2.25.25_CIP ICT 1500-2500 SOW_Final Version.pdf

STATEMENT OF WORK (SOW)

REPAIR OF ICT-1500/2500 DETECTION, CONTROL AND MOTION SYSTEMS

709TH MAINTENANCE SUPPORT SQUADRON (MXSS)

ICBM Flight Systems Division AFNWC, BUILDING 984/2113

2/25/2025

Repair of ICT-1500/2500 Detection, Control and Motion Systems i

TABLE OF CONTENTS

1 BACKGROUND

2 SCOPE

3 GENERAL REQUIREMENTS

4 ICT-2500 SPECIFICATIONS/BACKGROUND INFORMATION

5 ICT-1500 SPECIFICATIONS/BACKGROUND INFORMATION

6 MOTORS AND CONTROLS

7 SOFTWARE

8 OTHER REQUIREMENTS

9 SECURITY REQUIREMENTS

10 TESTING AND PERFORMANCE REQUIREMENTS

11 TRAINING:

12 ADDITIONAL INFORMATION

13 CDRLs (Contract Document Requirements List):

14 APPENDICES

APPENDIX A – ACRONYMS and ABBREVIATIONS

APPENDIX B – SAFETY……………………………………………………………………….28

1 BACKGROUND

The Industrial Computed Tomography 1500/2500 (ICT-1500/2500) and associated subcomponents located in BLDG 2113 and 984 respectively are sophisticated Computed Tomography (CT) inspection systems. This system uses computed tomography to inspect solid rocket motors internally for anomalies in a non-destructive manner and are vital to the inspection and sustainment of the Minuteman III (MMIII) Intercontinental Ballistic Missile (ICBM) weapon system.

2 SCOPE

This Statement of Work (SOW) defines the scope for this “Extension of Life Plan” that includes replacement and upgrades of obsolete key components necessary for the continued use and sustainability for the ICT 1500/2500. The SOW also identifies requirements of the contractor for a contract to perform on-site repairs for the Industrial Computed Tomography (ICT) 1500/2500 system and associated subcomponents.

3 GENERAL REQUIREMENTS

This Statement of Work (SOW) defines the contractor’s responsibilities for the Extension of Life for the ICT 1500/2500 to include replacement of all related part and hardware of the ICT-1500/2500 system to include Linear Diode Array, Scintillator Assembly, Reference Detector, Printed Circuit Boards (PCB’s), all included components within the Detector Assembly (power supply, mother boards, analog processor boards, detector modules which house the crystals, analog-to-digital converter, and detector input output boards), Motors and Controls, Motion Controls, External Encoders, Operational Software and Operation/Diagnostic Workstations. The Contractor Shall perform all work in accordance with the Statement of Work (SOW).

3.1 The contractor shall provide a proposal for all areas of the project, when completed and ready for final inspection, shall meet all pertaining codes and governments’ statement of work (SOW).

3.2 The Contractor Shall perform the service required after coordinating with Hill Air Force Base (HAFB) POC’s as listed. Normal working hours are 0600 to 1530 Monday through Friday. No overtime costs shall be allowed.

3.3 The Contractor Shall provide a Project Manager/Superintendent for all projects. A Project Manager/Superintendent as identified shall be responsible for the daily logistics of all operations pertaining to the removal and installation of all components and parts as listed in this SOW.

3.4 Items not specifically mentioned in this SOW or associated specifications, but which are essential and necessary for the completion of the work and to make all systems or equipment operational and complete, shall be considered as incidental and shall be included as part of the work.

3.5 All components within the ICT-1500 & ICT-2500 upgrade shall be upgraded to current, modern technology, standards.

3.6 This project is combined to maintain uniformity between both ICT-1500 and ICT-2500 systems. This project is to be worked as an 80-week project with phases to upgrade the ICT-1500/2500 respectively. See the following for details:

3.6.1 Contractor shall perform upgrade on ICT-1500 first while preparing for the upgrade on the ICT-2500. Both upgrades shall be coordinated with the shop supervisor and the process engineer.

The final project phase for both ICT systems will be the x-ray source upgrade as lead times are much longer on these kits. Once the x-ray source kit for the ICT-2500 (15MEV) is delivered and ready to be installed, contractor shall install kit as soon as possible while coordinating with the shop supervisor and process engineer.

- Contractor shall adhere to a project POP of 80 weeks from award.

3.7 The Contractor Shall maintain the physical and functional integrity of all removed PCB’s and other components of the ICT-1500/2500 and at the completion of work and provide those components to the HAFB POCs. In the event that the system upgrade is unsuccessful, installation of old parts is to completed in order to bring the system back to a fully functioning state.

3.8 The Contractor may request specific items to be sent to them for design purposes. All items sent to the contractor shall be returned in same condition as sent.

3.9 Hill AFB requires an LDA built of modern designs and components that can be sustainably sourced (COTS items).

3.10 The Contractor Shall maintain the Original Equipment (OE) Linear Diode Array (LDA) concept and arrangement meanwhile replacing the electronics and sensors as stated in this SOW. The circuit boards and modules shall “Plug and Play” into the existing machine without significant modification. Modifications are limited to the Detector Housings to accept alternate form factor photodiode and electronics bay to support new PCB’s. A new LDA detector housing may be developed as a “drop-in” install to help eliminate downtime as long as the design does not exceed current dimensions and functionality remains the same.

3.11 The detector housing for the ICT-2500 is an improved design that places the crystals in a tungsten light-tight housing. A similar design is to be used for this application to maintain image quality. The ICT-1500 detector housing is currently not as robust which allows for detector crosstalk from neighboring detectors. There was a software fix for this, but the contractor shall develop an improved detector housing design to eliminate this issue.

