F-16_JFS_SOW_09_Mar_2017.pdf

DISTRIBUTION STATEMENT A. Approved for public release: Distribution is unlimited.

9 March 2017

Statement of Work (SOW) for

F-16 Jet Fuel Starter Test Stand

NSN: 4920-01-472-5167

Prepared by

COMMODITIES SUPPORT MAINTAINENCE GROUP

309TH CMXG

HILL AFB UT 84056

THIS PAGE HAS BEEN INTENTIONALLY LEFT BLANK

TABLE OF CONTENTS

1. SCOPE

2. TEST EQUIPMENT REQUIREMENTS

2.1. Test stand requirements

2.1.1. Technical order testing requirements

2.1.2. Required adaptors

2.1.3. High speed shaft

2.1.4. Hose requirements

2.1.5. Waterbrake system

2.1.6. Emergency stop

2.1.7. Calibration ports

2.1.8. Wire labeling

2.1.9. Test stand label

2.1.10. Item Unique Identification (IUID) requirements

2.1.11. Caution plates

2.1.12. Cable requirements

2.1.13. Data acquisition system

2.2. Electrical

2.2.1. General

2.2.2. General wiring methods

2.2.2.1. Interconnecting wiring

2.2.2.2. Internal wiring

2.2.2.3. Existing wall penetrations

2.2.3. Grounding

2.2.4. Door interlocks and test in progress lights

2.3. Ergonomics

2.3.1. Emergency stop

2.3.2. Installing Jet Fuel Starter

2.4. Facility

2.4.1. Facility services

2.5. Information assurance (IA)

2.5.1. IA reporting/tracking

2.5.1.1. Malicious logic protection

2.5.2. Software

2.5.2.1. Password protected access

2.5.2.2. User interface

2.5.2.3. Automation

2.5.2.3.1. Speed control

2.5.2.3.2. Data logging

2.5.2.3.3. Strip chart recorder

2.5.2.4. Software alarms and alerts

2.5.2.5. Power outage

2.5.2.6. Manual data acquisition

2.5.3. Calibration

2.5.4. Computer and operating system

2.5.4.1. Computer Program Identification Number (CPIN)

2.6. Life cycle sustainment

3. DOCUMENTATION

3.1. Operation and maintenance manual

3.2. Drawing package

3.2.1. Engineering Data

3.2.2. Engineering Data Guidance Conference

3.2.3. In-Process Review (IPR) of the TDP

3.2.4. Relationship of Contractor with Subcontractors/Vendors

3.2.5. Engineering Data Updates and Revisions

3.3. Calibration quality standard

3.3.1. Calibration and measurement traceability

3.4. Acceptance Test Plan and Report

3.4.1. Functional Configuration Audit

3.4.2. Physical Configuration Audit

3.4.3. Fault insertion

3.4.4. Validation/verification

4. GOVERNMENT FURNISHED EQUIPMENT (GFE)

4.1. Assets loaned by the Government

4.2. GFE protection

4.3. Damage reporting

4.4. Shipping costs responsibility

5. INSTALLATION

5.1. Facility modifications

5.2. Removal of current equipment

5.2.1. Test stand

5.2.2. Electrical connector box

5.2.3. 28 Volt control boxes

5.2.4. Fuels sytem

5.3. Final acceptance costs

5.4. Furnishing of tools

6. SPARE PARTS

6.1. Contractor provided spare parts

7. PERIOD AND LOCATION OF PERFORMANCE

7.1. Meetings and scheduling

7.1.1. Preliminary design review (PDR)

7.1.2. Critical design review (CDR)

7.1.3. Configuration audit and factory acceptance test

7.1.4. Installation of the test stand

7.1.5. Validation/verification testing of test stand

7.1.6. Reliability testing

7.1.7. Final acceptance

8. WARRANTY

8.1. Warrant commencement

8.2. Length of warranty

8.3. Warranty certificate

9. TECHNICAL DATA DELIVEREABLES

10. ACCESS TO FACILITIES AND PROPERTY

11. TRAINING

11.1. Engineer training

11.2. Equipment operator training

11.3. Calibration training

11.4. Maintenance training

12. LABELING, MARKING, AND NAmEPLATES

12.1. Permanent component identification

12.2. Label location

12.3. Wire labeling

12.4. Wire number covering

13. DATA RIGHTS

13.1. Data Rights

APPENDIX A

APPENDIX B

APPENDIX C

1. SCOPE

The purpose of this Statement of Work is to provide two (2) F-16 Jet Fuel Starter Test Stands, with all equipment, fixtures, software, manuals, and accessories as described herein. The test stand shall fulfill all operational testing requirements outlined in the Air Force Technical Order 2JA3-57-3.

