PURCHASE_SPECIFICATION.pdf

PURCHASE SPECIFICATION FOR

NEW PYLON AND ROTATIONAL CONTROL SYSTEM FOR

MARK V RADAR

13 July 2015

1. SCOPE.

This specification describes the minimum requirements for the design, fabrication, installation, and verification testing of a Low Radar Cross Section (RCS) Pylon with Azymuth/Elevation (Az/El) Positioner for the existing Mark IV Radar system. Obtain a new Digital Rotational Control System consisting of a RCS Pylon and Az/EL Positioner and replacing the current aging Analog Rotational Control System, which is located in Building 1424 at Hill Air Force Base (HAFB), Utah. This specification includes the requirement for technical manuals and personnel training for the operation and maintenance of the new Rotational Control System testing equipment and software.

2. APPLICABLE DOCUMENTS.

2.1. Government Documents.

2.1.1. Specifications and Standards. The following specifications and standards form a part of this purchase description to the extent specified herein.

2.1.1.1. SPECIFICATIONS – MILITARY

2.1.1.1.1. ASME Y14.24 Engineering Drawing Practices, 05 April, 2013

2.1.1.1.2. MIL-STD-130 Identification Marking of U.S. Military Property, 16 November, 2012

2.1.1.1.3. MIL-DTL-15024F Plates, Tags, and Bands for Identification of

Equipment, 28 Nov 97

2.1.1.1.4. MIL-P-15024/5 Plates, Identification, 18 April, 2014

2.1.1.2. STANDARDS – FEDERAL

2.1.1.3. FED-STD-H28 Screw Thread Standards for Federal Service, 10

Sep 01

2.1.2. Other Government Documents and Publications. The following other Government documents and publications form a part of this purchase description to the extent specified herein.

2.1.2.1. U.S. DEPARTMENT OF LABOR

2.1.2.1.1. 29 CFR 1910 Occupational Safety and Health Standard

(OSHA) 1990

(Application for copies should be addressed to the Superintendent of Documents, Government Printing Office, Washington, DC 20402).

2.1.2.2. Other Publications. The following documents form a part of this purchase description to the extent specified herein. American National Standards Institute (ANSI) National Fire Protection Association (NFPA)

2.1.2.2.1. ANSI/NFPA–70 National Electric Code, 17 November, 2014

2.1.2.2.2. NFPA–79 Electrical Standards for Industrial Machinery, 19

May, 2014 (Application for copies should be addressed to the NFPA, Batterymarch Park, Quincy, MA 02269).

3. SECURITY.

Contractor shall submit the First, Middle and Last Name, Social Security Number, Driver License Number and State of issue for each employee entering HAFB and building 1424 through 309 Commodities GSSO, 5816 D Avenue (Building 507) Hill AFB, UT 84056, (801) 586-1704 a minimum of five (5) working days in advance of the visit Employees will be checked using Joint Personnel Adjudication System (JPAS). Entry to the facility is controlled and all visitors must be escorted while in the facility. Personally owned cameras, recording devices, personally owned computers/software and cell phones are prohibited. All personnel entering and exiting the facility are subject to random entry/exit inspections. Employees driving on HAFB shall submit to Pass and Registration (South or West Gate Visitors Center), driver’s license, vehicle registration, and proof of insurance.

4. REQUIREMENTS

4.1. New RCS Position Control System Parameters. The Low RCS Pylon and Az/EL Positioner shall meet or exceed all performance requirements specified herein.

4.2. General Overview. HAFB is purchasing a Low RCS Pylon and Az/El Positioner control system (hereafter called the pylon). The pylon system shall be designed and fabricated at contractor’s facilities and installed and integrated into the existing Indoor RCS Range located at HAFB. This document provides the requirements under which the Pylon shall be procured and installed.

4.2.1. Equipment Specifications.

4.2.1.1. Capacity: 3,000 pounds (lbs.)

4.2.1.2. Horizontal center of gravity (CG) offset (extending along EL axis): 1.0 inches maximum (max.) for 3,000 lbs. target.

4.2.1.3. Vertical CG offset (extending along Az axis): 9 inches above lower flange max.

for 3,000 pound target.

4.2.1.4. Base: flat steel plate to be bolted to solid surface

4.2.1.5. Height: 114 inches high (from floor to top of target mounting flange).

4.2.1.6. Az travel: no limit – continuous rotation.

4.2.1.7. Az velocity: 0 to 2 degrees (deg.)/second (sec) (3 minute full rotation).

4.2.1.8. Elevation travel: 26 degrees (-6.0 to 20.0 deg.).

4.2.1.9. Elevation velocity: 0 to 1 deg. /sec. (30 second full travel).

4.2.1.10. Manual Pendant control at Pylon, plus manual control in the radar control room.

4.2.1.11. Control system shall be a standalone, standard product which will support a minimum of four (4) axes (AZ, EL plus two (2) unused) for future expansion.