3.11.1 One of the features of the ICT-2500 system that made it viable for rocket motor inspections is the current detector housing design that reduces stray radiation. Stray radiation entering the detector crystals will create image noise and loss of contrast sensitivity, which translates into a loss of confidence in the imagery. Contractor shall take these issues into consideration and propose a design for both systems that improves image quality and eliminates stray radiation anywhere possible in the detector housing.

3.12 The Contractor Shall upgrade and modernize the Scintillator Assembly. The contractor shall use (CdWO4) cadmium tungstate crystals or equivalent within the Scintillator as part of the upgrade. The proposed contractor design shall be approved by Hill AFB prior to proceeding with full design and installation.

3.13 The Contractor Shall upgrade the reference detector by including a method to use the same proposed scintillator assembly with a revised detector housing as stated in this SOW. Mounting and shielding shall be mounted in the same position with upgraded mounting brackets, housing and shielding. Communication to the host computer will be part of the main detectors serial chain.

3.14 The Contractor Shall upgrade the PCB’s that perform the Analog to Digital (A/D) conversion by consolidating all of these exterior functions into a single detector PCB as stated in this SOW. The detector boards would be interchangeable from position to position within the LDA and via high speed and deterministic control communicate with their peers to handle all functions of image acquisition. Elements of the new PCB’s shall include no less than 20 bit A/D’s for the ICT-1500 and ICT-2500, Xilinx FPGA or Hill AFB approved equivalent processor, individual gain corrections, linear accelerator synchronization, data storage, power isolation, fiber optic communication and faraday shielding.

3.15 The Contractor Shall incorporate interchangeable PCB’s between both the ICT-1500 and ICT-2500 systems. Components within the detector package include: (power supply, mother boards, analog processor boards, detector modules which house the crystals, analog-to-digital converter, and detector input output boards). Both systems need a diagnostic function to determine which PCBs and any components that affect the image acquisition are bad/need to be replaced.

3.16 Unless otherwise instructed by the CO, the Contractor shall participate in a Government-scheduled Kick-Off Meeting within 10 days of award (CDRL A001). Contractor personnel shall participate in the Kick-Off Meeting. The purpose of the Kick-Off Meeting is to (1) aid both the Government and Contractor personnel in achieving a clear and mutual understanding of all requirements, and (2) identify and resolve potential problems.

The Contractor shall be prepared to discuss any contract requirements requiring clarification. The Government, with mutual input from the Contractor, will schedule the Kick-Off Meeting to be conducted. The location of the Kick-Off Meeting will be negotiated between the Government and the Contractor. The Contractor shall prepare an agenda for the Kick-Off Meeting and submit this agenda to the Government Representative (GR) and Contracting Officer’s Representative (COR) five (5) business days before scheduled Kick-Off Meeting. The Contractor shall incorporate any GR and/or COR comments into the agenda prior to the Kick-Off Meeting. The Contractor shall provide meeting minutes within three (3) business days after the conclusion of the Kick- Off meeting.

3.17 Contractor to hold monthly meetings with government personnel involved with the project (CDRL A001) to include but not limited to engineer team, production, COR.

3.18 Contractor shall proceed with the design efforts of the ICT-1500 and ICT-2500 within this design timeframe. Contractor shall prepare a technical report/review of concepts (CDRL A002) at 4 phases throughout the project the 1st report will be at the beginning of the effort, 2nd at 65% 3rd at 90% and the final at completion. Contractor shall travel to Hill AFB to review entire system at initial phase, and at any additionally phases as determined by the Government. Each phase report shall include the following material. Government acceptance is required at each phase:

• Requirements Traceability Matrix

• Any issues, risk, design factors, limitations, etc., requiring review and/or approval by the

Government.

• Action Items generated during the review.

3.18.1 Contractor shall verify delivery of all necessary items for the upgrade prior to initiating upgrade.

3.19 The Contractor shall provide Engineering Drawings (CDRL A006) with sufficient information to permit Government maintenance, modification, re-procurement/re-manufacture, and engineering analysis of all manufactured items. All engineering drawings generated shall adhere to best commercial practices and shall, at a minimum, follow American Society of Mechanical Engineers (ASME) Y14.100 standards.

3.19.1 The Contractor shall provide a complete drawing set for all the new and modified equipment that is provided. Reverse engineering may be required to complete the drawing set.

3.19.2 Drawings need to be provided in a PDF and .dwg file format.

3.19.3 The Contractor shall create engineering documentation packages (which include corrections, engineering drawings, schematics, and associated technical data)

3.20 The Contractor shall provide the necessary administrative, financial, quality assurance, analyst, specialist, technical, and managerial personnel, and resources necessary to provide a single-point solution for system requirements. These personnel shall also provide a program management organization to manage the internal requirements, serve as the focused point of contact, and ensure all aspects of this program are adequately controlled and monitored.

3.20.1 The Contractor shall develop and provide a Program Management Plan (PMP) (CDRL A007), including their established quality system that details the activities to be performed under this effort, within 60 days of award. The PMP shall provide information on the Contractor’s organization, practices and techniques to be used in managing the program and working relationships with OEMs / subcontractors. The PMP shall include, but is not limited to, the plan purpose, scope, schedule, budget, performance plan, quality plan, risk plan, and any additional support plans required to complete the requirements of this effort. The PMP shall describe how the Contractor will take over all contract functional areas from the outgoing Contractor. At a minimum, it shall address in detail the following areas:

a. Phase-In Transition Plan

b. Evidence of working relationships with OEMs and/or other DoD Contractors that could potentially be utilized as subcontractors for the requirements of this effort.

c. Identification of key personnel positions and how they will be phased-in for each of their respective areas.

d. Approach to ensure technical experts have appropriate training and certification.

e. Approach to assuming accountability of Government Furnished Property (GFP) / GFE

(includes joint inventory with incumbent / OEM Contractors)

f. Acquisition of Contractor Common Access Cards (CAC) (as required)

g. Acquisition of other facility access card(s) as applicable

h. Ensure appropriate Security clearances (if applicable)

i. Timeline for submitting contract data requirements.

j. Approach to ensure open communication with incumbent Contractor and the Government to include, periodic (daily, weekly, etc.) reviews documenting progress until transition is complete.

k. Internal processes for manufacturing, quality control, and inspection.