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 two (2) existing F-16 Jet Fuel Starter Test Stands. Government use rights for all technical data shall be provided to the United States Air Force upon final acceptance of the test stand. This specification lists minimum requirements and is not intended to restrict or limit design improvements that the contractor has either available or under development. All requirements stated herein are applicable to both test stands.

2. TEST EQUIPMENT REQUIREMENTS

2.1. Test stand requirements.

2.1.1. Technical order testing requirements. The test stand shall perform F-16 Jet Fuel Starter testing in accordance with Technical Order 2JA3-57-3. Testing shall be automated by computer and/or programmable loop controller and shall have a computer interface for the test stand operator. The test stand shall include a color laser jet printer for producing test reports containing all required data of Figure 8-2 “Sample Test Data Sheet” from Technical Order 2JA3-57-3.

2.1.2. Required adaptors. The contractor shall provide all required adaptors, fixtures, cables, hoses, etc. required for testing, excluding any items listed in Appendix B.

2.1.3. High speed shaft. The contractor shall provide a high speed shaft to connect the JFS to the test stand gear box. The contractor shall also provide production drawings for the shaft and recommended maintainence/inspection criteria.

2.1.4. Hose requirements. 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 stand 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, and date of manufacture.

2.1.5. Waterbrake system. The test stand shall include a closed loop waterbrake system. The contractor may use the existing chilled water system to cool the closed loop waterbrake system.

The water tanks shall be stainless steel. The contractor shall include water treatment requirements in the operation and maintainence manual.

2.1.6. Emergency stop. The test stand shall have an emergency stop button that shall immediately establish a safe condition for the test operator, test stand, and for the unit under test.

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

2.1.8. Wire labeling. All wiring shall be labeled on both ends to match the electrical schematic.

Multi-stranded wire shall be ferrule ended or tinned with solder.

2.1.9. Test stand label. The test stand shall have a part number and serial number. The test stand shall have a label plate installed showing the test stand nomenclature, part number, National Stock Number (NSN), 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).

2.1.10. Item Unique Identification (IUID) requirements. The test stand shall contain a single Unique Identification (UID) marking in accordance with MIL-STD-130N. The contractor shall use the IUID registry, located on the internet at the following website:

http://www.acq.osd.mil/dpap/pdi/uid/data_submission_information.html. The test stand must be recorded in the DoD IUID Registry.

2.1.11. Caution plates. 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, temperature, etc.

2.1.12. Cable requirements. 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. Drawings of the cables shall be included in the drawing package.

2.1.13. Data acquisition system. An overview of the minimum measurements required for the test stand is given in Table 2-1. The test stand shall have all measurement devices needed to meet these requirements and any other requirements required by the Technical Order. The accuracy of the data acquisition cards shall be considered when selecting corresponding sensors to ensure that the combined accuracies meet the requirements listed in Table 2-1.

Table 2-1 Data acquisition accuracies

Measurement Unit Range Required Accuracy Barometric Pressure** In HgA 0-30 ± 0.15 Exhaust Gas Temperature (EGT) (Including tail pipe EGT and JFS dual probe EGT)

ºF 32-1400 ± 10.0

Rotor Speed RPM 0-65,000 ± 25.0

Output Horsepower* HP 0-250 ± 2.5 Compressor Inlet Temperature ºF 0-130 ± 2.0

Compressor Discharge Pressure psig 0-50 ± 0.5

Oil Sump Temperature ºF 0-250 ± 2.0

Oil Pressure After Filter psig 0-100 ± 0.5

Engine Vibration Displacement Mils peak-peak

0-1 ± 0.05

Slave Gearbox Case Pressure psig 0-1 ± 0.005

*Torque measurement accuracy and range to be determined by Contractor in order to meet horsepower accuracy requirements. Horsepower accuracy shall be determined using root square sum method for combining torque and speed accuracy.

