Atch 01 Statement of Work Flip Tower 29 Jun 23.pdf

STATEMENT OF WORK

Project: Target Flip Equipment

1.0 Purpose: The 704th Test Group (704 TG) mission is to be the premier provider of unique test and evaluation capabilities relevant to tomorrow’s warfighter through world-class people improving technical excellence, cost-effectiveness, and agility. The 704 Test

Group/ Detachment 1 (Det. 1) is assigned to the 704 TG and conducts Static Radar Cross

Sectioning for both military and civilian customers. The 704 TG/Det. 1 manages the

National Radar Cross Section Test Facility (NRTF), which consists of the Department of

Defense’s (DoD) only outdoor, static radar signature measurement range known as the

RCS Advanced Measurement System (RAMS).

RAMS test range offers one-of-a-kind, unique resources and test capabilities. These capabilities often require the use of large target that must be moved and oriented in different positions by utilizing the flip tower. The flip tower system is a combination of structures and equipment utilized to reorient a target by lifting it to a specified height, rotating it about a single axis, then lowering it back to the ground. The main system components consist of two structural steel towers which support two lifting systems connected by an axle which uses two rotational units to rotate the axle and the connected target.

2.0 Scope or Mission: The contractor shall design and deliver target flip components able to rotate complex targets in a safe and effective way.

3.0 Period and Place of Performance: The Contractor shall deliver the target flip components no later than 40 weeks ARO. All hardware and operating documents shall be delivered to the 704 Test Group/Det 1. ATTN: Major Gabrielle Llanos and Michael

Mcguire.

4.0 Background: One other target flip tower has been built in the United States. The 704 TG expects to emulate this build at the RAMS site. Applicable photos are attached for reference.

5.0 Performance Objectives: The vendor shall design the support structure and foundation to accommodate and support the lifting and rotating system. The vendor shall be responsible for verifying all mating, structural, electrical, loading, and rotation requirements of the lifting and rotating system.

5.1 Key Performance Parameters (KPP)

5.1.1 Threshold: Ability to perform target rollover with limited resources. Six persons, five hours exposure, -1 shift, 12 knots wind limit

5.1.2 Objective: Ability to perform target rollover with limited resources. Four persons, four hours exposure, -1 shift, 15 knots wind limit

5.2 Lifting and Rotating System Requirements

5.2.1 The Automated Target Rollover system shall support a lifting and rotating automated roll beam.

5.2.2 Lifting and Rotating Capacity of up to 30,000lb.

5.2.3 Dead Load for the Lift Carriages and Rotating Beams of approximately 68,000lb.

5.2.4 Total Vertical Load of approximately 98,000lb.

5.2.5 Center of Gravity of the model may be offset from the centerline of the rotator by as much as 6’-0”.

5.2.6 The rotator will be designed to generate a rotational torque of approximately

180,000 ft-lb to rotate the model.

5.2.7 The Load Pipe is powered/rotated by 2 motors with brakes and 2 gear reducer assemblies at both ends, for a total of 4 motors and 4 gear reducers, capable of producing a torque of up to 90,000ft-lb at each end.

5.2.8 Length (Span): 75’-0” (approximate) center-to-center of track wheels that resist the rotation torque

5.2.9 Load cells shall be installed in such a way to facilitate real-time reporting of the load supported or transferred by the PFLOW Lift Carriage.

5.2.10 Rotation speed: 1/4 RPM minimum and 1 RPM maximum, and selectable continuous rates of one-half and one-quarter RPM, as well as the ability to step position in 0.1 degree or smaller increments for fine adjustment.

5.2.11 Rotation range: 180 degrees, +/-10 degrees

5.2.12 ASME BTH-1 Category B, Service Class 1 (up to 100,000 load cycles in its operation life).

5.3 Towers and Foundation Design Requirements

5.3.1 The vendor shall design the support structure and foundation to accommodate and support the lifting and rotating automated roll beam at its specified capacities listed in these criteria.

5.3.2 The vendor shall be responsible for verifying all mating, structural, electrical, loading, and rotation requirements of the lifting and rotating automated roll beam.

5.3.3 The system shall consist of two steel towers with internal stairs. The towers shall be capable of supporting the lifting and rotating system and target at any vertical lift height or rotational angle.

5.3.4 Towers and foundation design shall be milestone-based with deliverable design packages. Ideally, the foundation design would be the first milestone followed by the towers design. The expectation would be the designs would be released as they are completed in such order to expedite construction contracting processes without delay.