4 ICT-2500 SPECIFICATIONS/BACKGROUND INFORMATION

Contractor shall ensure the upgrade of the ICT system adheres to the following:

• Translate-Rotate acquisition system.

• Source and detector move in an upward and downward motion.

• CT table rotates circular and moves north and south.

• Asset on table moves through beam and rotates 18 degrees and goes back through the beam 10 times for 180 degrees creating a half scan.

• Inspection envelope: 8ft in diameter 29ft in height.

• Field of View: 500mm to 2500mm.

• Resolution aperture (detector): 1.5mm to 2.5mm.

• Thickness aperture (detector): 6mm to 50mm.

• Source to detector distance: approximately 10ft.

• Weight Capacity: 120,000lb

5 ICT-1500 SPECIFICATIONS/BACKGROUND INFORMATION

Contractor shall ensure the upgrade of the ICT system adheres to the following:

• Translate-Rotate acquisition system.

• Source and detector move in an upward and downward motion.

• CT table rotates circular and moves east and west.

• Asset on table moves through beam and rotates 18 degrees and goes back through the beam 10 times for 180 degrees creating a half scan.

• Inspection envelope: 4.5ft diameter, 100in height.

• Field of View: 200mm to 1500mm.

• Resolution aperture (detector): .6 to 2.4mm.

• Thickness aperture (detector): 5mm to 50mm.

• Source to detector distance: approximately 6ft.

• Weight Capacity: 10,000lb

6 MOTORS AND CONTROLS

The existing motion control system incorporates technology considered very high-end during its construction. The precision and repeatability are still required. The accuracy is heavily influenced by the outstanding mechanical design. The Contractor Shall provide a modern and sustainable servo motor and control package that benefits from the inherent precision of the machine which remains unaltered as stated in this SOW.

6.1 Currently the motion controls are a complex array of motors, drives cards, sensors, processors, power supplies, interconnecting cables, etc. which take up several large equipment cabinets to support. The points of failure on such a system are too great for the maintenance person and must be maintained by an Engineer or System Manufacturer. The Contractor Shall replace the hardware controls with a single multifunction multi-axis controller by Bosch Rexroth as stated in this SOW. The Bosch Rexroth controller can run up to eight axis and be configured for servo motors with absolute encoders. The controller has inputs for limit and home switches, encoder or resolver inputs, serial/USB/Ethernet communication, pulse on position, BiSS for external encoders, 16 general purpose inputs and outputs for safety switches or other facility/machine devices. Depending on the larger servo motors (>750W) exact system specification, external amps may be necessary. The amps would be an inline extension of the Bosch Rexroth controller and simply provide the additional motor current/power.

6.2 Only Bosch Rexroth motors are to be used. The contractor shall select the appropriate servos to be used in this system. Motor cables shall be shielded from radiation and be oil resistant.

6.3 External Encoders: In addition to the motors feedback encoders/resolvers, the motion control also receives position data from 4 very high precision absolute encoders mounted to the output stage of the gantry and turntable axis. These encoders (3 linear, 1 rotary) shall be replaced with modern equivalents that meet or exceed the current system (200 counts/mm on linear stages and 2000 counts/degree on rotary stage). The Contractor Shall provide radiation shielding of the external encoders electronic modules as stated in this

SOW.

6.4 Ensure upgrade of motion system design for the two detector aperture axes is included.

These are currently driven with stepper motors without encoders allowing for too much positioning error. The detector resolution aperture is currently disabled on the ICT-2500 requiring manual adjustment of the aperture position. The contractor shall address these known issues with the detector aperture positioning system, propose an improved design, and remedy these issues.

6.5 The contractor shall ensure the positioning of all axes are to be user designated for setup and alignment.

6.6 The contractor shall provide data rights for motion control components.

6.7 The contractor shall maintain or exceed the current timing of the CT systems, i.e. firing, measuring, pulsing, positioning, rotations, and accuracy, of all integrated components within the system (detector, x-ray source, motion system, and mechanical communications).

7 SOFTWARE

7.1 The motion system position control software with GUI interface will run all the aspects of generation and processing image data. With a single User Interface an operator may control the motion systems, detectors, sources and integrate combination of these elements into an automated scan plan. The Imaging Acquisition and Analysis software includes acquisition tools; tools for the post processing of images as well as file management/data base of all variables including user annotations, measurements, position, setup, corrections, pixel maps, etc. The Contractor shall ensure the software be expanded to communicate with the new LDA, Reference Detector and the handling of the external encoders. Upgraded Software to be equivalent or better than Hill AFB’s current software, CATS and IVIEW.

7.1.1 Software shall include the following packages:

7.1.1.1 High Energy Acquire Software

- Specialized Digital Imaging Software configured for linear accelerator/detector

- Accelerator and detector control and synchronization software module and hardware.

