Revised_Atch_1_16T_C1_Compressor_Blades_SOW.pdf

14424-17-004A

Distribution A - Public Release Distribution Unlimited

IRA-2620, PA-AEDC2016-195

SOW NO. 14424-17-004A

21 April 2017

STATEMENT OF WORK

FOR

16T C1 COMPRESSOR ROTOR BLADES

ARNOLD ENGINEERING DEVELOPMENT COMPLEX

ARNOLD AIR FORCE BASE, TN 37389-9998

Distribution A Public Release Distribution

Unlimited

Table of Contents-1

TABLE OF CONTENTS

1. SCOPE

2. APPLICABLE DOCUMENTS

2.1. Government Documents

2.2. Non-Government Documents

3. REQUIRMENTS

3.1. General

3.2. Program Management

3.3. Engineering Analysis

3.4. Engineering Data

3.5. Coordination Meetings

3.6. Verification and Acceptance

3.7. Training

3.8. Submittals

Appendix A – Submittal Procedure

Appendix B - AEDC SECURITY RULES AND REGULATIONS

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1. SCOPE

1.1 The Contractor shall furnish and deliver up to 204 compressor blades for the C1 compressor in the 16T wind tunnel at Arnold AFB, TN. The work includes structural analysis and design, manufacturing, prototyping, testing and delivery of a full production run of blades to Arnold AFB, TN.

1.2 Background: The C1 Compressor (asset ID 16T C1 COMPRESS) provides airflow for the 16T wind tunnel. The C1 compressor accomplishes this through standard axial flow technology. The compressor is a large three-stage axial flow machine with a rotor blade tip-to-tip diameter of 30.2 ft. Each stage is composed of rotating blades separated by variable pitch stator blades. The composite rotor blades are designed with an offset center of gravity (CG) which limits the bending stress in the blade by resisting aerodynamic loading. In addition, the blades are pinned which allows them to rotate, further reducing the blade stresses and the load transferred into the composite spacers installed between the blades. The spacers restrict blade rotation to prevent interference between the rotor and stator blades.

2. APPLICABLE DOCUMENTS

2.2. Government Documents:

2.1.1. Specification Number 14424-17-003 16T C1 Compressor Blade Structural Design/Analysis, Tooling, Testing Units, and Manufacturing.

3. REQUIREMENTS

3.1 General:

3.1.1 The Contractor shall design, fabricate and inspect (both dimensional and Non- Destructive Inspection (NDI)) the following parts per the requirements detailed within this specification. Prior to full production, ten (10) prototype blades shall be manufactured and tested. These include three for each Row A, B, and C Prototype blades, and an additional Row C blade for damage and repair testing.

After successful testing of the prototype blades, nine (9) Low Rate Initial production (LRIP) blades shall be manufactured and tested. The LRIP blades shall include three each for Rows A, B, and C. The LRIP blades shall be qualified in the same manner as the prototypes (with the exception of destructive testing) by the Contractor and Government. The following full production quantities shall be provided:

A. Sixty-five (65) Row A blades with installed blade cuff and disc/blade interface bushings

B. Sixty-nine (69) Row B blades with installed blade cuff and disc/blade interface bushings

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C. Seventy (70) Row C blades with installed blade cuff and disc/blade interface bushings

D. One Hundred (100) spare tip caps

E. Thirty (30) spare blade cuffs (Ten (10) A-Row, Ten (10) B-Row, and Ten

(10) C-Row spare blade cuffs) if the blade cuff is not made an integral part of the blade. The Contractor shall include the cost of these cuffs with their trade study for integrating the cuff.

3.1.2 The Contractor shall supply full-scale rapid prototype models ( stereolithography, selective laser sintering, or other processes such as machining of durable plastic, whose material properties allow for handling and installation without damage) which represents the outer mold line of their design for the blade assembly (including blade and cuff design) up to section D2 as shown on drawing

3202100.6. If the vendor cuff design maintains thin composite strips similar to the current cuffs then the strips need not be machined completely, but the material shall have a minimum 1/4" recess so that the location and the thickness of the strips is visible. One model for each row shall be provided. The Contractor shall supply a dimensional inspection report verifying that the rapid prototypes accurately represent their blade design. The Government will use these models for an air-off check fit in the wind tunnel compressor. Maximum weight of these models shall be 150 lb each.

3.2 Program Management:

3.2.1 The Contractor shall develop and deliver CDRL A0004, Program Management Plan (PMP). Preliminary PMP is due 30 days after contract award and update monthly. An updated PMP shall be included with the Technical Design Review (TDR) and Final Design Review (FDR) packages 21 days prior to those reviews.

The schedule portion of the PMP shall include:

A. TDR Meeting.

B. Rapid prototype completion date.

C. FDR Meeting.

D. Tooling fabrication complete date.

E. Prototype production complete date.

F. Prototype testing complete date.

G. LRIP completion date.

H. LRIP testing complete date.

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I. Full rate production completion date.

3.2.2 The Contractor shall implement and maintain the Program Management Plan.

(PMP). The Contractor shall develop, implement, and maintain an Integrated.