**The barometric pressure shall be measured inside the test cell with the JFS.

2.2. Electrical.

2.2.1. General. All electrical hardware, including materials, devices, and sub-systems used on the equipment and its systems shall comply with the current editions of the U.S. National Electrical Code (NEC), and National Fire Protection Association (NFPA) 79 (Electrical Standard for Industrial Machinery).

2.2.2. General wiring methods.

2.2.2.1. Interconnecting wiring. The contractor shall furnish all interconnecting wiring, conduit, and wire-ways.

2.2.2.2. Internal wiring. Wiring within boxes, panel boards, and equipment shall be neatly dressed, tied, and labeled.

2.2.2.3. Existing wall penetrations. The contractor shall reuse existing wall penetrations to connect the test stand to the user interface.

2.2.3. Grounding. All metallic equipment shall be grounded to a single accessible point, which shall be a multiple-wire grounding strip. No more than one (1) wire per screw.

2.2.4. Door interlocks and test in progress lights. The test stand shall incorporate a door interlock system and test in progress light. The contractor may reuse existing door switches and test in progress light. With the doors open the door interlocks shall prevent the JFS from starting and abort a test in progress.

2.3. Ergonomics. The contractor shall provide a desk (or table) and two adjustable chairs so that the test operator and a second observer are able to clearly view the unit under test and computer monitor from a seated position. The operator shall face the viewing window of the test cell. The desk/table shall have adequate surface area for the keyboard, mouse, monitor (minimum 19 inches), existing camera monitors, printed technical order (11” x 17”) and the work control document (8.5” x 11”). The chairs shall be made of non-porous material (no cloth) so that dust and debris can be removed with a cleaning rag.

2.3.1. Emergency stop. The test operator shall be able to reach an emergency stop button from a seated position.

2.3.2. Installing Jet Fuel Starter. The design of the test stand shall minimize strain on the test operator while installing and removing Jet Fuel Starters (JFS). The test operator shall not be required to exert more than 20 lbs. of force when installing a JFS. The test stand shall include a mechanism to assist in the installation and removal of the unit under test. The contractor may reuse one (each) existing crane part number PPRO-FS-125-6-8-T.

2.4. Facility.

2.4.1. Facility services. The following facility services are available. It shall be the responsibility of the contractor to route new piping, cables, conduit, etc. from the existing facility connection points.

a. Electrical – 480VAC, 3 Phase, 60 Hertz (Hz), 20 Amperes

b. Electrical – 120VAC, 20 Amperes, Multiple Sources

c. Electrical – 28VDC, 4/0 American Wire Gauge (AWG)

d. Fuel – ½ inch NPT, 30 PSI

e. Shop Air – 100 psig, ¾ National Pipe Thread (NPT)

f. Water Brake Supply – 1-1/2” NPT, 50-80 ºF, 50 psig

2.5. Information assurance (IA)

2.5.1. IA reporting/tracking. The Contracting Officer (CO) shall be notified upon discovery of any virus or malware associated with the equipment being procured.

2.5.1.1. 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.

2.5.2. Software. The software package for the stand shall be capable of executing the operational tests outlined in Section 8 of Technical Order 2JA3-57-3 along with the additional requirements and modifications listed below. The contractor shall provide the software application and client access licenses for all software used in, on, or in support of the test stand.

2.5.2.1. Password protected access. The test program shall have three (3) levels of password protected access: Administrator (Engineering), Operator, and Calibration Technician. Only an administrator shall have rights to create and delete user accounts and enter any diagnostic menus (if available). 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 tests.

2.5.2.2. User interface. The software shall display all key paramaters and controls required for safe operation of the test stand. All units shall be displayed in the Imperial System.

2.5.2.3. Automation. The software developed for the test stand shall be capable of conducting all operational tests outlined in technical order 2JA3-57-3. Testing shall be automated by default with an option of manual override. Each main test segment shall be initiated individually by the operator. The software shall control all unit under test conditions (e.g. speed, waterbrake load, etc.). The software shall automatically record test results (e.g. speed, torque, time, etc.) and automatically terminate the test when complete.