- Includes two 100 ft. DB9 Cables to interconnect detector, accelerator and sync module

- Includes up to 6 axes of coordinated motion, plus accessory control outputs

7.1.1.2 Review Software

- Integrated ASTM 1695 and ASTM 2737 Module

- Integrated Simplified Reporting

- Fully automated data capture and reporting

7.1.1.3 Assist Software with full ADFR (Automated Defect and Feature Recognition) Capability

- Add-on module for automated geometry and FOD detections

- Includes initial development of detection algorithms for a single component

- Can analyze standard DR Images or CT Slice images

- Software to provides initial development of detection algorithms for additional component

7.1.1.4 Computed Tomography Software

- Includes three days of onsite operator training

- Isocal geometry calibration Phantom included

- 2D Image Processing (Scatter Correction, Beam Hardening)

- Detector Specific Corrections (REA, Lag Correction)

- Reconstruction (FDK Filtering, Back Projection, Filter Optimize, Normalization, Iterative Recon)

- CT Image Based Correction (Hounsfield Calibration, Ring Correction)

- Geometry Optimization (Isocal Calibration SW Tool, Isocal phantom)

- 3D Image Processing (Scatter Correction, Beam Hardening) o 3D and reconstruction software must be equivalent or better to IVIEW (current software).

7.1.1.5 Contractor shall provide a troubleshooting software package that allows the user to see real-time signals to detect any issues with the detector and/or its electronics.

7.1.1.6 Hill’s current troubleshooting software package (ICT Analyze) provides insight on detector and x-ray source performance issues by providing air values, transmission values; mean/max values, standard deviation and the capability to flag outliers.

7.1.1.6.1 Software can see the air values for each channel to determine which AP card has a defect within the LDA.

7.1.1.6.2 Software tracks the whole scan and provides data for each traverse.

7.1.2 The software shall comply with government approved coding language.

7.1.3 The image post processing controls shall run with CATS (Computer

Aided Tomography System, current software) or equivalent, ImageJ, and Volume Graphics.

7.1.4 - Sinogram view (front view) and top-down view (sliced image) shall be able to be reviewed simultaneously to the motor being scanned. One operator/user on one computer and the other operator on another. Each containing the different inspection methods. See example below.

Figure 1: Sinogram

Figure 2: Top-Down View

7.1.5 - User must be able to reconstruct 3D images post-scan and be able to save/transfer images.

7.1.6 - Imaging must be able to lock in place with respect to theta.

7.1.7 - User must be able to clock the motor in order to accurately mark a defect location within the motor.

7.1.8 - This is done based on the degrees of the table and location of a known point (raceway).

7.2 Scan Setup: User shall be able to input the following values during scan setup (clarify with Hill AFB for clarification as needed):

Scan Geometry Sampling Setup Apertures Series Setup Scan Height:

Fld of View:

Table Angle:

# of Samples:

Pulses/Sample:

# Traverses :

# Interleaves:

Preamp Gain:

Resolution:

Thickness:

# of Scans:

Z Incr:

Reconstruction Algorithm: Bicubic

Reconstructed Image Size:

Table angle: angle of table 0 deg to 360 deg to start scanning # of samples: 1024, 2048, 4096 Pulses/Sample: 1 or 2 # of Traverses: Adjustable. Minimum 10, maximum 14 (contact Hill AFB for preferences) # Interleaves: Adjustable. Hill AFB always sets to 0.

Preamp gain: Adjustable/auto. Hill AFB typically uses auto. Must be efficient enough for proper image acquisition.

Resolution aperture: Adjustable. Hill AFB currently adjusts between 0mm and 2.5mm.

Thickness aperture: Adjustable. Hill AFB currently adjusts between 0mm to 50mm.

7.2.1 Output data shall include an Annotations Report:

7.2.2 Annotations Report shall include the following capabilities:

• Section slice # slice number that the defect was found in.

• Z slice height: scan height that the defect was found in.

• Defect type

• Radial position: how far from the center the defect is.

• Theta degree: where the defect is located based on table degrees and part marker to match degrees of table.

• Radial extent: width of defect.

• Circumferential extent: how long circular the defect is.

• Axial extent: how many slices the defect goes through.

• CT Defect: pixel value of defect.

• Accept/Reject

• Tech Order reference

• Analyst initials

• User Notes

7.3 Image Acquisition Requirements

7.3.1 The software shall allow acquisition of computed tomography (CT) and digital radiographic (DR) images. The image acquisition techniques shall be user selectable to include the following:

• Object Type

• Object Serial Number

• Scan Height (CT) or Scan Extent (DR)

• Field-of-View

• Starting Table Angle

• Image Matrix (e.g., 1024, 2048 or 4096)

• Number of Traverses

• Detector Aperture Settings

7.3.2 Image Quality Requirements:

7.3.2.1 Hill AFB is currently using ASTM E1695 for system performance checks. ASTM E1695 gives methodology for measuring image quality.

The standard focuses on the modulation transfer function (MTF) for measuring spatial resolution and equally on the contrast discrimination function (CDF) for contrast sensitivity. It is possible to tweak a system design to obtain great MTF results with poor CDF results. This is to be avoided since the poor contrast sensitivity obscures any gains in the spatial resolution and the entire imaging system suffers for it. Contractor shall provide a system design to maximize MTF and CDF.

7.3.3 Sensitivity: Modulation Transfer Function (MTF) shall meet a minimum of .3-line pairs per millimeter (lp/mm). MTF and Contrast Discrimination Function (CDF) shall be reviewed via system diagnostic test by creating charts.

7.3.4 • System performance check must be a current, state of the art method for checking resolution, contrast, and noise sensitivity.

7.3.5 • Differentiate densities of material using colors

7.3.5.1.1 The density range and color palette shall be adjustable.

7.3.5.1.2 Currently, our system is color palette selectable with denser materials showing a lighter color/shade and less dense materials showing a darker color/shade.

7.3.6 The system shall allow operator review of calibration files (e.g., detector dark current files and detector light field files), raw sinogram files, and reconstructed CT image files. The system shall allow display and analysis of reference detector readings.