5.3.5 Towers shall be designed to mate with the Lifting and Rotating System

5.3.6 Foundation shall include groundwork int the surrounding are to allow for the ease of transport of the model to and from the flipping are via the existing road network.

5.3.7 Foundation shall require integration into existing site electrical lines, to include a transition from overhead lines to underground lines and the requisite electrical infrastructure needed to support the towers, foundation and lifting and rotating system electrical designs.

5.3.8 Tower and mating surfaces shall not impede any movement of or repair of the lifting and rotating system and shall not obstruct access to any adjustment bolts, access covers, inspection points or lubrication points/grease fittings.

5.3.9 All tower levels and equipment access landings (except uppermost roof) shall be stair accessible for the maintenance of all equipment.

5.3.10 Towers and associated equipment (lights, Conduit, paint, etc.) supplied by the vendor shall be engineered, designed, constructed and finished such that they will withstand corrosion, extreme temperatures and are protected from wind and sand.

5.3.11 Towers and structural steel shall be hot dipped and galvanized and painted white.

5.3.12 Steel nuts and bolts shall be grade eight with yellow zinc coating.

5.3.13 Towers shall have separate electrical conduit to support lifting and rotating system power and control cabling as needed.

5.3.14 Tower shall be designed with lighting protections and grounding in compliance with NFPA 70.

5.3.15 Towers shall have UL listing for all electrical equipment as necessary.

5.3.16 Towers shall have both red and white area lighting with standard E26 base sockets and dimming capability.

5.3.17 Towers and foundation shall be designed to have a service life of no less than 20 tears.

5.3.18 A Geotechnical study shall be required prior to foundation design and engineering.

5.3.19 Towers will provide a mounting location for the lifting and rotation system control panel and environmental control unit.

5.3.20 Towers shall be designed to support the lifting and rotation system center beam at a maximum height of 65’ during the target rotation and a wind load of 6,500lbs.

5.3.21 Tower and foundation designs shall meet a safety factor of 3:1.

5.3.22 The space between the tower feet and foundation shall be filled with expanding grout after installation.

5.3.23 The Automated target Rollover system towers will provide a mounting location for the lifting and rotating automated roll beam Control Panel and Environmental

Control Unit.

5.3.24 The Automated Target Rollover tower shall be designed to support the lifting and rotating automated roll beam at the maximum height of 65 ft during the target rotation and a wind load of 6500 lb. And wind speeds of up to 100 mph from any radial direction with the beam lowered and no target installed.

5.3.25 All routine maintenance shall be able to be performed by end-user technicians without the use of specialized personnel lifts, and any specialized tools required for maintenance shall be provided.

5.3.26 The design process shall include adequate opportunity for milestone-based design review and end-user input and functional evaluation.

5.3.27 The device shall incorporate control via local wireless controller (Not Bluetooth) or a cable pendant mobile HMI, and reliably without significant lag to allow the user the freedom to closely observe any moving component under control.

5.3.28 There shall be an engineered failsafe method to control the device manually via hardware control-panel interface as an option rather than software interface.

5.3.29 The beam and mechanical mechanisms shall be able to be secured in a fail-safe manner at any height to mitigate suspended load hazards.

Documentation Requirements:

The following documentation shall be completed and provided upon commissioning:

Note: All drawings and manuals shall be provided as electronic (PDF and/or DWG/DXF).

Hard copies are also requested but not mandatory.

A. Operation and Maintenance manuals for the Automated Target Rollover system (i.e.

towers, foundation and any/all subsystems (lights, lightning protection, grounding, etc.))

B. Complete System Drawings, Mechanical Drawings, Electrical Wiring

Diagrams/Schematics and Interconnect Drawings, and all vendor proprietary drawings shall be provided for the Automated Target Rollover towers and foundation and all subsystems as applicable.

C. The operator’s manual shall include a contingency procedure to mechanically rotate and lower the beam with installed target, in the event of total power loss, (by backup power or manual control interface).

D. Load charts that encompass the entire as-designed operating envelope of the mechanism.

E. A vendor-recommended maintenance interval schedule and detailed instruction.

A detailed list of all components listing the Manufacturer, Part numbers, Quantities, and recommended number of spares to keep on hand, along with all component manufacturer-provided technical data sheets.

6.0 Deliverables / Schedule: The contractor shall complete acceptance testing at the manufacturing site NLT 40 weeks ARO. Following successful acceptance testing the contractor shall deliver all equipment to 704 TG/Det 1.