Master Schedule to be included in the PMP. The Contractor shall integrate scope, schedule, constraints, and cost information from all subcontractors into the PMP.

3.2.3 Within the PMP the Contractor shall develop, implement, and maintain a risk-management process that systematically identifies and mitigates program cost, schedule, and technical risks. Incorporate identified risk handling strategies into program level plans and schedules.

3.2.4 The Contractor shall track risk management throughout the program through CDRL A0003, Risk Assessment. The Contractor shall deliver the updated risk management report on a monthly basis with the PMP.

3.3 Engineering Analysis:

3.3.1 Structural analysis shall consist of Finite Element Analysis (FEA) utilizing maximum stress/strain, Tsai Wu, Tsai Hill, and Hashin criteria. First ply failure for each criteria shall be reported, but the factor of safety shall be based on ultimate failure using progressive failure analysis. The report shall include “ply discounts” used for the progressive failure analysis. The failure criteria proposed for use in the design shall be presented at TDR and approved by the Government before proceeding. Backup hand calculations shall be performed for blade bending and twisting stresses.

3.3.2 Progressive failure criteria modeling shall also be reported. For the TDR this progressive failure analysis shall be reported using the Contractor proposed failure theory. If a different theory is approved by the Government at this stage then the Government approved failure theory shall be used for the FDR analysis.

The value associated with “ply discounts” at each stage of the progressive failure analysis steps shall be reported as well.

3.3.3 All closed form calculations shall be included in the analysis report. All analysis shall be documented and supplied to the government in report form including detailed assumptions, analysis methods, boundary conditions, and conclusions.

This report shall be supplied in Portable Document Format (.pdf).

3.3.4 Structural analysis shall be performed assuming each of the damage conditions shown in Specification 14424-17-003 section 3.8.1

3.3.5 Structural assessment of proposed repairs for the damage conditions shown in Specification 14424-17-003 section 3.8.1 shall also be analyzed to show that original limits are met following repair.

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3.3.6 All FEA shall be submitted as a part of the analysis report including assumptions, boundary conditions, results, and conclusions (.pdf file format) and in a digital format compatible with ANSYS FEA software version 14.0 and newer. The FEA model submitted shall be fully functional and all analysis shall become property of the Government on contract completion.

3.3.7 A service life analysis shall be performed which will involve a combination of coupon level fatigue testing to produce S-N curves in combination with structural analysis to determine the fatigue life of the blade assembly. See Specification 14424-17-003 section 4.1.4 for detailed testing requirements.

3.4. Engineering Data:

3.4.1. Final as-built design drawings shall be supplied for the blade and blade cuff (if applicable) including ply cutting definitions, ply layup definitions, 3-D CAD models, and fully dimensioned 2-D drawings. Final as-built design drawings shall be supplied for all tooling. These drawings shall include 3-D CAD models and fully dimensioned 2-D drawings. Drawing shall be in accordance with ANSI Y14.5 1994 or 2009. Drawings and 3-D CAD models shall be delivered in a format compatible with Autodesk Inventor 2015 (e.g. .SAT, .STP) and newer as well as in PDF format (2-D Drawings only). The dimensional drawings and solid models shall be in English imperial units. All models and drawings shall become property of the Government upon contract completion.

3.4.2. Bills of material, details, and assembly information shall be provided. Certified blade assembly weight and center of gravity location shall be provided on the assembly drawing. Blade center of gravity shall be measured and provided for the first production blade.

3.4.3. All special tooling, jigs, and fixtures manufactured under this contract shall become property of the Government after contract completion. Drawings and 3- D CAD models shall be delivered in a format compatible with Autodesk Inventor 2015 (e.g. .SAT, .STP) and newer as well as in PDF format (2-D Drawings only).

The dimensional drawings and solid models shall be in English imperial units. All 2-D drawings and CAD models of this tooling shall become property of the Government on contract completion.

3.4.4. Manufacturing process development and production documentation shall be provided in order to fully document the critical manufacturing, processing, and disassembly steps in laying up, assembling, curing, and post-processing the blades.

3.4.5 Accept/reject criteria for blade defects or damage which determines suitability for blade delivery to the Government and accept/reject criteria for blade defects or damage used by the Government during blade operation (reference Specification 14424-17-003 section 3.8.1) shall be provided.

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3.5 Coordination Meetings:

3.5.1 The Contractor shall conduct the following design review meetings at the Government facility. These meetings shall include discussions on the blade, blade cuff, and blade tooling. The Contractor shall submit to the Government all information as identified below three weeks prior to the meeting. The Manufacturing Readiness Review (MRR) shall be conducted at the Contractor’s facility.