7.3.7 The system shall allow density calibration to a standard material. For example, the ICT 1500 and ICT 2500 were originally calibrated to show CT numbers in mg/cc (approximated) with exact densities for aluminum (6061).

7.3.8 Image Display and Analysis Requirements

7.3.8.1 The software shall allow typical image display and analysis tools, such as the following:

• Colormap Selection

• Brightness and Contrast Adjustment

• Image Magnification Selection

• Image Lineout Graphing

• Region-of-Interest Statistical Analysis

• Nondestructive Image Annotation

7.3.9 Image Quality Measurement

7.3.9.1 The software shall allow automated ASTM analysis of disk phantoms, showing the resulting modulation transfer function and contrast discrimination function. (See ASTM E 1695.)

7.3.10 Image File Format

7.3.10.1 The system shall be capable of reading, displaying, and saving images in a non-proprietary and .tif format without degradation of image quality. The software shall also be capable of reading and displaying historical data in the ARACOR file format.

7.3.11 Contractor’s software shall be able to recognize/read ARACOR file format for viewing images. User will be responsible for reconstructing all original Sinogram files.

7.4 Workstations

7.4.1 Workstations are specific to the needs of Hill AFB’s application and needs to be met. Often the suggested workstations are customized beyond the primary task. Post processing will be performed by an off-line station, and use a PC as listed below. Operating software shall be Microsoft Windows 11 Enterprise. Computers and file server shall adhere to the 2GIT requirements.

7.4.2 Replace 1ea operating workstations (operator station) and 1ea 2-D reconstruction (acquisition station) workstations in each building (for a total of 4 computers)

7.4.3 Replace 1ea 3D rendering (reconstruction station) workstation to whole new operating system including software for each building (for a total of 2 computer replacements).

7.4.4 Computer components to the following or govt approved equivalent.

7.4.4.1 Description:

7.4.4.1.1 Processor – Current generation Intel i9 or Xeon processor minimum 3.0Ghz Intel Xeon 4GHz, 4Core, 8.25MB Cache, DDR4-2666

7.4.4.1.2 Video Cards: For the six (6ea) computer systems, Nvidia RTX A5500 24GB DDR6 (workstation class GPU or better with approval)

7.4.4.1.3 NIC - 1x Fiber, 2x Gig Ethernet

7.4.4.1.4 Ram - 128GB DDR5

7.4.4.1.5 Storage - PCIe 2TB SSD

7.4.5 Replace NAS (network attached storage) with Windows File Server and latest server OS.

7.4.5.1 Both the ICT 1500/2500 systems require a Windows File Server for storage to communicate with 3D modeling computers (reconstruction station). Must connect file server to 3D modeling computer to analyze data (LAN/Fiber connectivity). Server shall communicate with all workstations.

7.4.5.2 File Server Requirements:

7.4.5.2.1 20TB Solid State Drive

7.4.5.2.2 Backup/Archive 20TB Solid State Drive

7.4.5.2.3 Optical - DVD+/- RW

7.4.5.2.4 Optical - Blueray drive

7.4.5.2.4.1 Power - 950W

7.4.6 Monitor Requirements:

7.4.6.1 Each ICT system requires 2ea of the following for a total of 4ea. One for the image acquisition station and another for the review and reconstruction station.

7.4.6.1.1 Each Double Black Imaging CL8MPS32C 8MP Monitor

7.4.6.1.2 32" 8MP Color LCD with Medical Certs, Calibrated

7.4.6.1.3 Brightness of 350cd/m2

7.4.6.1.4 1300:1 contrast ratio

7.4.6.1.5 3-Year, 10,000 hour warranty - Parts, Labor, Backlight

7.4.6.1.6 ISC-AFS Add-on Front Sensor

7.4.6.1.7 CFS-Local Imsage Systems Calibration Feedback System Local Client SW - remote installation

7.4.6.1.8 CFS-WEB-MANAGER Network administration SW - remote

installation

7.4.6.1.9 Productivity Tools includes Auto Dim, Cursor Genie, Cursor Locator, Cursor Wrap and PinPoint

7.4.6.1.10 Hot Swap 3-Year Advanced Product Replacement

7.4.6.2 Each ICT system requires 2ea monitors for the operator system for a total of 4ea.

7.4.6.3 Each ICT system requires 4ea monitors for the 2 operator systems for a total of 8ea monitors.

7.4.6.3.1 Brand/Model: Dell S2725DS

7.4.6.3.2 Size: 27”

7.4.6.3.3 Resolution: 2560 x 1440 (QHD)

7.4.6.3.4 100Hz

7.4.7 Camera System Requirements:

7.4.7.1 Contractor shall replace each camera that is currently in place. Each ICT system requires 2, live-feed, cameras located in 2 locations, pointing towards the CT table. Contractor to propose a camera system solution, which is shielded from radiation, that shall be approved by Hill AFB.

The surveillance system shall include, but not limited to the following features and specifications:

7.4.7.2 Cameras: 2ea cameras per system for a total of 4 cameras.

7.4.7.2.1 Cameras to be 4k, high definition, with the following capabilities:

7.4.7.2.1.1 Zoom in and out.

7.4.7.2.1.2 Pan capabilities, left and right, 180 degrees rotation

7.4.7.2.1.3 Tilt capability, up and down, 90 degrees rotation

7.4.7.2.2 No video data storage required.

7.4.7.3 Camera enclosures: Each camera shall be shielded from radiation.

7.4.7.4 Monitors: 1ea 27” monitor per system for a total of 2 monitors.

7.4.7.4.1 Each monitor shall be capable of displaying both cameras in a split screen configuration utilizing the camera resolution.

7.5 The contractor shall replace the x-ray source packages for both the ICT-1500 and ICT- 2500. Contractor shall purchase both of the following within 3 weeks of award to reduce delivery lead times.