2.5.2.3.1. Speed control. The loop control for speed shall respond faster than the loop control for the waterbrake load. The speed loop control shall ensure that required rotor speeds are maintained within tolerane while transitioning between horsepower load set points.

2.5.2.3.2. Data logging. The software shall include a data logger that starts automatically anytime the JFS is rotating. All test parameters shall be recorded to a delimited text file once per second.

2.5.2.3.3. Strip chart recorder. The software shall include a strip chart recorder that starts automatically during testing. A software administrator shall have the ability to select the default channels displayed in the strip chart.

2.5.2.4. Software alarms and alerts. The software shall have programmed safety features that protect the operator and the unit under test. The software shall prevent the unit under test from exceeding any test procedure limitations. Alarms and alerts shall automatically latch. Test operators shall have the ability to unlatch alarms and alerts. An alarm condition shall abort the test and bring the test stand to a safe condition. A latched alarm shall prevent a test from starting. An alert shall notify the operator of a condition. Alarms shall be recorded to a .txt log file that includes a timestamp and description of the alarm.

2.5.2.5. Power outage. The test stand shall default to the safest possible condition in the case of a power outage or emergency stop.

2.5.2.6. Manual data acquisition. Manual data acquisition (i.e. gauges independent from software system) shall not be used for certifying test parameters. Manual gauges shall be for reference only and do not require calibration.

2.5.3. Calibration. 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 validation. The calibration technician shall be able to view both the raw and scaled values. Upon successful calibration and certification by the calibration technician, the software shall prompt the calibration technician to enter a new calibration due date. The software shall not allow a user with an operator password to conduct a test if the calibration due date has passed. The software shall allow an administrator to conduct testing with an expired calibration date. The calibration due date shall be displayed on the main test screen. Only calibration technicians shall have the ability to modify calibration parameters.

2.5.4. Computer and operating system. Test stand computer shall be commercial off-the-shelf and have Windows 10 as the operating system. The computer shall have a mirrored backup hard drive.

The computer hard drives shall have a minimum of one (1) TB of memory. The computer shall include a DVD-RW drive and have one undedicated USB port.

2.5.4.1. Computer Program Identification Number (CPIN). A Computer Program Identification Number (CPIN) shall be embedded into the software source code to be displayed on the login screen and test reports (CDRL A006). The Government Representative will provide the CPIN number to the contractor prior to the Critical Design Review (CDR). Prior to installation at Hill AFB, discs containing the software installation discs shall be provided to the Government. The installation discs shall contain any needed drivers for proper software execution. The contractor shall provide two copies of the install disk for the software. Each disc (CD or DVD) shall be labeled with the following information: CPIN number, Revision, Date, Classification, Units (e.g.

1 of 1, 1 of 2, etc.) and the Title (see CDRL A006).

2.6. Life cycle sustainment. In order for the Government to minimize life cycle costs and equipment down time, the test stand design shall allow the Government to competitively select service providers for all future repairs without involving the original manufacturer of the test stands. Wherever possible, the contractor shall use components that are commercially available, commonly used in comparable industry equipment, and competitively priced.

3. DOCUMENTATION

The following documentation shall be provided with the test stand:

3.1. Operation and maintenance manual. See attached Technical Manual Contract Requirements (TMCR) for Technical Manual requirements (in accordance with CDRL A008).

3.2. Drawing package. See attached Contract Data Requirements List (in accordance with CDRL A009) for drawing requirements.

3.2.1. 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 items(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. Vendor item Control Drawings shall be used to specify the requirements for purchased items when such items have been approved for use in the design and are used without alteration, selection or source qualification (testing of an item prior to procurement action to ensure that it satisfies the specified requirements).

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 ta Specification drawing 9579776 Revision M (CAGE 98752), reference CDRL A009 Block 16.

3.2.2. Engineering Data Guidance Conference: The contractor shall support and co-chair 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. The contractor shall address, discuss, and provide status on the following:

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

b. TDP review requirements and schedules.

c. TDP requirements and schedules.

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

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

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

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

h. Digital Technical Data Package (TDP) deliverables.

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

3.2.3. In-Process Review (IPR) of the TDP: The contractor shall host, support, and co-chair and 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 the AFLCMC/LZPEM 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 shall be made available for review. If the quantity of separate IPR at the subcontractor’s/vendor’s facility.

