, and accepted configuration of the defined delivered items. 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 using Government funding as a result of this contract shall be considered a part of the TDP and shall be delivered to the Government with unlimited rights. The TDP shall be delivered in accordance with Air Force Product Data Specification drawing 9579776 Revision L (Cage 98752). See attached CDRL for drawing requirements. Product Drawings and Associated Lists CDRL A004/DI-SESS-8100E/T

4.2.1 The Contractor shall levy on sub-contractors the same requirements for

Technical Data Packages as are levied on them by this contract. This requirement shall apply at all tiers of sub-contractor levels associated with this contract.

4.2.2 The Contractor shall update and maintain engineering data for the items designed, developed, modified, produced, and funded by this contract for the duration of the contract and shall incorporate all changes in accordance with the following:

4.2.2.1 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 for a change involving safety, which shall be incorporated immediately.

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

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

4.2.2.4 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.

4.3 Calibration Quality Standard and Traceability – With Calibration

Measurement Requirement Summary (CMRS): The Contractor shall ensure the developed system is capable of being calibrated and its calibration is verified in accordance with Air Force Metrology and Calibration (AFMETCAL) requirements.

Calibration and measurement traceability shall be identified and documented in accordance with MIL-STD-1839D. MIL-HDBK-1839C shall 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 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 paragraphs

2.1 and 2.2 of this purchase specification. The Contractor shall deliver the Calibration Measurement Requirements Summary (CMRS) in accordance with DID DI-QCIC-80278A and the Contract Data Requirements List (DD Form 1423).

CDRL A005/DI-QCIC-80278B and A006 DI-QCIC-80798B

4.4 Acceptance Test Plan and Report: The Contractor shall provide an Acceptance Test Plan (ATP) that includes an Acceptance Test Report (ATR) provided in the Contractor’s format. This plan shall outline procedures for providing objective evidence that the new test equipment meets each requirement outlined in this purchase specification. This plan shall be provided to the Government representative in advance of the scheduled tests to allow opportunity for review and feedback. The Acceptance Test Plan shall contain the following critical events:

CDRL A007/DI-ATTS-80282B and A008/DI-ATTS-80283B

4.4.1 Functional Configuration Audit (FCA): The Functional Configuration

Audit shall be performed to verify all developed or modified software for the test system. The Functional Configuration Audit shall be performed jointly by the Government and the Contractor (at the Contractor’s facility) with the Government chairing the audit. The Contractor shall document the results of the Functional Configuration Audit and shall correct all audit discrepancies documented in the Acceptance Test Report.

4.4.2 Physical Configuration Audit (PCA): The Government and the Contractor shall conduct a Physical Configuration Audit jointly (at the Contractor’s facility) with the Government chairing the audit. The Physical Configuration Audit shall verify the drawings reflect the “as built” configuration of all developed or modified portions of the hardware. A product baseline shall be established upon completion of and Government acceptance of the Physical Configuration Audit. A complete preliminary copy of the drawing package shall be delivered 15 days prior to the Physical Configuration Audit.

4.4.3 Fault Insertion: As part of acceptance testing, the Contractor shall insert non-destructive faults into the test system for self-test verification (at the Contractor’s facility. The testing shall include a Fault Candidate List (FCL) for the test set and any test set adapters. The Fault Candidate List shall consist of 25 faults for the console and any test adapters. Each Fault Candidate List shall describe how they will be inserted and what the anticipated outcome is. Destructive faults shall not be included in the Fault Candidate List.

4.4.4 Validation/Verification: The validation/verification test shall include verification of proper installation and power-up (at Hill AFB), official calibration conducted by Air Force technicians, and the execution of a full Air Force operational tests of serviceable unit under tests (listed in Tables 2- 1 & 2-2) provided by Hill AFB.

5. Process Chiller System Requirements:

5.1 A closed loop process chiller system shall be supplied and installed by the

Contractor as a turn-key system including the startup. Existing chiller and exterior plumbing shall be palletized and moved to a location not more than 50 feet away from Building 252 at Hill AFB.

5.2 Existing chiller piping internal to Building 252 may be reused.

5.3 The new system shall be air cooled and use a propylene glycol/water mixture as the coolant. Corrosion inhibitors shall be added to the coolant to prevent corrosion of the plumbing.

5.4 The system shall be sized to support 150% of the projected maximum possible load from all three test stands running simultaneously.

5.5 The Contractor may reuse the existing concrete pad for the new chiller. If the new chiller does not fit on the existing isolation pad, the Contractor shall be responsible for providing a new concrete pad. The approximate pad size available is 42” x 68”.

