Purchase_Specification_20160303.docx

PURCHASE SPECIFICATION

SHOCK ISOLATOR TEST TOWER

14 March, 2016

Prepared by 309th MMXG/MXDEA

HILL AFB, UTAH 84056

1.0 INTRODUCTION

The work described herein is to design, fabricate, assemble, test, install, start up, qualify and document a Shock Isolator (SI) Test Tower (SITT) per the requirements that are contained in this document. The SITT will be used to test operating parameters of liquid spring and pneumatic SIs. The SIs are critical components of the United States Air Force (USAF), Minuteman III Intercontinental Ballistic Missile (ICBM) ground support system. The SIs are currently being tested with an existing, 4 decade old, test tower. Two new SITTs will be installed in Bay F of Building 850 at Hill Air Force Base, Clearfield, Utah.

2.0 REFERENCE DOCUMENTS

62-CMP ICBM Configuration Management Plan MIL-STD-1472G Human Engineering 11 January 2012 Section 5.9.4 and Section 4.12

3.0 PERFORMANCE REQUIREMENTS

The High Level Objectives for this project include replacing the current SITT with two newly designed testers that meet, or exceed Technical Requirements Document (TRD) for Shock Isolator Test Tower (SITT) and this document.

3.1 Functional

3.1.1 The SITT design shall provide adequate work space as defined in MIL-STD-1472G Human Engineering 11 January 2012 Section 5.9.4 around each of the shock isolators so that operators can perform all required manual operations during loading, testing and unloading of shock isolators.

3.1.2 All tests and configuration changes on the tower shall require no more than two technicians.

3.1.3 The SITT shall be designed such that shock isolators can be loaded into the tower from their handling carts without using external handling equipment. The carts shall be rolled into the SITT at floor level. The handling cart is 49 inches tall, 54 inches long and 40 inches wide.

3.2 Control System

3.2.1 The SITT control system shall perform data acquisition. It shall have an interactive operator interface that allows the operator to select pre-programmed tests and to start, stop, resume and manually override the SITT functions and tests. The controller shall have a visual display of SITT functions, shock isolator parameters, and data which shall be a live feed.

3.2.2 All required test and data acquisition steps shall be pre-programmed into the control system by the contractor.

3.2.3 The SITT shall consistently perform all specified MSS, LER and LCC SI tests and record all specified test data per Attachment A, Technical Requirements Document (TRD) for Shock Isolator Test Tower (SITT).

3.2.4 The control system shall be located so that the operator can see the SI during testing and shall allow for both towers to be operated simultaneously.

3.3 Data Acquisition

3.3.1 The system shall be of either a Programmable Logic Controller (PLC) or a Programmable Automation Controller (PAC) type.

3.3.2 Data shall be captured, archived and then transferred via non re-writable CD or DVD.

3.4 Pneumatic Lines

3.4.1 Facility pneumatic lines provide 600-800 pounds per square inch (psi) air pressure.

3.4.2 SITT interfaces shall interface with the current, in-place, pneumatic lines. Location of pneumatic line drops are notated on the drawing in Appendix F.

3.4.3 Routing and mounting of the pneumatic lines shall be in such a way as to allow required movement of the LCC shock isolator during test procedures.

3.5 Silicone Fluid Line

3.5.1 Provision shall be made in the SITT for the routing and mounting of a flexible, high pressure, silicone fluid line that is required to pressurize MSS and LER shock isolators while they are loaded in the SITTs. The facility will be equipped with the fluid line and the fluid pump. Location of the silicone pumps are notated on the drawing in Appendix F.

3.6 Foundation

The contractor shall design below grade and reinforced concrete foundation and footings. The concrete foundation for the SITTs shall be designed in such a way that testing done on SITTs does not affect the rest of the facility or production in the facility.

3.7 Facility

3.7.1 The electrical power supply will be: 480 VAC / 3 Phase / 60 Hz. The main distribution panel is located in the Southwest corner of Bay F in Building 850, inside the wood shop. The drawings for the facility are in Appendix F with the location for the power panel identified. The contractor shall be responsible for running power from the panel to the location of both SITTs. The conduit shall parallel any conduit already present in the facility. Where there is no other conduit present, the contractor shall run the conduit at ceiling level.

3.7.2 The two new SITTs shall be placed at the West side of Bay F, Building 850 as noted on the drawings in Appendix F.

3.7.3 Maximum height of the SITTs shall not exceed 22 feet. Maximum footprint per SITT will not exceed 20 feet by 20 feet and will not interfere with the footings already in place for the building support columns. A drawing of the footings of the building is in Appendix F.

3.8 Safety Requirements

3.8.1 All applicable OSHA standards shall be met or exceeded for systems with 6,000 psi pneumatic pressure and 25,000 psi hydraulic pressure.

3.8.2 The SITT shall be designed to contain a SI pressurized to 25,000 psi hydraulic pressure in the case of failure.

3.8.3 The SITT shall be designed so that a SI is not damaged in the case of SITT failure.

3.9 Throughput

The SITT shall be able to support a work load of testing any two SIs per one 8 hour work shift.

3.10 Change Over Requirement

3.10.1 The SITT shall be designed so that all tests for any given SI can be run in sequence without having to remove the SI from the SITT or change the configuration of the SITT.

3.10.2 The MSS, LER and LCC SIs are of different physical configurations. The SITT shall be configuration changeable to accommodate each SI configuration. All required hardware for the configuration changes shall be provided. SITT configuration changes between the different types of SIs shall be able to be accomplished within a 2 hour time period by 2 trained technicians.

3.10.3 If any configuration changes need to made between tests for a specific SI it shall take one technician no longer than 30 minutes.

3.11 Automation

The SITT shall at a minimum maintain the same level of automation as the current SITT. Contractor shall verify current Test Tower automation requirements after award. All automation should be done in accordance with MIL-STD-1472G Human Engineering 11 January 2012 Section 4.12.

4.0 GOVERNMENT FURNISHED EQUIPMENT

MSS SI

Qualification Test Procedure (QTP)/ATP Only

LER SI

QTP/ATP Only

LCC SI W1

QTP/ATP Only

LCC SI W3/5

QTP/ATP Only