A. Technical Design Review (TDR - ~50% design complete) – The Contractor shall present a detailed presentation of their design and analysis. The Contractor shall submit drawings and calculations to the Government for the technical review. Requirements for the Technical Design Review are:

1. Design and Analysis:

a. Narrative describing the design and analysis process, including assumptions made, development of preliminary material properties, and any additional concepts considered and why they were rejected.

b. Preliminary design calculations shall include a Finite Element Analysis (FEA) model and stress report which determine the mix of materials in the blade, show critical structural areas, and show loads which will be imparted on the rotor disc, cuff, spacer, and blade adapter. Preliminary micromechanical or lay-up stiffness calculations shall be included. Preliminary back-up hand calculations shall be included.

c. Preliminary design drawings shall include blade layout, internal structure, and material thicknesses. The drawing package shall include preliminary 3-D Computer Aided Design (CAD) models.

d. Preliminary service life analysis.

e. Preliminary description of design for repairability.

f. Trade Studies for potential integrated cuff and strong-back redesign. Include an itemized list of costs for each proposed solution. Do not proceed with fabrication work until receiving Government approval.

g. Summary of engineering change proposals.

h. The Contractor shall build 10”x10” flat panels of their proposed materials and thicknesses at sections D1-D1, D- D, and C-C from drawing 3202100.6 sheet 1 for Government approval of visual inspectability.

2. Verification:

a. Traceability document for sections 3 and 4 of Specification 14424-17-003.

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b. Update risk analysis and risk management strategy.

c. Preliminary prototype and LRIP blade test plan.

d. Material characterization plan.

e. Impact panel test report.

3. Manufacturing:

a. Preliminary Tooling Drawings which reflect the proposed tooling concept.

b. Initial manufacturing plan (including tooling, manufacturing methodology, NDI, and other inspections).

c. Preliminary accept/reject criteria.

4. Schedule:

a. Program Management Plan update.

B. Final Design Review (FDR – 100% design complete) –The Contractor shall conduct a detailed presentation of their final design. The Contractor shall submit to the Government drawings and calculations for the technical review. Requirements for the Final Design Review are:

1. Design and Analysis:

a. Final Narrative describing the design and analysis process, including assumptions made, development of preliminary material properties, and any additional concepts considered and why they were rejected.

b. Final design calculations shall include an FEA model and report which include the final lay-up configuration, show critical structural areas, and show loads which will be imparted on the rotor disc, cuff, spacer, and blade adapter.

Final back-up hand calculations shall be included.

c. Final design drawings shall include blade layout, internal structure, and ply tables with orientations and overall thickness. The drawing package shall include final 3-D CAD models.

d. Final service life analysis.

e. Final description of design for repairability.

f. Approved engineering change proposals.

g. Preliminary Design and Analysis of the instrumentation for prototype testing including preliminary strain gage placement.

2. Verification:

a. Final Traceability document for sections 3 and 4 of Specification 14424-17-003.

b. Update risk analysis and risk management strategy.

c. Material characterization report.

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3. Manufacturing:

a. Final Tooling Drawings which reflect the FDR design.

b. Manufacturing plan updated from TDR (including tooling, manufacturing methodology, NDI, and other inspections)

c. Updated Blade accept/reject criteria

d. Safety Data Sheets (SDS) for materials to be used in manufacturing

e. Blade preliminary repair procedures.

4. Schedule:

a. Program Management Plan update.

C. Manufacturing Readiness Review (MRR) – This review shall occur prior to production of the prototype blades. Any changes to documents presented as exit criteria resulting from prototype production shall be presented for approval prior to production of the LRIP blades.

1. Final production plan and procedures (including tooling and NDI).

2. Final accept/reject criteria overview.

3. Final blade repair procedures and any special tooling required for repairs.

4. Blade geometric inspection plan

5. Blade Cuff Installation Procedure (if required).

6. Final Design and Analysis of the instrumentation for prototype testing including final strain gage placement and analysis of the gage placement for sensitivity to operational vibration modes.

7. Final prototype and LRIP blade test plan

8. Tooling geometric inspection reports, any special instructions for use, and a list of all disposable materials for use with tooling.

3.5.2 The Government reserves the right to request updates and coordination teleconferences as required during the design process.

3.6. Verification and Acceptance:

3.6.1 Technical Surveillance: Government or Government representative reserves the right to visit the Contractor and manufacturer facilities to assess manufacturing capability, readiness, and/or progress.

3.6.2 Testing Responsibilities: The Contractor shall be responsible for all material testing to qualify the composite material for design of the blade structure. The Contractor shall be responsible for instrumentation and full scale testing of the prototype and LRIP blades. The Contractor shall be responsible for panel impact testing. The Government will approve all test plans.

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3.6.3. If the prototype blades pass qualification, production authorization will be given for the nine (9) LRIP blades. If any of the prototype or LRIP blades do not pass testing, the Contractor shall provide a root cause analysis and report for the failure. Once the root cause analysis report and corrective action is approved by the Government, the Contractor shall produce additional blades to replace the failed blades. These replacement blades will then be subjected to the entire prototype qualification testing procedure. This process shall continue until all blades produced pass qualification testing.