3.2.4. 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.

3.2.5. 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:

a. 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.

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

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

d. Revisions to existing engineering drawing/models and associated lists and other documentation to be included to 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.

3.3. Calibration quality standard. Calibration quality standard and traceability with calibration measurement requirement summary (CMRS).

3.3.1. Calibration and measurement traceability. 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 this purchase specification. The contractor shall deliver the CMRS in accordance with

CDRL A007.

3.4. 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 (in accordance with CDRL A003 and CDRL A004). 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 ATP shall contain the following critical events:

3.4.1. Functional Configuration Audit. 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 after the audit and shall correct all audit discrepancies documented.

3.4.2. Physical Configuration Audit. 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 complete preliminary copy of the drawing package shall be delivered 15 days prior to the Physical Configuration Audit.

3.4.3. 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. 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.

3.4.4. 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 three (3) full operational tests of serviceable jet fuel starters provided by Hill

AFB.

4. GOVERNMENT FURNISHED EQUIPMENT (GFE)

4.1. Assets loaned by the Government. 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 as soon as possible after the Post Award Conference with the exception of the F-16 Jet Fuel Starter, part number: 160001-1100A. The F-16 Jet Fuel Starter will be provided immediately prior to factory acceptance testing.

4.2. GFE protection. The contractor shall protect all GFE by keeping it in a secured facility when not in use.

4.3. Damage reporting. The contractor shall report any suspected damage of GFE to the Government Representative within 24 hours.

4.4. Shipping costs responsibility. The Government will be responsible for all costs associated with shipping of the GFE to the contractor, and the contractor shall be responsible for all costs associated with shipping of the GFE to the Government.

5. INSTALLATION

The contractor shall provide all services required to install the test stand in Building 240 at Hill

AFB.

5.1. Facility modifications. No facility structural modifications are authorized.

5.2. Removal of current equipment. The contractor shall disassemble, remove and palletize the existing test stand components that will be replaced. The palletized components shall be placed in a designated location outside building 240 (no more than 50 feet away). The contractor shall offer the government a credit for the gearboxes retained by the contractor at time of disassembly. The Government will drain all chemicals before removal, but the contractor can expect some residue.

5.2.1. Test stand. The contractor shall remove the exising test fixture, frame assembly, operator console, and associated piping and electrical wires/cables. The existing exhaust tail pipe may be reused. The existing floor drain shall be reused.

5.2.2. Electrical connector box. The contractor shall remove electrical connector box directly above the existing test stand frame. The existing cable trays may be reused.

5.2.3. 28 Volt control boxes. The contractor shall remove the 28 volt control boxes and cable trays located outside the test cell. The contractor may reuse existing 28 volt cables.

5.2.4. Fuels sytem. The contractor shall remove all fuel piping and components down stream of the second fire shut off valve. The contractor shall also remove the fuel piping to and from the heat exchanger, remove the heat exchanger, and replace the isolation valves with straight piping. The chilled water piping to and from the heat exchanger shall be removed and capped within 12 inches of the headers.

5.3. Final acceptance costs. 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.

5.4. Furnishing of tools. 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.

6. SPARE PARTS.

6.1. Contractor provided spare parts. The contractor shall provide the following spare parts and recommend logical spare parts to be included in the technical manual:

a. Two (2) EGT Temperature Probes and two (2) Compressor Inlet Temperature Probes

b. Two (2) Fuel Filters and two (2) Oil Filters

c. One (1) Exciter ignition cable

d. One (1) of each type Pressure Transducer

e. One (1) High Speed Cassette Assembly

f. One (1) High Speed Shaft

g. One (1) Vibration Pick Up and Mount

7. PERIOD AND LOCATION OF PERFORMANCE

7.1. Meetings and scheduling. The contractor shall schedule and organize the following events listed in Table 7-1:

Table 7-1 Period and location of performance

Event/Milestone Timeline Location Preliminary Design Review (PDR) TBD* TBD* Critical Design Review (CDR) TBD* TBD* Technical Interchange Meeting

(TIM)

As Required TBD*

Configuration Audit and Factory Acceptance Test

<9 months of contract award Contractor’s Facility

Installation Test Stand

TBD

(after AFMETCAL acceptance of calibration procedure)

Hill AFB Building 240

Validation/Verification Immediately following installation

Hill AFB Building 240

Reliability Testing 1 month after validation/verification

Hill AFB Building 240

Final Acceptance Immediately following Reliability Testing

E-mail notification

Delivery of Warranty Certificate Upon final acceptance E-mail notification Release of Data Rights 30 days from final acceptance E-mail notification

*To be proposed by the contractor

7.1.1. Preliminary design review (PDR). The purpose of the PDR 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. The contractor shall record meeting minutes and deliver them to the Government within one (1) week for review (in accordance with CDRL A015).