5.6 A coolant tank and pump shall be included. The coolant tank shall be at least a 75 gallon, insulated coolant reservoir made of corrosion resistant material mounted on a structural steel base. The pump shall circulate coolant through the chiller and the test stands. The coolant shall be supplied and installed by the Contractor. The Contractor shall provide a Material Safety Data Sheet (MSDS) for any chemical used in the cooling system. CDRL A010/FED-STD-313D.

5.7 The cooling system shall operate in ambient temperatures of -10⁰F to 105⁰F.

5.8 A programmable logic controller (PLC) with an enclosure shall be provided and installed. The PLC shall control the system cooling water temperature. A remote monitoring panel shall be located in the same room as the test stands.

5.9 All three (3) of the test stands shall be connected to the cooling system.

Additionally the cooling system shall have connection points for two (2) additional test stands. In order to minimize production down time, the Contractor shall temporarily connect any remaining existing test stands to the new chilled water system until all three new test stands are ready to be installed. All plumbing and hardware required to connect the test stands to the system shall be provided and installed by the Contractor.

5.9.1 Each test stand inlet and outlet connection shall have a minimum 2 foot section of hose. The hose shall have a pressure rating higher than the expected system pressure.

5.9.2 Each test stand inlet and outlet connection shall have isolation valves and temperature gages.

5.9.3 Each test stand outlet connection shall have a flow-meter and balancing valve.

5.10 All system piping shall be insulated.

5.11 The coolant distribution system shall have a relief valve to maintain system operating pressure. The relief/relieving valve shall be sized large enough to maintain acceptable system pressure when all five (5) loads (new and existing test stands) are isolated.

5.12 The Contractor shall provide a schematic of the process chiller system that includes specifications of the chiller, pump(s), piping sizes, and valve types. The schematic shall be approved through a design review process prior to installation. The schematic shall identify the maximum expected load of each connected piece of equipment.

6. Government Furnished Equipment:

6.1 The Government will furnish the assets listed in Appendix B for the purpose of test stand development and Factory Acceptance Testing. These parts will be delivered to the Contractor within four (4) months after the Post Award Conference.

6.2 The Contractor shall protect all Government-Furnished Equipment by keeping it in a secured facility when not in use.

6.3 The Contractor shall report any suspected damage of Government-Furnished Equipment to the Government Representative within 24 hours.

7. Installation: The Contractor shall provide all services required to install the test stands, central workstation, and closed loop chilling system in Building 252 at Hill AFB.

7.1 No facility structural modifications are authorized.

7.2 The Contractor shall disassemble, remove and palletize the old test stand components that will be replaced. The palletized components shall be placed in a designated location outside building 252 (no more than 50 feet away). The Government will drain all chemicals before removal, but the Contractor can expect some residue.

7.3 All costs associated with the shipping, installation, testing, and preparation of the equipment for final acceptance at Hill AFB shall be the responsibility of the Contractor. The Contractor shall have a representative on site to receive delivery of shipment to Hill.

7.4 The Contractor shall be responsible to furnish all tools and equipment required to install the upgrades and perform the tests specified in this specification.

The Government shall furnish no tools or equipment.

8. Spare Parts

8.1 The following spare parts shall be included:

• Two (2) of each type of fuse

• Two (2) of each type of temperature probe

• Two (2) of each type of replaceable filter

• One (1) of each detachable cable

9. Timeline:

9.1 Meetings and Scheduling. The Contractor shall schedule and organize the following events. The final delivery date shall not exceed 18 months.

9.2 Universal Fuel Control Accessory Test Stand Timeline:

Table 9-1 Event/Milestone Timeline Location

Post Award Conference <1 month of contract award

Hill AFB Building 252

Engineering Guidance Conference

<60 days from contract award Teleconference

Preliminary Design Review To be proposed by the contractor Teleconference

In-Process Review of the Technical Data Package

To be proposed by the contractor

Contractor’s Facility

Critical Design Review To be proposed by the contractor Teleconference

Configuration Audits and Factory Acceptance Test

<10 months of contract award

Contractor’s Facility

Installation of first test stand and Central Workstation

<4 weeks from Factory Acceptance Test

Hill AFB Building 252

Validation/Verification of first Test Stand and Central Workstation

Immediately following installation

Hill AFB Building 252

Reliability testing of first Test Stand and Central Workstation

1 month after validation/verification

Hill AFB Building 252

Installation of second and third Test Stands

<3 months after completion of reliability of first Test Stand

Hill AFB Building 252

Validation/Verification of second and third Test Stands

Immediately following installation

Hill AFB Building 252

Reliability Testing of second and third Test Stands

1 months after validation/verification

Hill AFB Building 252

Final Acceptance Immediately following Reliability Testing

E-mail notification

Release of Data Rights and Delivery of Warranty

<1 week from final acceptance

9.2.1 Post Award Conference. The purpose of this conference will be to review the requirements of this Purchase Specification and the applicable test instructions, tour the facility where the test stands will be installed, watch the operator conduct testing on the existing test stand, and provide the opportunity for the Contractor to ask questions. The duration of this conference is not expected to exceed three (3) days, but may be scheduled longer if requested in advance by the Contractor. The Contractor’s lead design engineer of the test stands shall be present for this event. At the conclusion of the conference, both the Contractor and Hill AFB should have a clear understanding of how the project is to proceed. The contractor shall prepare an agenda and record the minutes of the Post Award Conference.