3.6.4 One set of master NDI calibration standards shall be provided. The calibration standards shall employ built-in NDI calibration targets embedded in the standards to facilitate calibration of the NDI equipment. These flaws shall at a minimum represent the smallest flaw that is outside the bounds of the accept/reject criteria for the blade manufacturing process (see Specification 14424-17-003 section 3.8.1)

3.6.5 Government performed tests:

A. The Government plans to perform acceptance testing of nine Prototype blades and nine (9) LRIP blades at AEDC. This testing will consist of installation of the blades in tunnel 16T Compressor C1 and running the blades at various test conditions. A Contractor representative may witness this testing and shall comply with all security and safety requirements at the installation.

B. The Government plans to install the first 97 production blades and run a tunnel calibration test before approving production of additional blades.

C. The Government will dimensionally inspect blades when they are received at AEDC.

D. The Government may send out the prototype, LRIP, and a random sampling of production blades for independent NDI inspection.

3.6.6 Following Government testing in compressor C1, the Contractor shall test three prototype to structural failure at the maximum compressor temperature of 320F.

One blade shall be failed by distributed loading in bending, one by distributed loading in torsion, and one due to CF load applied at section E-E.

3.6.7 Acceptance: The Government will accept the blade assemblies, upon successful tests, within 30 days of delivery to AEDC.

3.7. Training:

3.7.1. The Contractor shall supply training materials for repair to include any specialized repair tooling, procedures, sample repairs, any NDI requirements for completed repairs, step-by-step repair pictures, and a video of the repair process. The training material shall also include all maintenance manuals, parts

Page-9 lists, operating instructions, etc. required for maintaining and operating the blades. Provide training materials in a 3-ring binder.

3.7.2. The Contractor shall present a repair course at AEDC which shall include an overview of the repair procedures and training materials as well as making a sample repair for zones 5, 6, and 7. Course materials shall be delivered to the Government for 10 attendees. The Government shall furnish a prototype blade for the purpose of showing example repairs.

3.8. SUBMITTALS:

3.8.1. The Contractor shall submit all documentation in accordance with Appendix A – Submittal Procedure. A summary table of required submittals is listed in Table 1

– Required Submittal List.

3.8.2. Contractor shall provide a summarized submittal listing with delivery dates 14 days after contract (or contract modification) award.

3.8.3 Submittal Table:

Table 1 - Required Submittal List No. Section

Reference Submittal Description Due

1 SOW 3.8.2 Summarized Submittal listing and project schedule with delivery dates

14 days after contract(or contract modification) award

2 SOW 3.1.2 Rapid Prototype Model for each Row

5 weeks prior to FDR

3 SOW 3.1.2 Geometric Inspection report for the Rapid prototype blades

5 weeks prior to FDR

4 SOW 3.2 Program Management Plan 30 days after contract award, updated monthly and included with the TDR and FDR review packages 21 days prior to the review.

5 SOW 3.2 Risk Analysis and Risk Management Strategy

30 days after contract award, updated monthly and included with the TDR and FDR review packages 21 days prior to the review.

6 SOW 3.5.1.A TDR Presentation 21 Days prior to TDR Meeting

7 SOW 3.5.1.A Preliminary Design Narrative 21 Days prior to TDR Meeting

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8 SOW 3.5.1.A Preliminary design drawings and calculations

21 Days prior to TDR Meeting

9 SOW 3.5.1.A Preliminary Service Life Analysis

21 Days prior to TDR Meeting

10 SOW 3.5.1.A Preliminary Repair Considerations in design

21 Days prior to TDR Meeting

11 SOW 3.5.1.A Trade Studies for Integrated Cuff and Strong-back Redesign

21 Days prior to TDR Meeting

12 SOW 3.5.1.A Initial Engineering Change Proposals

21 Days prior to TDR Meeting

13 SOW 3.5.1.A Visual Inspectability Panels 21 Days prior to TDR Meeting

14 SOW 3.5.1.A Initial Traceability Documentation

21 Days prior to TDR Meeting

15 SOW 3.5.1.A Preliminary Blade Test Plan 21 Days prior to TDR Meeting

16 SOW 3.5.1.A Material Characterization Plan 21 Days prior to TDR Meeting

17 SOW 3.5.1.A Impact Panel Test Report 21 Days prior to TDR Meeting

18 SOW 3.5.1.A Initial Manufacturing Plan (including tooling and NDI)

21 Days prior to TDR Meeting

19 SOW 3.5.1.A Preliminary Accept/Reject Criteria

21 Days prior to TDR Meeting

20 SOW 3.5.1.B Final Design Narrative 21 Days prior to FDR 21 SOW 3.5.1.B Final design drawings and calculations 21 Days prior to FDR Meeting

22 SOW 3.5.1.B Final Service Life Analysis 21 Days prior to FDR Meeting

23 SOW 3.5.1.B Final Design for Repairability 21 Days prior to FDR Meeting

24 SOW 3.5.1.B Approved Engineering Change Proposals

21 Days prior to FDR Meeting

25 SOW 3.5.1.B Prelminary Prototype Testing Instrumentation Design and Analysis

21 Days prior to FDR Meeting

26 SOW 3.5.1.B Final Traceability Documentation

21 Days prior to FDR Meeting

27 SOW 3.5.1.B Final Material Characterization Report

21 Days prior to FDR Meeting

28 SOW 3.5.1.B Updated Manufacturing Plan (including tooling and NDI)

21 Days prior to FDR Meeting

29 SOW 3.5.1.B Updated Accept/Reject Criteria

21 Days prior to FDR Meeting

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30 SOW 3.5.1.B Safety Data Sheets (SDS) for all blade materials

21 Days prior to FDR Meeting

31 SOW 3.5.1.B Preliminary Blade Repair Procedures

21 Days prior to FDR Meeting

32 SOW 3.5.1.C Final Manufacturing plan and procedures (including NDI)

21 days prior to MRR

33 SOW 3.5.1.C Final Accept/Reject Criteria 21 days prior to MRR 34 SOW 3.5.1.C Procedures to repair damage shown in the specification.