7.1.2. Critical design review (CDR). The purpose of the CDR 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. The contractor shall record meeting minutes and deliver them to the Government within one

(1) week for review (in accordance with CDRL A015).

7.1.3. Configuration audit 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. The contractor shall record meeting minutes and deliver them to the Government within one (1) week for review (in accordance with CDRL A003 and A004).

7.1.4. Installation of the test stand. Upon notice to proceed, the contractor shall remove one of the existing test stands and install the new test stand.

7.1.5. Validation/verification testing of test stand. 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 (in accordance with CDRL A003 and A004).

7.1.6. Reliability testing. After successful implementation and commissioning, Hill AFB personnel will verify test stand reliability by testing for a one month period. Any failures of the test stand, resulting from inherent deficiencies in the design and installation of the test stand, during this period shall be repaired at the expense of the contractor and shall restart the reliability testing period.

7.1.7. Final acceptance. Upon successful completion of the reliability testing, the Government will sign for final acceptance of delivered stand.

8. WARRANTY

8.1. Warrant commencement. The warranty shall commence upon written final acceptance of the entire test system and after acceptance of all data deliverables.

8.2. Length of warranty. The test stand shall come with a written industry standard warranty.

8.3. Warranty certificate. The certificate shall be prepared in the contrator’s preferred format. The warranty certificate shall contain at a minimum, the following information:

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

b. Contract number

c. Warranty start and end date

d. The contractor’s contact information

e. Explanation of warranty coverage

9. TECHNICAL DATA DELIVEREABLES

All Contractor/Depot data developed under this contract shall be prepared and delivered on electronic media via the latest MS Office (Power Point, Excel, or Word) format and on bound/stapled 8 ½ by 11 inch bond paper, unless specified otherwise in the CDRL. In the case of computer listings, the hardcopy shall be the paper standard used at the Hill AFB facility.

The contractor shall provide a technical data package as stated in Table 9-1:

Table 9-1 Technical data package

Deliverable CDRL# DID Reference

Not Applicable A001 Not Applicable Not Applicable

Not Applicable A002 Not Applicable Not Applicable

Acceptance Test Plan A003 DI-NDTI-80566A 3.4, 7.1.3, &

7.1.5

Acceptance Test Report A004 DI-NDTI-80809B/T 3.4, 7.1.3, &

7.1.5 Not Applicable A005 Not Applicable Not Applicable

CPIN A006 DI-MISC-81454C 2.5.2.1

Calibration A007 DI-QCIC-80278B 3.3.1

Technical Manuals A008 TM-86-01P 3.1 Drawings A009 DI-SESS-81000E/T 3.2 & 3.2.1

Not Applicable A010 Not Applicable Not Applicable Not Applicable A011 Not Applicable Not Applicable Not Applicable A012 Not Applicable Not Applicable Not Applicable A013 Not Applicable Not Applicable Not Applicable A014 Not Applicable Not Applicable

PDR Meeting Minutes A015 DI-ADMN-81250A 7.1.1 & 7.1.3 CDR Meeting Minutes A015 DI-ADMN-81250A 7.1.1 & 7.1.3

Not Applicable A016 Not Applicable Not Applicable Not Applicable A017 Not Applicable Not Applicable Not Applicable A018 Not Applicable Not Applicable

10. ACCESS TO FACILITIES AND PROPERTY

The Contracting Officer will assist with security and access requirements. To obtain access to Hill Air Force Base (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, driver’s license number, and state listed on license 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 Building #408, 5830 F Ave, Hill AFB.

11. TRAINING

11.1. Engineer training. The contractor shall provide up to 8 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.

11.2. Equipment operator training. The contractor shall provide 20 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.

