Rotor Stator Test Stand SOW.pdf

STATEMENT OF WORK (SOW)

FOR

ROTOR STATOR TEST STAND (RSTS)

BUILDING 9001

Oklahoma City Air Logistics Center

Tinker Air Force Base

Prepared by

Malcolm Bellard

76 CMXG/MXDEC

13 May 2025

RSTS

Statement of Work

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Table of Contents

1. SCOPE OF WORK

1.1. Scope:

1.2. Background:

2. APPLICABLE GOVERNMENT AND INDUSTRY STANDARDS:

2.1. Government Standards:

2.2. Non-Government Standards:

2.3. Order of Precedence:

2.4. Applicable Standards

2.5. Prohibited Materials:

2.6. Environmental Protection:

3. TEST STAND REQUIREMENTS:

3.1. General:

3.2. Construction:

3.3. Interchangeability:

3.4. Maintainability:

3.5. Lubrication:

3.6. Utilities and Maintenance Access:

3.7. Installation Plan:

3.8. PC and PLC Control System:

3.9. Calibration Equipment:

3.10. Test Stand Preliminary/Final Calibration:

3.11. Code Compliance:

3.12. Safety Analysis:

3.13. Test Stand IVV and As-Built Drawing Review:

3.14. UUT Fixtures, Tooling, and Power Cables:

3.15. Software:

3.16. PC and Software Security:

3.17. Extended Spares Kit:

4. ACCEPTANCE TESTS

4.1. Factory Acceptance Test Report:

4.2. Vibration Baseline Testing:

4.3. Equipment Health Checkout:

4.4. Audible Noise Test:

4.5. Software Test Report:

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4.6. Correlation Test Report:

4.7. Monthly Status Report:

4.8. Test Plan:

4.9. Training Plan:

4.10. Warranty:

5. QUALITY ASSURANCE PROVISIONS

5.1. Responsibility for Inspections:

5.2. Responsibility for Compliance:

5.3. Environmental Conditions

5.4. Visual Examination:

6. DESIGN REVIEWS

6.1. Preliminary Design Review:

6.2. Intermediate Design Review:

6.3. Critical Design Review:

6.4. Factory Acceptance Test:

6.5. Test Stand Correlation:

6.6. Final Acceptance:

6.7. Emergency POC:

7. TECHNICAL DATA REQUIREMENTS

7.1. Manuals/Drawings:

7.2. Work Plan Drawings

7.3. As-Built Drawings

7.4. Software Documentation: The following software documentation will be provided as part of each design review and will retain the same completeness requirements as the design review itself

7.5. Commercial Manuals:

7.6. Level 3 Drawings:

7.7. Documentation:

8. TRAINING REQUIREMENTS

8.1. General:

8.2. Operator Training

8.3. Electrical/Mechanical Training:

8.4. Calibration Training:

8.5. Software/Process Engineer Training:

9. SPECIAL PROVISIONS

9.1. Government Occupancy of Facilities & Responsibilities:

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9.2. Government Installation Access:

9.3. Working Hours:

9.4. Safety, Foreign Object Debris (FOD), Dropped Object Prevention (DOP) & Quality Control

9.5. Housekeeping

9.6. Tool Control and Accountability:

9.7. Filed Verify:

10. PROPOSAL BY CONTRACTOR:

10.1. Description:

10.2. Requirements:

10.3. Notice:

11. OTHER WRITTEN SUBMITTALS:

11.1. Required Submittals

12. GOVERNMENT FURNISHED PROPERTY AND SERVICES

12.1. Government Furnished Property (GFP)

12.2. Shared Property of the Government

12.3. Shared Storage Area

12.4. Cease to Use and Return to Government

12.5. Government Furnished Services:

12.6. Intangible Government Property

12.7. Government Furnished Drawings

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Table of Tables

Table 1 – Summary of Required Submittals

APPENDICES

Appendix A: Reliability Centered Maintenance and Vibration Severity Chart

Appendix B: Safety Specifications

Appendix C: Glossary and Definitions

Appendix D: Environmental

Appendix E: Certification Test Plan

Appendix F: Test Stand Technical Manual: Operation and Maintenance Instructions

Appendix G: Drawings-Basis of Design and Component Locations

Appendix H: UUT & Sub-component Test Specifications

Appendix I: Design Guidelines 450

Appendix J: Test Stand Technical Manual: Item Parts Breakdown

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1. SCOPE OF WORK

1.1. Scope: The following establishes the minimum requirement for the purchase, delivery, and installation of one (1) Rotor Stator Test Stand (RSTS) with equipment and accessories specified herein; and training on the maintenance, calibration, programming, and use of said test stand. The test stand will be used to test Stators for the F100, F101, F108, F110, F118, and the TF33 Speed Sensor as per their relevant Technical Orders

(T.O.’s). The Contractor shall supply all engineering, labor, materials, parts, tools, equipment, supplies, transportation, software, and incidentals necessary to operate the test stand. The overall project shall be considered a whole and complete procurement with final acceptance requirements met and approved by the appropriate Government

POCs and operational training having been completed. Acceptance testing must be performed onsite at B9001 and the government shall supply the end-items for the acceptance testing.

1.2. Background: Test stand is required to replace all capabilities of Bauer/Electro Inc., Model: PWA 53120-1, NSN: 4920012248880, and some additional capabilities equivalent to GE Aircraft Engines, Model: 3C3960G05; NSN: 4920013193772. The test stands described in this document are intended for use in the Aerospace Repair Industry.

The equipment shall be installed in Building 9001, Post U31, at Tinker AFB, OK. This shop runs one 8 hour shift, 0545-1345, Monday through Friday with possible overtime hours on the weekend. All installation work associated with this contract shall have no impact on production.

2. APPLICABLE GOVERNMENT AND INDUSTRY STANDARDS:

Contractor, at a minimum, is required to comply with the current editions of the following requirements for design, construction, installation, and safety as applicable. The term “most recent edition” shall be understood to mean “most recently released edition as of date of issuance of contract.”

2.1. Government Standards: The following documents form a part of this purchase description to the extent stipulated herein.

2.1.1. U.S. DEPARTMENT OF LABOR

2.1.1.1. 29 CFR 1910 – General Industry, OSHA Safety and Health Standards (29

CFR 1910), 2010 or most recent edition (available at http://www.osha.gov/)

2.1.1.2. (Application for copies should be addressed to the U.S. Department of

Labor, 200 Constitution Ave, Washington, D.C. 20210)

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2.1.2. ENVIRONMENTAL PROTECTION AGENCY

2.1.2.1. 40 CFR 82 – Protection of Stratospheric Ozone, 2010 or most recent edition

2.1.2.2. (Application for copies should be addressed to the U.S. Department of

Labor, 200 Constitution Ave, Washington, D.C. 20210)

2.1.3. FEDERAL STANDARDS

2.1.3.1. FED-STD-H28A – Screw Thread Standards for Federal Services, 1994

(R2001) or most recent edition

2.1.3.2. FED-STD-H28/21B – Screw Thread Standard for Federal Service, Metric

Screw Threads, 1984 (R2006) or most recent edition

2.1.3.3. UFC 3-600-01 – Fire Protection Engineering for Facilities

2.1.3.4. UFGS 07 84 00 – Firestopping

2.1.3.5. UFGS 21 13 13 – Wet Pipe Sprinkler Systems

2.1.3.6. UFGS 21 13 22 – Foam Fire Extinguisher for Haz/Flam Material Facility

2.1.3.7. UFGS 21 21 01 – Carbon Dioxide Fire Extinguishing (High Pressure)

2.1.3.8. UFGS 21 21 02 – Carbon Dioxide Fire Extinguishing (Low Pressure)

2.1.3.9. UFGS 28 31 64 – Fire Detection and Alarm System

2.1.3.10. (Application for copies should be addressed to Superintendent of

Documents, Government Printing Office, Washington, D.C. 20402-001).