21 days prior to MRR

35 SOW 3.5.1.C Geometric Inspection Plan

21 Days prior to MRR Meeting

36 SOW 3.5.1.C Blade Cuff Installation Procedure (if Required)

21 Days prior to MRR Meeting

37 SOW 3.5.1.C Final Design and Analysis of Prototype Testing Instrumentation

21 days prior to MRR

38 SOW 3.5.1.C Final Prototype And LRIP Test Plan

21 days prior to MRR

39 SOW 3.5.1.C Tooling Geometric Inspection reports, tooling instructions, and disposable materials used for tooling

21 days prior to MRR

40 SPEC 4.1.2.D Void content testing for manufacturing process

21 days prior to MRR

41 SOW 3.6.4 Master NDI calibration Standards

Prior to Prototype Production

42 SPEC 4.1 Copies of all proposed test plans

14 days prior to testing

43 SPEC 4.1.6.A Baseline NDI inspection report for each blade

At Blade Delivery

44 SPEC 4.1.6.B Post-Testing NDI of Prototype and LRIP Blades

4 weeks after Contractor Receives Post-test Prototype and LRIP blades

45 SPEC 4.1.1 Prototype Testing Report 3 weeks after testing is complete

46 SPEC 4.1.1 LRIP Testing Report 3 weeks after testing is complete

46 SPEC 4.1.7 Modal Analysis test report Delivered with each blade 47 SPEC 4.1.9 Production Part Log Delivered with each blade 48 SOW 3.7.2 Repair training course at

AEDC

Prior to completion of the first 97 blades

49 SOW 3.4.1 Final As-Built Drawings 14 days prior to the completion of the first 97 blades

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Appendix A-1

APPENDIX A

SUBMITTAL PROCEDURE

PART 1 GENERAL

1.1 DESCRIPTION OF REQUIREMENTS. This section specifies procedural requirements for non-administrative submittals, including but not limited to shop drawings, product data, manufacturer’s certificate, design data, calculations, and verifications, manufacturer’s instructions, manufacturer’s field service reports, samples, operation and maintenance manuals, and other miscellaneous work-related submittals. These submittals are required to amplify, expand, and coordinate other information contained in the contract. This section describes the type and content of submittals that may be required for this work. The required submittals are included in the Statement of Work.

Non-work-related submittals are addressed elsewhere in the contract rather than in the specification and may include items such as: contract progress schedule, permits, payment applications, performance and payment bonds, insurance certificates, and progress reports.

The Contracting Officer may request submittals in addition to those specified when deemed necessary to adequately describe the work covered in the respective sections of the specification or statement of work.

1.2 SUBMITTAL PROCEDURE

A. Definition: For the purposes of this section, the term “Contractor” denotes the prime Contractor.

B. Listing: At the end of the Statement of Work is a summarized listing of item submittals requiring approval for the work. The listing is included for the convenience of users of the contract documents. The listing may not be all inclusive and additional item submittals may be required. Within 10 days after receiving contract award, Contractor shall submit a copy of the summarized submittal listing with calendar dates assigned to each item submittal indicating when submittal will be received by the Government. If contract requires a pre-construction conference, Contractor may submit completed submittal listing at the conference.

C. Risk: Do not proceed with the part of the work covered by an item submittal including purchasing, fabricating, and delivering until approval is received.

Machinery, equipment, material, and articles that do not have the required approval shall be installed or used at the risk of subsequent rejection. Any fabrication or other work performed in advance of the receipt of accepted item submittals and approvals shall be entirely at the Contractor’s risk and expense.

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Appendix A-2

D. Transmittal Timing: Coordinate the preparation and processing of item submittals with the performance of the work. Prepare and transmit each item submittal to the Contracting Officer sufficiently in advance of the performance of related work and other applicable activities. Transmit related item submittals for the same unit of work so that processing will not be delayed by the Government's need to review submittals concurrently for coordination. No delay damages or time extensions will be allowed for time lost in late submittals.

E. Content: Each submittal shall be complete and in sufficient detail to allow ready determination of compliance with contract requirements. Complete AF Form 3000 and attach as cover sheet for each submittal. Contractor may include multiple item numbers on an AF Form 3000.

F. Language: All item submittals shall be written in English, including documents, notes on drawings, sketches, and/or samples, calculations, manuals, and all other instances of written text and communication.