4.2.1.12. All interface designs required for the Delta Sigma Company controller radar interface, build, installation, and integration with the existing radar system in the Indoor Range. This DOES NOT include radar modifications to the Signal Processing Corporation (SPC) MK V radar. Radar communications for motion commands and position data will be via Ethernet.

4.2.1.13. Conductive finish with corrosion protection.

4.3. Schedule. The system will be delivered and operational within 10 months after receipt of order. A delivery date and installation timeframe shall be provided at the kick-off meeting.

4.4. Interface Control Document (ICD). An Interface Control Document (ICD) dated 5 January 2015 (Attachment A) which describes user level mechanical interface, mechanical dimensions, surface finish, edge sharpness, environmental requirements, electrical connections, etc. HAFB will re-configure existing tooling mounting fixtures to fit contractor’s pylon interface.

4.4.1. Contractor shall coordinate with SPC (Original Equipment Manufacturer (OEM) of Mk V Radar system) regarding radar software changes needed to support the positioner control system change.

5. PROGRAM MANAGEMENT.

5.1. Design Review Meeting. One design review meeting shall be held at a time agreed upon by HAFB and contractor personnel. The meeting will be approximately two (2) hours in length and shall be held via a web meeting (such as GoTo Meeting) about 30 business days after receipt of order.

5.2. Factory Acceptance Review

A factory acceptance review shall be held at Delta Sigma Corporation’s facility prior to shipment of the Pylon. Delta Sigma Corporation shall prepare a Factory Acceptance Test Plan (CDRL A002) prior to execution of the tests. The tests shall include the following parameters:

• Overall Quality Inspection & Workmanship

• Travel & Direction Control

• Limit to Limit Travel

• Smooth Operation

• Motor Current

• Velocity control

• Position Accuracy

• Backlash

• Vertical Load

• Delivered Torque

• Side Bending Moment

6. DOCUMENTATION.

6.1. Delivered Documentation. The following documentation shall be delivered with the proposed product.

6.1.1. Low RCS Pylon Maintenance Manual (Parts List, Schematic Wiring Diagram, Mechanical

Assembly Drawings, Maintenance Procedures) (CDRL A001)

6.1.2. Acceptance Test Plan (CDRL A002)

6.1.3. Acceptance Test Report (CDRL A003)

7. INSTALLATION TRAINING & WARRANTY.

7.1. On-Site Installation. On-site installation of the Low RCS Pylon shall be performed by contractor personnel at HAFB. HAFB shall be responsible for unloading the Pylon from the truck and placing it in the Indoor Range. Contractor shall be responsible for on-site installation labor, training and support.

7.2. The Training will consist of (as a minimum).

7.2.1. System Operations

7.2.2. Overview of the Positioning Subsystem

7.2.3. Overview of system interconnection diagram

7.2.4. Overview of system cabling

7.2.5. Periodic Maintenance (PM) procedures

7.3. Product Warranty. Standard commercial warranty for the Low RCS Pylon and rotational Control System against defects in materials and workmanship for a period of One (1) year from the date of government final acceptance. During the Warranty period, Contractor shall repair or replace any material or equipment that exhibits defects or fails to perform per specifications due to workmanship.

8. ACCEPTANCE TEST PLAN

8.1. Contractor shall prepare an Acceptance Test Plan (to be delivered to HAFB 30 days prior to installation). HAFB will reply with corrections/approval within seven (7) days after receipt. The tests shall include the following parameters (as a minimum):

8.1.1. Overall QA Inspection & Workmanship.

8.1.2. Final Electrical / Mechanical Configuration.

8.1.3. Load test with demonstration of full range of travel and direction control.

8.1.4. Smooth Operation with constant velocity control.

8.1.5. System compatibility with existing MK V radar. IAW ICD.

8.2. The Low RCS Pylon and Rotational Control System shall successfully pass all acceptance tests prior to HAFB final acceptance of the product. HAFB personnel do not intend to visit the factory during component fabrication, but reserves the right to do so with reasonable advance notice.

8.3. Final Acceptance Testing. Acceptance testing shall be performed at HAFB per the Government-approved acceptance test plan.

9. DELIVERY.

9.1. Preparation. Handling, storage, packaging, preservation, and delivery of the components shall be designed to prevent damage during transit. The Low RCS Pylon system shall be packed to prevent damage during shipment. All containers shall be labeled to indicate which side should be opened and identify the location of the packing slip. The Pylon shall be shipped via air ride trailer to mitigate any shipping damage.

10. Freight. Shipping costs will be free on board at destination.