11.3. Calibration training. 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.

11.4. Maintenance training. The contractor shall provide up to four (4) 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.

12. LABELING, MARKING, AND NAMEPLATES

12.1. Permanent component identification. Permanent component identification shall be used for all electrical components located in a control panel, enclosure, or junction box.

12.2. Label location. Labels shall be installed adjacent to all electrical components such as purchased devices, switches, receptacles, terminal blocks, control stations, disconnects, and control panels.

12.3. Wire labeling. All wires shall be tagged and numbered per wiring diagrams at all terminal locations. All conductors and cables shall be provided with permanent labels. Wrap-on labels are acceptable. (standard for electrical schematics)

12.4. Wire number covering. Oil and grease resistant numbers or a clear heat-shrink, oil/grease resistant covering for all wire numbers is required.

13. DATA RIGHTS

13.1. Data Rights: The contractor shall provide data rights to all data produced as a result of this contract in accordance with the applicable CDRL’s and shall provide Government purpose rights for data developed prior to award of this contract.

APPENDIX A

ACRONYMNS AND ABBREVATIONS

AFB Air Force Base AFI Air Force Instruction

AFMAN Air Force Manual AFMETCAL Air Force Metrology and Calibration

ATP Acceptance Test Plan ATR Acceptance Test Report AWG American Wire Gauge BOM Bill of Materials CAD Computer Aided Design CDR Critical Design Review

CDRL Contract Data Requirements List CMRS Calibration and Measurement Requirement Summary CPIN Computer Program Identification Number CO Contracting Officer

COR Contracting Officer Representative DID Data Item Description DoD Department of Defense EGT Exhaust Gas Temperature FCA Functional Configuration Audit FCL Fault Candidate List FTP File Transfer Protocol GFE Government Furnished Equipment HP Horse Power IA Information Assurance in HgA Inches of Mercury Absolute IPR In-Process Review

IUID Item Unique Identification JFS Jet Fuel Starter MS Micro Soft

NED National Electrical Code NFPA National Fire Protection Association NSN National Stock Number NPT National Pipe Threading PCA Physical Configuration Audit PDR Preliminary Design Review PSIG Pounds per Square Inch – Gauge RPM Revolution Per Minute SOW Statement of Work TBD To Be Determined TDP Technical Data Package

TMCR Technical Manual Contract Requirements

TPS Test Program Sets US United States

USAF United States Air Force UUT Unit Under Test VAC Volts Alternating Current VDC Volts Direct Current

APPENDIX B

GOVERNMENT FURNISHED EQUIPMENT

Part Number Description NSN Quantity Unit Price 160001-1100A F-16 Jet Fuel Starter 2835-01-308-

1 each $56,074.59

160034-400 Fuel Control 2910-01-135-

1 each $32,425.46

10-397050-5A or 5901038

Exciter 2925-01-057-

1 each $2,336.42

V5000-4720 Fuel Solenoid Valve – 2 pin 2995-01-052-

2 each $637.53

V5000-4920 Fuel Solenoid Valve – 3 pin 2995-01-053-

2 each $592.40

110243-2 Ignition Cable 2825-01-115-

1 each $167.14

160021-2 Thermocouple 6685-01-054-

1 each $230.51

5902996 V-band Exhaust Clamp 4730-01-183-

1 each $34.32

5902091 V-band Clamp 5342-01-053-

1 each $113.11

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

BUILDING 240 F-16 Jet Fuel Starter Test Stand

DATE 2 Nov 2015 Prepared by:

Tim Helms

OO-ALC/SE

801-586-6038

Control Number: TH151101

SECTION I - GENERAL REQUIREMENTS

A. Safety Program Requirements.

The contractor will implement a safety program plan 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.

2. A Safety Plan that addresses, as a minimum, the subjects listed in Section II –Specific Requirements, and will be used during the performance of the work described in the contract. The Safety Plan will be accepted by OO-ALC/SE (Safety Office) prior to commencement of any work described in this contract.