G. Units: All item submittals shall be marked or show dimensions and values in the same units as specified in the contract documents.

H. Review Time: Allow sufficient time so that contract performance will not be delayed as a result of the time required to properly process submittals, including time for re-submittals, if necessary. Allow 10 working days for initial Government processing of each submittal. No extension of time will be authorized because of the Contractor's failure to transmit submittals to the Government sufficiently in advance of the work.

I. Contractor Certification: All submittals shall be carefully reviewed by an authorized representative of the Contractor prior to submission to the Government. Each submittal shall be dated, signed, and certified by the Contractor as being correct and in strict conformance with the contract documents. No consideration for review by the Government of any Contractor’s submittal will be made for any items which have not been so certified by the Contractor. All noncertified submittals will be returned to the Contractor without action taken by the Government, and any delays caused thereby shall be the total responsibility of the Contractor.

J. Deviations: Should any item submittals required by the contract documents show deviations from the contract requirement, the Contractor shall make specific mention of such deviations in the letter of transmittal, including stating cost effects, and product and system limitations which may adversely affect the work, in order that if acceptable, suitable action may be taken for proper adjustment of the contract; otherwise the Contractor will not be relieved of the responsibility for executing the work in accordance with the contract documents and the approved submittals. Contractor shall clearly mark the proposed variation in all documentation and specifically

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Appendix A-3 point out deviations from contract requirements in transmittal letters. Failure to point out deviations may result in the Government requiring rejection and removal of such work at no additional cost to the Government. Deviations from contract requirements require Government approval and will only be considered when advantageous to the Government. When proposing deviations, deliver written request to the Contracting Officer, with documentation of the nature and features of the deviation and why the deviation is desirable and beneficial to the Government. If lower cost is a benefit, include an estimate of the cost savings. In addition to documentation required for deviation, include the submittal information required for the item. Allow an additional 10 working days beyond normal submittal review period for consideration by the Government of submittals with deviations.

K. Approved Submittals: The part of the work covered by the approved item submittal may proceed provided it complies with the requirements of the contract documents. Final acceptance will depend upon that compliance.

The term “Approved” shall only indicate that there is no exception taken to the submittal. Approval of the item submittal shall not be construed as a complete check, and indicates only that the general method or other information appears to meet the contract requirements. Approval does not relieve the Contractor of the responsibility for any error which may exist.

After item submittals have been approved by the Contracting Officer, no resubmittal for the purpose of substituting materials or equipment, or changes to any other information will be considered unless accompanied by an explanation of why a substitution or change is necessary.

L. Disapproved Submittals: Contractor shall correct disapproved item submittals and resubmit for approval within timeframe noted. If no date is given, Contractor shall submit corrected submittal within 10 working days.

If the Contractor considers any correction or notation on the returned submittal to constitute a change to the contract drawings, specification, or statement of work the Contractor shall notify the Contracting Officer.

M. Responsibility: The Government’s review of Contractor submittals shall not relieve the Contractor of the entire responsibility for the correctness of details and dimensions and conformance to the specifications. The Contractor shall assume all responsibility and risk for any mistakes and/or costs due to any errors in submittals.

N. Inconsistencies: If a conflict or inconsistency arises between an approved item submittal and the contract documents, the contract documents shall govern.

1.3 SPECIFIC SUBMITTAL DESCRIPTIONS AND REQUIREMENTS: Submittal requirements for individual units of work are specified in the applicable specification section or Statement of Work (SOW). Except as otherwise indicated

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Appendix A-4 in the individual specification sections or SOW, comply with the following requirements for each type of submittal.

A. Shop Drawings: These are technical drawings and data specially prepared for this contract including fabrication and installation drawings, setting and seaming diagrams, and coordination drawings (for use on-site). Shop drawings include drawings, diagrams and schedules specifically prepared to illustrate some portion of the work, diagrams and instructions from a manufacturer or fabricator for use in producing the product and as aids to the Contractor for integrating the product or system into the project, or drawings prepared by or for the Contractor to show how multiple systems and interdisciplinary work will be coordinated. Information required on shop drawings includes dimensions, identification of specific products and materials which are included in the work, compliance with specified standards, and notations of coordination requirements with other work.

Provide special notations of dimensions that have been established by field measurements. Highlight, encircle, or otherwise indicate deviations from the contract documents on the shop drawings. Furnish one hard copy and one electronic copy.

B. Product Data: This data includes standard printed information on manufactured products that has not been specially prepared for this contract, including manufacturers' product specifications illustrating size, physical appearance and other characteristics of materials, installation instructions, standard color charts, catalog cuts, illustrations, schedules, standard wiring diagrams, standard product operating and maintenance manuals, and samples of warranty language when the contract requires extended product warranties. General information required specifically as product data includes manufacturers' standard printed recommendations for application and use, compliance with recognized standards of trade associations and testing agencies, the application of their labels and seals (if any), special notation of dimensions which have been verified by way of field measurement, and special coordination requirements for interfacing the material, product, or system with other work. Furnish three hard copies and one electronic copy.