(CDRL A011 and CDRL A012)

9.2.2 Engineering Data Guidance Conference: The contractor shall support and cochair a Guidance Conference with AFLCMC/LZPEM 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. (CDRL A011 and CDRL A012) The contractor shall address, discuss, and provide status on the following:

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

9.2.2.2 Technical Data Package review requirements and schedules.

9.2.2.3 Technical Data Package delivery requirements and schedules.

9.2.2.4 Contractor’s drafting practices/procedures/drawing formats/CAD programs.

9.2.2.5 The Contractor’s quality assurance procedures relating to the technical data package documents, including quality control of subcontractor and vendor data.

9.2.2.6 The role of subcontractors and vendors who may deliver technical data package documents under this contract.

9.2.2.7 The Contractor’s configuration management system, including methods for releasing documents, approving documents, and incorporating changes into documents.

9.2.2.8 Digital technical data package deliverables.

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

9.2.3 Preliminary Design Review. The purpose of the preliminary design review is to allow Hill AFB personnel to review the preliminary mechanical and electrical test stand diagrams, preliminary software flow charts (and any other documentation provided for review by the Contractor) and provide early feedback to the Contractor. Any questions or feedback shall be resolved via teleconference or e-mail. The Contractor shall provide preliminary copies of the system diagrams, a proposed list of major components, and a brief description of the proposed software methodology.

This information shall be e-mailed (or mailed on CD ROM) to the Government representative one week in advance of the conference call. File Transfer Protocol (FTP) is not permitted unless there is an existing Air Force approved site.

9.2.4 In-Process Review of the Technical Data Package Conference. The contractor shall host, support, and co-chair an in-process review of the engineering drawings and associated lists and other documentation to be included in the TDP. The review shall be conducted only after the contractor’s quality assurance personnel have completely reviewed the data and determined that the data are of sufficient quality that Government time will be effectively utilized during the review. The review may be scheduled when the data has reached at a minimum the 50% completion point and may be held in conjunction with other design review events. The Contractor shall notify AFLCMC/LZPEM a minimum of 30 days prior to the anticipated date of completion point. The review 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 review effectively. All available subcontractor/vendor data shall be made available for review. The contractor shall prepare an agenda and record the minutes of the conference.

(CDRL A011 and CDRL A012)

9.2.5 Critical Design Review. The purpose of the critical design review is to perform a thorough review of technical manual and drawing package in preparation for Government final approval. The Contractor shall also provide the test plan for the Factory Acceptance Test. Any questions or feedback shall be resolved via teleconference or e-mail. This information shall be e-mailed (or mailed on CD ROM) to the Government representative one week in advance of the conference call. (CDRL A007)

9.2.6 Configuration Audits and Factory Acceptance Test. Prior to installation at

Hill AFB, the Contractor shall host Government personnel at their facility in order to demonstrate testing capability using Factory Acceptance Test Plan.

The Contractor shall document the results of the test on the plan report. Any deficiencies identified at the factory test shall be corrected prior to shipping the test stand to Hill AFB.

9.2.7 Installation of the first test stand. Upon notice to proceed by the Government, the Contractor shall remove one of the existing test stands and install one Universal Fuel Control Accessory Test Stand. Additionally, the Contractor shall install the Central Workstation and Process Chiller System.

9.2.8 Validation/Verification Testing of the first Universal Fuel Control

Accessory Test Stand, Central Workstation, and Process Chiller System.

The Contractor shall execute the Test Plan for Validation/Verification Testing and shall document the results. This testing shall include calibration certification by Hill AFB calibration technicians. Any deficiencies identified during this test shall be corrected prior to starting the Reliability Testing. (CDRL A007 and CDRL A008)

9.2.9 Reliability Testing of the first Universal Fuel Control Accessory Test Stand, Central Workstation, and Process Chiller System. After successful implementation and commissioning, Hill AFB personnel shall verify test stand reliability by testing for a one month period. Any failures of the test system during this period shall be repaired at the expense of the Contractor and shall restart the reliability testing period.