7.5.1 ICT-2500: VAREX LINATRON K MODULAR HIGH-ENERGY

15MEV (K15) X-RAY SOURCE and assembly including the chiller, x-ray tube, power distribution cabinet, Power source box and associated equipment.

7.5.2 ICT-1500: VAREX LINATRON MODULAR HIGH-ENERGY 9MEV

(M9) X-RAY SOURCE and assembly including the chiller, x-ray tube, power distribution cabinet, Power source box and associated equipment.

7.6 The contractor shall upgrade and integrate the interlock system to ensure compliance/compatibility with the ICT system upgrade for both buildings (B984/2113).

7.6.1 - Interlock requirements shall follow standard procedures outlined in Air Force T.O. 33B-1-1.

7.6.1.1 - Radiation Safety shall adhere to the following:

7.6.1.1.1 - AFMAN 48-148 Chapter 4

7.6.1.1.2 - DAFMAN40-201

7.6.1.1.3 - OSHA 29 CFR 1910.1096

7.6.2 The Area Alarm and interlock unit provides programmed control of visual and audible warning signals associated with industrial radiography, in shielded applications.

7.6.3 The system operates and monitors the condition of warning lamps, while providing an audible pre-warning signal and a preset time delay warning radiation to be eminent. The interlock is designed to be installed outside the shielded enclosure and will also monitor the condition of all interlock switches associated with the shielded radiographic enclosure.

7.6.4 The interlock is designed to be installed outside the shielded enclosure and will also monitor the condition of all interlock switches associated with the shielded radiographic enclosure. The interlock unit incorporates a solid-state advanced technology programmable controller. When installed with a shielded x-ray bay. The controller monitors the conditions of the room interlocks, status of the x-ray unit, and operation of the warning beacons. A ‘start/exit’ sequence allows the operator to ensure that the x-ray room is clear of personnel, monitors the entrance door interlock to prevent operation of the x-ray control if the door has been opened after the prewarn alarm. Visual and audible alarms on the front panel provide a pre-warning alarm for a minimum of twenty seconds before allowing the initiation of x-rays. A red flashing signal light on the front panel provides indication during “X-ray On” condition.

7.6.5 The unit front panel provides operation instructions. An “Emergency Manual Off” (EMO) push-button on the front panel provides an additional means for personnel to terminate or prevent x-ray operation.

8 OTHER REQUIREMENTS

8.1 The Contractor Shall provide all labor, tools, parts, supplies, equipment, lodging, transportation, and other necessary items needed to perform the required services on the ICT-1500 & ICT 2500 located in building 2113 & 984 at Hill Air Force Base (HAFB).

8.2 Upon award and on-boarding the contractor for the ICT-1500/2500 upgrade, the contractor shall be responsible in working with Interwest Physics to assist in any repairs needed to maintain both the ICT-1500 and ICT-2500 systems during the POP of both system upgrades.

9 SECURITY REQUIREMENTS

9.1 The Contractor Shall comply with all security, force protection and anti-terrorism requirements enforced at HAFB.

9.2 The Contractor Shall complete a "Request for Identification Credential (AFMC Form 496)" for each employee of the Contractor requiring access to HAFB. The requests shall be submitted to the MXSS/NDI Element Chief.

9.3 The MXSS/NDI Element Chief will be responsible and ensure that the Contractor is given base access at the South Gate Visitors’ Center by on-line access request. The access process will be based on the security requirements at that time. A representative from the 709th MXSS will then provide an escort to the MSA I & II area and building 984 & 2113.

9.4 The Government will provide access to the necessary facility where the equipment resides. The place of performance shall be on HAFB. The Contractor shall coordinate required access/usage times and dates with MXSS/NDI supervisor(s) and/or 309

MXSG/709 MXSS.

9.5 The Contractor understands any contractor employee may be summarily and immediately removed from or denied access to any government property, facility, and installation at the sole discretion of competent government authority; if that authority determines such action is necessary to protect or preserve government property, safety, and security, or to maintain good order and discipline.

9.6 In the event of an accident/mishap, the contractor shall take reasonable and prudent action to establish control of the accident/mishap scene, prevent further damage to persons or property, and preserve evidence. An email copy of the mishap / incident notification shall be sent within three calendar days to the 309 MXSG/MXDSA COR or 309 MXSG/MXDVA Shop Supervisor, who will forward it to OO-ALC safety.

10 TESTING AND PERFORMANCE REQUIREMENTS

10.1 Upon completion of ICT-1500/2500 Extension of Life repairs, The Contractor Shall demonstrate the functional performance and accuracy for acceptance by representatives of Interwest Physics, AFNWC/NAID, RSLP, and the 709th MXSS to ensure Computed Tomography system performance specifications have been met. The final acceptance inspection shall be accomplished by the representative from Interwest Physics and Hill AFB, 709th MXSG/MXSS POC prior to contractor departure.(CDRLS A003/A004)

10.2 Contract technical acceptance shall meet the following for both ICT Systems:

10.2.1 Both ICT Systems will need 2 stages to the system acceptance criteria.

10.2.1.1 Part 1: All components aside from the linatron x-ray source/associated components to follow acceptance criteria. System shall be a fully functioning system.

10.2.1.2 Part 2: Upon installation of linatron x-ray source, adhere to same acceptance criteria to ensure the system is fully functional prior to final buy-off.

10.2.2 Motion System Requirements

10.2.2.1 Motion system accuracy and detector aperture positioning accuracy shall be at least as good as the original system.

10.2.2.2 Motion control shall be allowed from the bay or from the control room in a manner that does not allow concurrent control of the motion system.