C. Design Data: Design data includes design calculations, analyses or other data pertaining to a part of work. Refer to individual sections of the specification or statement of work for required quantities, formats, and signatures or certifications required. Furnish three hard copies and one electronic copy.

D. Test Reports: These include reports signed by an authorized official of a testing laboratory that a material, product or system identical to the material, product or system to be provided has been tested in accordance with the specified requirements. Testing shall have been within three years of date of contract award for the project. Reports also include findings of tests

IRA-2620, PA-AEDC2016-195

Appendix A-5 required to be performed by the Contractor on an actual portion of the work or prototype prepared for the project before shipment to the job site, findings of tests made at the job site or on a sample taken from the job site, investigation reports, daily logs and checklists, and final acceptance test and operational test procedures. Furnish three hard copies and one electronic copy of each such report required.

E. Manufacturer’s Instructions: Preprinted material describing installation of a product, system or material, including special notices and Material Safety Data sheets concerning impedances, hazards and safety precautions.

Furnish three hard copies and one electronic copy.

F. Operation and Maintenance Data: Data furnished by the manufacturer, or the system provider, to the equipment operating and maintenance personnel, including manufacturer’s help and product line documentation necessary to maintain and install the equipment, and needed by operating and maintenance personnel for the safe and efficient operation, maintenance, and repair of the item. The data is intended to be incorporated in an operations and maintenance manual or control system. Furnish two hard copies and one electronic copy.

G. Final Design Drawings and Documentation: Final design documentation including drawings, CAD models, specifications, estimates, and other required deliverables. Electronic documentation submitted shall include every associated component file of drawings and other documentation, including raster images, jpeg, tiff, Excel, and any related items required to view, modify, or manipulate the electronic files. Furnish a CD or DVD-ROM of all final design documentation, and drawings in a format compatible with Autodesk Inventor 2015 format or later, to the Contracting Officer for approval prior to applying for final payment.

H. Miscellaneous Submittals: These are work-related, non-administrative submittals that do not fit in the previous categories, including the following:

1. Project photographs. Furnish both hard copies and digital files.

2. Qualification certificates. Furnish one hard copy and one electronic copy.

3. Warranties.

END OF APPENDIX A

Appendix B-1

APPENDIX B

AEDC SECURITY RULES AND REGULATIONS

1. Security: The Contractor shall be required to comply with all security directives and other security requirements identified in this contract.

A. Pass and Identification Items: The Contractor shall ensure the pass and identification items that may be required for contract performance (e.g., Common Access Card (CAC), proximity badge) are obtained for employees by following established procedures at each operating location. The Contractor shall retrieve all identification media from employees who depart for any reason before the contract expires, e.g., terminated for cause, retirement, etc.

B. The Contractor shall comply with all installation access requirements as directed in AAFB 31-101, Integrated Defense Plan. The AEDC/CC reserves the right to refuse entry and / or re-entry of any person to AEDC for just cause to protect personnel, facilities, and property under their control through the use of a barment order when such actions are deemed necessary.

2. For Official Use Only (FOUO): The Contractor shall comply with Freedom of Information Act (FOIA) requirements IAW DOD 5400.7-R, FOIA Program, Chapter

4. This regulation sets policy and procedures for the disclosure of records to the public and for marking, handling, transmitting, and safeguarding FOUO material.

A. The Contractor shall safeguard FOUO information provided under this contract as specified in DODM 5200.01-V4, DoD Information Security Program: Controlled Unclassified Information (CUI). CUI is information that does not meet the standards for National Security Classification under Executive Order 13526, dtd Dec 2009, but is pertinent to the national interests of the United States or to the important interests of entities of the Federal Government, and (ii) under law or policy that requires protection from unauthorized disclosure, special handling safeguards, or prescribed limits on exchange or dissemination. If FOUO is lost, misused, compromised, or accessed by unauthorized persons, it could adversely affect U.S. national interest, the conduct of DoD programs, or the privacy of DoD personnel. CUI comes in many forms: personal data under the Privacy Act, personnel records, privileged data (chaplain and judge advocate records), investigative data, scientific and technical information (STINFO), export controlled data (critical technologies), proprietary data, or FOUO data. Sensitive information meets the criteria for exemption from mandatory public disclosure under FOIA. For guidance with marking CUI, contact AEDC/TSD-IP at (931) 454-3290.

B. If access to CUI / Export Control / STINFO information is required, the Contractor shall be required to be registered as a certified Government Contractor through the Joint Certification Office, Defense Logistics

Appendix B-2

Information Service (DLIS). To request DLIS Certification submit a DD Form 2345, Militarily Critical Technical Data Agreement, to the DLIS, Battle Creek, MI address indicated at the top of the DD Form 2345 along with a copy of the company's state business license, incorporation certificate, sales tax identification form, or other documentation, which verifies the legitimacy of the company. A copy of their DD2345, Militarily Critical Technical Data Agreement, must be provided when issued. Except as allowed by DFARS 252.225-7048, Export-Controlled Items, foreign nationals shall not have access to export-controlled information without an export license. All export control laws as stipulated i n both Export Administration Regulation and International Traffic in Arms Regulation must be followed without exception. For guidance in applying appropriate export control markings, contact AEDC/XP2 at (931) 454- 7329.