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

4. Competent personnel to provide surveillance of the Safety Plan.

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

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

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

B. Mishap Notification

1. The contractor shall notify OO-ALC/SE (801-586-6038) or the Hill AFB Command Post (801- 777-3007) after normal duty hours, and the designated Government Representative (GR), i.e., the ACO, Procuring Contracting Officer (PCO), or DCMA COR (Contracting Officer's 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. A written or email copy of the mishap/incident notification shall be sent within three calendar days to the GR, who will forward it to OO-ALC/SE. For information not available at the time of initial notification, the contractor shall provide the remaining information no later than 20 calendar days after the mishap, unless extended by the ACO.

Mishap notifications shall contain, as a minimum, the following information:

(a) Contract, Contract Number, Name and Title of Person(s) Reporting

(b) Date, Time and exact location of accident/incident

(c) Brief Narrative of accident/incident (Events leading to accident/incident)

(d) Cause of accident/incident, if known

(e) Estimated cost of accident/incident (material and labor to repair/replace)

(f) Nomenclature of equipment and personnel involved in accident/incident

(g) Corrective actions (taken or proposed)

(h) Other pertinent information

2. The contractor shall cooperate with any and all government mishap investigations. Additionally if requested by government personnel or designated government representative (GR), i.e., the ACO, PCO, or DCMA COR, the contractor shall immediately secure the mishap scene/damaged property and impound pertinent maintenance and training records, until released by safety investigators.

3. The contractor shall provide copies of contractor data related to mishaps, such as contractor analyses, test reports, summaries of investigations, etc. as necessary to support the government investigation.

4. The contractor shall support and comply with the safety investigation and reporting requirements of AFI 91-204, Chapters 1 – 5.

C. General Safety Requirements:

If the safety plan is modified, the contractor shall submit the proposed modification, in writing, to the Contract Administration Office safety representative.

The contractor is solely responsible for compliance with all federal, state and local laws, the Occupational, Safety and Health Act (OSHA) (Public Law 91-596) and the resulting standards, OSHA Standards 29 CFR 1910 and 1926, as applicable, Air Force Occupational Safety and Health Standards (AFOSH STD), to include AFI 91-203, Air Force Consolidated Occupational Safety Instruction, AFI 91-204, Safety investigations Reports, AFPAM 91-210, Contract Safety, and the protection of their employees. Additionally, the contractor is responsible for the safety and health of all subcontractor employees. All documents required as a result of OSHA 29 CFR 1910 and 1926 regulations, (i.e. certifications, training, respiratory protection program, workplace hazard assessments), shall be made available to the COR upon request.

The contractor shall ensure assigned personnel are adequately trained and qualified for the task being performed. Brief all personnel on the hazards involved with operations and applicable precautions to be taken.

Hazard Assessment. In accordance with 1910.132(d)(2), the contractor shall conduct a certified Hazard Assessment on all work areas. A follow-on survey shall be conducted by the contractor when the workload or environment conditions change. If respirators are necessary to protect the health of the employee or whenever respirators are required by the contractor, the contractor employer shall establish and implement a written respiratory protection program according to 29CFR 1910.134.

Contractor personnel must receive Explosive Safety Awareness Training if their duties require entry into the Explosive Clear Zone. This training will be provided by the OO-ALC Safety Office.

Contact Eric Covington at 586-0168.

A Risk Assessment will be required prior to any work being accomplished, if munitions will remain in the facility.

Compliance with OSHA and other applicable laws and regulations for the protection of contractor employees is exclusively the obligation of the contractor. Note: AFOSH STDs are annotated because many of the Air Force Standards exceed the OSHA standard criteria. If a conflict is noted, the most stringent requirement takes precedence. The government shall assume no liability or responsibility for the contractor's compliance or non-compliance with such requirements. The contractor shall furnish to each of his/her employees a place of employment, which is free from recognized hazards. The contractor shall brief his/her employees on the safety requirements of this contract and on hazards associated with prescribed tasks. The contractor is responsible for compliance with OSHA Public Law and the resultant standards identified within.

In addition, the contractor is required to flow down the safety requirements/specification to all subcontractors. This applies to Federal Acquisition Regulation (FAR) 12 commercial acquisitions as well. This contract shall in no way require persons to work in surroundings or under working conditions which are unsafe or dangerous to their health. The contractor must coordinate and perform work so as not to impact the safety of government employees or cause damage to government property. This requires providing personnel with protective equipment and associated safety equipment as may be necessary. The contractor must also protect personnel from hazards generated by the work.