2.2. Non-Government Standards: The following documents form a par of this document to the extent stipulated herein.

2.2.1. NATIONAL FIRE PROTECTION ASSOCIATION (NFPA)

2.2.1.1. NFPA 1 – Fire Code, 2010 edition or most recent edition

2.2.1.2. NFPA 11 – Standard for Low-, Medium-, and High-Expansion Foam, 2016 edition or most current

2.2.1.3. NFPA 12 – Standard on Carbon Dioxide Extinguishing Systems, 2018 edition or most current

2.2.1.4. NFPA 16 – Standard for the Installation of Foam-Water Sprinkler and Foam-

Water Spray Systems, 2019 edition or most current

2.2.1.5. NFPA 70 – National Electrical Code, 2014 edition

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2.2.1.6. NFPA 70E – Standard for Electrical Safety in the Workplace, 2011 edition or most recent edition

2.2.1.7. NFPA 79 – Electrical Standards for Industrial Machinery, 2007 or most recent edition

2.2.1.8. (Application for copies should be addressed to National Fire Protection

Association, Battermarch Park, Quincy, MA 02269)

2.2.2. TELECOMMUNICATIONS INDUSTRY ASSOCIATION (TIA) STANDARD

2.2.2.1. EIA/TIA-232-F – Interface Between Data Terminal Equipment and Data

Circuit-Terminating Equipment Employing Serial Binary Data Interchange, 1997 (R 2002) or most recent edition

2.2.2.2. (Application for copies should be addressed to IHS International Inc., http://www.ihs.com, or call 1-800-854-7179 for U.S. and Canada)

2.2.3. NATIONAL ELECTRICAL MANUFACTURERS ASSOCIATION (NEMA)

2.2.3.1. NEMA MG 1 – Motors and Generators, 2009 (R2010) or most recent edition

2.2.3.2. NEMA ICS 6 – Industrial Control and Systems: Enclosures, 1993 (R2006) or most recent edition

2.2.3.3. (Application for copies should be addressed to National Electrical

Manufacturers Association, 1300 N 17th Street, Suite 1752, Rosslyn, VA

22209)

2.2.4. AMERICAN NATIONAL STANDARD INSTITUTE

2.2.4.1. ASTM SI 10 – American National Standard for use of the International

System of Units (SI): The Modern Metric System, 2010 or most recent edition

2.2.4.2. (Application for copies should be addressed to American National Standards

Institute, Attn: Sales Department, 1430 Broadway, New York, NY 10018-

3363)

2.2.5. AMERICAN WELDING SOCIETY INC (AWS)

2.2.5.1. AWS D14.4 – Specification for Welded Joints in Machinery and Equipment, 1997 or most recent edition

2.2.5.2. (Applications for copies should be addressed to the American Welding

Society Inc., 550 North LeJeune Road, Miami, FL 33126)

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2.2.6. INTERNATIONAL ORGANIZATION FOR STANDARDIZATION

2.2.6.1. ISO 4413 – Hydraulic Fluid Power – General Rules and Safety

Requirements for Systems and Their Components, 2010 or most recent edition

2.2.6.2. (Application for copies should be addressed to International Organization for Standardization, 1, Ch. de la Voie-Creuse, Case postale 56, CH-1211

Geneva 20, Switzerland, e-mail central@iso.ch or IHS International Inc., http://www.ihs.com, or call 1-800-854-7179 for U.S. and Canada)

2.3. Order of Precedence: In the event of a conflict between the test of this specification and the references cited herein, the test of this specification takes precedence. Nothing in this document, however, supersedes applicable laws and regulations unless a specific exception has been obtained.

2.4. Applicable Standards

2.4.1. Dimensional Systems: U.S. Customary System of Units (US) shall be used in the design and construction. In this specification, all measurements, dimensions, sizes, and capacities are given in the U.S. Customary System of Units (US).

2.4.2. Measuring/Indicating Devices: All measuring and indicating devices, such as dial indicators, pressure gauges, temperature indicators, depth stops, and other similar devices used on the machine, shall be graduated in inch-pound units. Marking on all measuring and indicating devices shall be permanently and legibly engraved or etched on a non-glare background. All dials and other type indicating devices shall be securely mounted in place. Such devices shall be located to allow reading from the operator’s normal workstation.