C. The Contractor must obtain Foreign Disclosure Office (FDO) approval through the CO prior to allowing any non-U.S. or un-validated U.S. Lawful Permanent Resident persons access to CUI or export-controlled information. (Also, see DFARS 252.225.7048, Export-Controlled Items).

3. Reporting Requirements: Contractor personnel shall report to an appropriate authority any information or circumstances of which they are aware may pose a threat to the security of DoD personnel, Contractor personnel, resources, and classified or unclassified defense information. Contractor employees shall be briefed by their immediate supervisor upon initial on-base assignment.

4. Physical Security: The Contractor shall be responsible for safeguarding all Government property and controlled forms provided for Contractor use. At the end of each work period, all Government facilities, equipment, and materials shall be secured.

5. Computer Security (COMPUSEC) / Automated Information System Requirements: If access to unclassified computer systems is required, the following requirements apply: Users must be a U.S. Citizen, or receive AEDC or Air Force Materiel Command (AFMC) Foreign Disclosure Office (FDO) approval prior to access being granted; requestor must have a favorable National Agency Check with Inquiries (NACI) clearance or an approved Interim Automated Information Systems (AIS) request on file; requestor must complete the Air Force (AF) Information Assurance (IA) Training. To request access to an unclassified computer system, users must complete a DD Form 2875, System Authorization Access Request (SAAR). Users bringing portable electronic devices (PEDs) on base and wanting to connect to AEDC computer systems / networks shall comply with AFPD 33-2, Informational Assurance Program, and AFI 33-200, Information Assurance (IA) Management. Employees shall complete any additional computer security training requirements mandated by the host base.

6. Information Security (INFOSEC): Information, regardless of media, shall be controlled and maintained in accordance with (IAW) with the National Industrial

Appendix B-3

Security Program Operating Manual (NISPOM) and guidance provided by the Servicing Security Activity (SSA), AEDC/TSD-IP.

7. Privacy Act: Comply with AFI 33-332, Privacy Act Program, when collecting and maintaining information protected by the Privacy Act of 1974, Title 5, U.S.C., Section 552a. Remove or destroy official records only IAW Air Force Records Information Management System, (AFRIMS) located on the internet at:

//www.my.af.Mil/afrims/afrims/afrims /rims.cfm

8. Operations Security (OPSEC): Comply with AFPD 10-7, Information Operations;

AFI 10-701, Operations Security; and DoD 5220.22-R, Industrial Security Regulation (ISR), Chapter 10; and local plans and publications.

9. Antiterrorism (AT) Training: DoD Contractors shall be provided AT information as required by DFARS Clause 252.225-7043, Antiterrorism, Force Protection for Defense Contractors Outside the United States. Level 1 AT Awareness Training will be available to all DoD Contractor employees.

A. All Contractors will have at least one antiterrorism representative assigned in writing and properly trained to assist in training requirements, random antiterrorism measures and protection of personnel.

10. Contractor Consent to Background Checks: The Contractor shall not employ persons to perform under this contract if such employee is deemed or identified as a potential threat to the health, safety, security, general well-being, or operational mission of the installation and its population; nor shall the Contractor or subcontractor employ persons under this contract who have an outstanding criminal warrant as identified by an approved government database such as the National Crime Information Center (NCIC). Background checks will validate that a person is not wanted by local, state, or federal agencies. All Contractor and subcontractor personnel must consent to background checks. Contractor and subcontractor personnel who do not consent to a background check will be denied access to the installation. Information required to conduct a background check includes: full name, driver's license number, and / or social security number, date of birth of the person entering the installation, and completion of a background check questionnaire. If requested the Contractor must have this information ready to provide to the Visitor Control Center.

A. Contractors must ensure their employees and those of their subcontracts have the proper credentials allowing them to work in the United States.

Persons later found to be undocumented or illegal aliens will be remanded to the proper authorities.

B. The Contractor shall not be entitled to any compensation for delays or expenses associated with complying with the provisions of this requirement.

Furthermore, nothing in this requirement shall excuse the Contractor from proceeding with the contract as required.

Appendix B-4

11. Access to Installation During Force Protection Conditions (FPCONs):

Gaining access to the installation during FPCONs will be done IAW the requirements outlined in the local Antiterrorism / Integrated Defense Plan(s).

Contractors will also be assigned a mission essential designation IAW requirements contained in Antiterrorism / Integrated Defense Plan(s). Only the installation commander or the unit commander requesting contract support will assign the mission essential designation.

12. Property Protection: Property protection for the facility where the Contractor's primary work center is located will be the responsibility of the local facility manager and local Security Manager, or their duly authorized representative IAW AFI 31- 101, Integrated Defense, and command / local directives to include Arnold Air Force Base (AAFB) Plan 31-101. The Contractor must safeguard all Government-owned equipment and materials in their possession or use.

END OF SOW AND APPENDICES