10.2.3 Motion System Safety

10.2.3.1 The original ICT system motion systems were designed with soft and hard limits to protect Air Force assets. Acceptance testing to include verification that the motion system will safely stop within limits when driven under full load towards the extreme positive and negative motion limits.

10.2.3.2 The contractor shall ensure positional accuracies and timing of all axes, encoders, CT table, drive motors, and ensure hard and soft limits are accurate and in place to protect explosive Air Force assets.

10.2.4 Personnel Safety

10.2.4.1 The original ICT system bays included safety interlocks to protect against radiation exposure of personnel. Acceptance criteria to include door interlocks, radiation monitoring interlocks and other safety features included in the original design. Testing of these features shall be included.

10.2.5 Detector Electronics Shielding

10.2.5.1 The detector system is required to be in the direct path of the x-ray beam. Detector electronics are in a high-dose environment. Acceptance criteria to include an evaluation of the detector electronics shielding design. The contractor shall design the shielding to meet the radiation environment of the associated Varex Linatron x-ray source in a way that will minimize dose to the electronic components.

10.2.6 Image Quality Metrics

10.2.7 Process control results must meet or exceed the following Certificate of

Conformance results:

Aluminum Phantom Disc Results

Image MTF Result CDF Result FOV: 900 mm

Res Ap: 1.0 mm Thick Ap: 40.0 mm

0.620 lp/mm at 5% modulation

7.689 at 0.440 mm

FOV: 1850 mm Res Ap: 1.0 mm

Thick Ap: 4.0 mm

0.332 lp/mm at 5% modulation

8.257 at 0.904 mm

10.2.7.1 Historically, performance of the ICT 1500 and ICT 2500 systems have been measured in accordance with practices outlined in ASTM E 1695, “Standard Test Method for Measurement of Computed Tomography System Performance.” Image quality is measured as described in the ASTM standard from the cross-sectional CT image of a uniform cylinder. Standard measures of the system modulation transfer function (MTF) and contrast discrimination function (CDF) are derived from the disk image. These two curves taken together provide a quantifiable measure of system performance. See previous test results below.

10.2.8 Image Acquisition Requirements

10.2.8.1 The software shall allow acquisition of computed tomography (CT) and digital radiographic (DR) images. The image acquisition techniques shall be user selectable to include the following:

• Object Type

• Object Serial Number

• Scan Height (CT) or Scan Extent (DR)

• Field-of-View

• Starting Table Angle

• Image Matrix (e.g., 1024, 2048 or 4096)

• Number of Traverses

• Detector Aperture Settings

10.2.8.1.1 The system shall allow operator review of calibration files (e.g., detector dark current files and detector light field files), raw sinogram files, and reconstructed CT image files. The system shall allow display and analysis of reference detector readings.

10.2.8.1.2 The system shall allow density calibration to a standard material. For example, the ICT 1500 and ICT 2500 were originally calibrated to show CT numbers in mg/cc (approximated) with exact densities for aluminum (6061).

10.2.9 Image Display and Analysis Requirements

10.2.9.1 The software shall allow typical image display and analysis tools, such as the following:

• Colormap Selection

• Brightness and Contrast Adjustment

• Image Magnification Selection

• Image Lineout Graphing

• Region-of-Interest Statistical Analysis

• Nondestructive Image Annotation

10.2.10 Image Quality Measurement

10.2.10.1 The software shall allow automated ASTM analysis of disk phantoms, showing the resulting modulation transfer function and contrast discrimination function. (See ASTM E 1695.)

10.2.11 Image File Format

10.2.11.1 The system shall be capable of reading, displaying, and saving images in a non-proprietary and .tif format without degradation of image quality. The software shall also be capable of reading and displaying historical data in the ARACOR file format.

10.2.11.2 Much of the archived historical data is saved only in the sinogram format (that is, prior to image reconstruction). It is desirable that the software can read and reconstruct ARACOR sinogram files.

10.3 Project upgrade shall include a standard one-year parts/labor warranty defect coverage and software updates/maintenance from date of installation. The Contractor Shall provide technical support by phone/email for the duration of the warranty period from 6:00 a.m. to 4:30 p.m. Mountain Standard Time (MST), Monday-Friday. The Contractor Shall respond to technical questions within one (1) business day of Government request. The Contractor Shall provide a telephone number and e-mail address to the MXSS/NDI supervisor(s)/COR/Process Engineer upon award of the contract. All parts needing replacement shall be replaced within five (5) business days. For long lead time items, the contractor shall procure items on a schedule agreed to by the MXSS/NDI supervisor(s).

10.4 Contractor shall provide spare parts for the following components being upgraded in each system:

10.4.1 Complete new LDA/FBC “Drop in” assembly

10.4.2 12ea LDA modules

10.4.3 12ea PCB A/D Boards

10.4.4 M9 VAREX Spare Parts Kit

10.4.5 K-15 Spare Parts Kit

10.5 Allowed downtime:

10.5.1 The ICT-1500 Shall have no longer than 5 weeks downtime for the install and integration of the motion control, software, imaging systems.

10.5.2 The ICT-1500 shall have no longer than 5 days of downtime for the install and integration of the Linatron and associated components.

10.5.3 The ICT-2500 Shall have no longer than 5 weeks downtime for the install and integration of the motion control, software, imaging systems, and associated components. (CDRL A007)

10.5.4 The ICT-2500 shall have no longer than 5 days of downtime for the install and integration of the Linatron and associated components.

10.6 We understand that the x-ray source packages for both the ICT-1500 and ICT-2500 have a long lead time. Everything aside from those shall be installed to fully functioning capability and be ready for the x-ray source and applicable parts to be installed at a later, coordinated date.