9.2.10 Installation of the second and third Universal Fuel Control Accessory Test

Stands. Upon completion of Reliability Testing of the installed stand, the Contractor shall remove the remaining existing test stands and install the new test stands.

9.2.11 Validation/Verification Testing of the second and third Universal Fuel

Control Accessory Test Stands. The Contractor shall execute the Test Plan for Validation/Verification Testing and shall document the results. This testing shall include calibration certification by Hill AFB calibration technicians. Any deficiencies identified during this test shall be corrected prior to starting the Reliability Testing.

9.2.12 Reliability Testing of the second and third Universal Fuel Control

Accessory Test Stands. After successful implementation and commissioning, Hill AFB personnel shall verify test stand reliability by testing for a one month period. Any failures of the test system during this period shall be repaired at the expense of the Contractor and shall restart the reliability testing period.

9.2.13 Final Acceptance. Upon successful completion of the reliability testing, the

Government shall sign for final acceptance of delivered stands.

9.2.14 Release of Data Rights and Delivery of Warranty. Within one week of Final Acceptance, the Contractor shall provide to the Government, an official letter providing unlimited data rights to all documentation generated as part of this contract. The Contractor shall also deliver the written warranty.

Warranty period shall start with the final acceptance of all the Universal Fuel Control Accessory Test Stands and shall not be affected by the acceptance tests.

10. Warranty

10.1 The test stands and cooling system shall come with a written industry standard warranty starting at the date of final acceptance.

10.2 During this warranty period, the Contractor shall be responsible for the replacement of any defective parts, systems or software, the failure of which is due to faulty materials, workmanship, design or inadequate service life. The Contractor shall be responsible for any shipping costs or travel costs during the warranty period.

Components normally consumed during this period, e.g. filters, shall be excluded from this requirement.

10.3 The warranty certificate shall contain at a minimum, the following information:

10.3.1 Part numbers/serial numbers of the new test systems.

10.3.2 Contract number

10.3.3 Warranty start and end date

10.3.4 The Contractor’s contact information

10.3.5 Explanation of warranty coverage

11. TECHNICAL DATA DELIVERABLES

The contractor shall provide a technical data package as stated in Table 11-1 and further explained below:

Table 11-1 Deliverable CDRL# DID Reference Automated Computer Program Identification Number (ACPIN) Data and Control Record

A001 DI-MISC-81454B/T 3.8.2

Computer Software Product A002 DI-IPSC-81488 3.8 and 3.8.2 Technical Manuals A003 TM-86-01N 4.1 Product Drawings and Associated Lists

A004 DI-SESS-81000E/T 3.1.3, 4.2

Calibration Measurements and Requirements Summary

(CMRS)

A005

DI-QCIC-80278B

4.3

Calibration Certification A006 DI-QCIC-80798B 4.3 Operational Test Program Set (OTPS) Acceptance Test Procedures (ATPs)

A007 DI-ATTS-80282B 4.4

Operational Test Program Set (OTPS) Acceptance Test Report (ATR)

A008 DI-ATTS-80283B 4.4

Technical Manuals A009 TM-86-01N 4.1

Material Safety Data Sheets

(MSDS) A010 FED-STD-313D 5.6

Conference Agenda A011 DI-ADMN-81249A 9.1, 9.2, 9.4

Conference Minutes A012 DI-ADMN-81250A 9.1, 9.2, 9.4

Contractor’s Standard Operating Procedure A013 DI-MGMT-81580

Appendix C para. A3, A4, C, Section II

Certificate A014 DI-MGMT-81842 3.7.1.2

12. 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.

13. Training:

13.1 The Contractor shall provide up to 40 hours of training for up to two (2) Air Force process engineers on the software provided. This training shall take place at the Contractor’s facility prior to the Factory Acceptance Test. The training shall cover the creation and modification of unit under test specific test programs sets, troubleshooting techniques, and general operation.

13.2 The Contractor shall provide 40 hours of training for up to three (3) Air Force equipment operators on test execution at Hill AFB. Training shall commence immediately following the Validation/Verification testing.

13.3 The Contractor shall provide up to eight (8) hours of training for up to three (3) Air

Force calibration technicians during the Factory Acceptance Test at the Contractor’s facility and up to an additional four (4) hours of training prior to Validation/Verification testing at Hill AFB.

13.4 The Contractor shall provide up to two (2) hours of training for up to three (3) Air Force maintenance workers. This training shall take place at Hill AFB prior to Validation/Verification testing.

14. Electrical

14.1 General:

14.1.1 The laws and codes in force at HAFB require third party labeling by a nationally recognized testing laboratory, accredited by the state, prior to final acceptance. The Contractor shall be responsible for ensuring electrical compliance.

14.1.2 All electrical hardware,…