10.6.1 Coordinate install of x-ray sources and associated parts/equipment with 709th production and process engineer.

11 TRAINING:

11.1 At the 709th MXSS discretion, the Contractor shall provide On-The-Job-Training (OJT) to Government/contractor, operator, engineering, NDI Level III personnel, and 309th Maintenance technicians in conjunction with the updated ICT-1500/2500 user software applications and equipment functions. Training to include a total of 5 days.

11.1.1 Training shall be provided immediately after acceptance is completed.

Some training will be required during installation. Training shall take place during core HAFB business hours and be pre-coordinated with the cognizant MXSG Engineer. Pre-coordination while the contractor is on-site for install is acceptable. Training shall cover the following, at a minimum:

11.1.2 Familiarization with all components and features.

11.1.3 Daily maintenance and prior-to-use inspections.

11.1.4 Periodic Maintenance Actions: 30, 60, 90, 180, 360 day frequency.

11.1.5 ICT System start-up (set-up) for scanning including all adjustments prior to scanning.

11.1.6 How to read scanned data and construct 3D imaging.

11.2 Training to include operator and general corrective and preventative maintenance and mild diagnostics.

11.2.1 The contractor shall provide on-site maintenance training upon completion of installation at HAFB. Training shall be provided for day shift personnel for five (5) consecutive business days. Training shall take place during core HAFB business hours and be pre-coordinated with the cognizant MXSG Engineer. Pre-coordination while the contractor is on-site for install is acceptable. Training shall cover the following, at a minimum:

11.2.2 Troubleshooting system errors and mechanical failures.

11.2.3 Familiarization with all components and features of the systems.

11.2.1 ICT System start-up (set-up) for scanning including all adjustments prior to scanning.

11.3 Contractor Shall provide Operator, Maintenance and Software manuals, both paper copy and electronic PDF for each system. (CDRLA005)

12 ADDITIONAL INFORMATION

12.1 The points of contact for this effort are Josh Pugeau @ (801) 777-6082 and Morgan Nielson @ (801) 586-6009, 709th MXSS Missile X-Ray / Computed Tomography Section Chief. Daniel Edlin @ (801) 777-1338 / Process Engineer.

12.2 The contractor shall notify the Contracting Officer, if there are any changes to the scope of work.

12.3 Contractor to develop acceptance criteria plan document for government review.

12.4 Contractor to work with 709th MXSS to ensure test acceptance procedures comply with all process requirements.

12.5 O&M and Software Manuals (CDRL A005). Operation and Maintenance and Software manuals shall be prepared and delivered on electronic media in pdf file format compatible with Adobe Acrobat and on 8 ½ by 11-inch bond paper and presented in appropriately sized three ring binders. Operation Manual, Maintenance Manual, and Software Manual shall be in separate binders. The contractor shall provide three (3) hardcopy O&M and Software manuals and one (1) CD-R ROM/DVD-R digital copy. The manual shall include, but is not limited to, the following:

12.5.1 Operation Manual – This manual is intended for the user.

12.5.1.1 Illustrated Parts Breakdown (IPB) with a full bill of materials (BOM) with all components, parts numbers, serial numbers, NSNs, and associated manufacturers and vendors.

12.5.1.2 Prior-to-Use Inspection Instructions if applicable. These instructions shall be performed by the user to inspect the system prior-to-use.

12.5.1.3 Operating Instructions. These instructions shall be performed by the user to set-up and operate the Software and ICT System.

12.5.2 Maintenance Manual – This manual is intended for maintenance personnel.

12.5.2.1 Maintenance Instructions. These instructions shall be performed by maintenance personnel and cover items/components that will require sustainment to include all materials and consumables required for maintenance and step by step instructions to complete required tasks.

12.5.2.2 Schematics for all electrical systems shall be included.

12.5.2.3 Recommended Preventative Maintenance Schedule. These instructions shall be performed by maintenance personnel.

12.5.3 Software Manual – This manual is intended for user and maintenance personnel.

12.5.3.1 The software manual shall include user startup, scanning/reading and troubleshooting instructions.

12.5.3.1.1 Troubleshooting instructions to include, but not limited to a troubleshooting tree diagram.

12.5.4 In the event the cognizant MXSG Engineer determines the manuals contains any inaccuracies or omitted information, a revision with complete corrections shall be submitted within two calendar days of government notice.

12.6 For each ICT system, provide the following: Final Design Technical Data Package (TDP) (CDRL A006). The engineering drawing package, or TDP, for all the new and modified equipment that is provided shall be prepared per ASME Y14.100 and shall be provided to the Government with unrestricted rights--no proprietary markings of any kind shall be included on the TDP. The final design, or TDP, shall be comprehensive and ensure that the Government can reproduce and modify the design. The TDP shall represent the MXSG Engineering approved design of the ICT Upgrade after Production Assessment has been completed. TDP data includes, but is not limited to, CAD data, CAD models, Bill of Materials (BOM) and parts list, schematics, wiring diagrams, and engineering drawings.

The TDP shall provide the necessary design, engineering, manufacturing, testing and quality assurance requirements information necessary to enable the procurement and 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. For any third party items procured for this effort, the contractor shall provide the OEM’s original nomenclature, key characteristics, and data sheets as part of the TDP.

12.6.1 The contractor shall deliver two (2) complete printed copies of the final engineering drawing package on 11 by 17-inch bond paper and presented in appropriately sized bound presentation booklets with plastic covers.

12.6.2 Digital copies of the engineering drawings shall be provided on two (2) CD-R/DVD-R in pdf file format compatible with Adobe Acrobat.

12.6.3 Digital copies of the schematics, CAD models and engineering drawings shall be provided on two (2) CD-R/DVD-R in SolidWorks file format compatible with SolidWorks 2022 or earlier.

12.6.3.1.1 SolidWorks CAD files for parts, assemblies, and drawings for the new and modified components of the system shall be compatible with…