2.4.3. Safety and Health: Covers, guards, and other safety devices shall be provided for all parts of the machine that present safety hazards. The safety devices shall not interfere with the operation of the machine. The safety devices shall prevent unintentional contact with the guarded part and shall be removable to facilitate inspection, maintenance and repair of the parts. All machine parts, components, mechanisms and assemblies furnished on the machine shall comply with all of the requirements of 29 CFR 1910.

2.4.4. Cautions–Warning Plates: Corrosion resistant “Caution” or “Warning” Plates shall be securely attached to the equipment in visible locations with any safety precautions to be observed by the operator or maintenance personnel permanently marked on the plates.

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2.4.5. Noise Levels: The noise level emitted by the equipment under load shall not exceed 80 dBA when measured at the operator’s workstation or at any other point at a distance of three (3) feet from any of the equipment associated with the test stand unit as measured on the “A” weighted scale of a standard Type II sound level meter.

2.4.6. Chemicals: The Contractor shall not transport, ship, or use any chemical, material or substance used in the performance of this SOW on Tinker AFB prior written approval is provided by 72 ABW/CEIE, Natural Infrastructure Management

(Environmental Compliance). The Contractor shall furnish to the Government

POC a list of all chemicals used in conjunction with the Installation of the equipment, container sizes and quantities, and their Safety Data Sheets (SDS) sixty (60) working days prior to shipment. The government reserves the right to reject use of any chemicals and request alternative(s) be proposed for completion of the installation. Proper use, storage and removal of any chemical required during installation of test stand shall be coordinated with the Tinker Unit

Environmental Coordinator (UEC). UEC info will be made available to

Contractor by Government POC, as needed. Contractor shall remove all unused chemicals from Tinker AFB. Contractor shall comply with all chemical and environmental requirements as stipulated in Appendix D.

2.4.7. Instruction Plates: All words on instruction plates shall be in the English language. Words shall be engraved, etched, embossed, or stamped in boldfaced letters on a contrasting background. Lettering shall be a minimum of 18-point font and the plates shall be sized accordingly to accommodate all standard text in this point size. Plates and lettering shall be fully compatible with MIL-PRF-7808L

Grade 3 synthetic turbine engine oil and suffer no degradation when subjected to it.

2.4.8. Nameplate: A corrosion resistant metal nameplate permanently and legibly marked with the following information shall be securely attached to the machine in a readily visible location. Nameplate and lettering shall be fully compatible with MIL-PRF-7808L Grade 3 synthetic turbine engine oil and shall suffer no degradation when subjected to it. Lettering shall be a minimum of 18-point font.

2.4.8.1. Nomenclature of the Machine

2.4.8.2. Manufacturer’s Name and Address

2.4.8.3. Manufacturer’s Model Number

2.4.8.4. Manufacturer’s Serial Number

2.4.8.5. Date of Manufacture

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2.4.8.6. Contract Number

2.4.8.7. Services Requirements – All service requirements to be included.

2.4.9. Castings and Forgings: All castings and forging shall be free from defects, scale, or mismatching. Processes such as welding, peening, plugging, or filling with solder or paste shall not be used on casting and forgings for reclaiming any parts of the machine. Such processes may only be used for enhancing surface finish and appearance.

2.4.10. Welding, Brazing, and Soldering: Welding, brazing, or soldering shall be employed only where those operations are included in fabrication of the original design. These operations shall not be employed as repair or reclamation measures for defective parts. Any excess material used for such operations shall be thoroughly removed from the part(s) upon completion of the operations.

Weldments shall comply with AWS D14.4.

2.4.11. Surface Finish: All surfaces of castings, forgings, molded parts, stampings, and welded parts shall be clean and free from sand, dirt film, sprues, flash, scale flux, and other harmful or extraneous materials. External surface edges shall be either rounded or beveled unless sharpness is required to perform a necessary function.

Except as otherwise specified herein, the condition and finish of all surfaces shall be commensurate with the manufacturer’s standard commercial practice.

2.4.12. Gears: All gears and pinions, if applicable, shall be designed and manufactured of a suitable ferrous material with proper width and size to transmit full-rated torque and horsepower throughout the speed ranges without failure for the expected service life of the machine.

2.4.13. Painting: Yellow or orange safety color-coding shall be used for designated physical hazards.

2.4.14. Screw Threads: All threaded parts used on the machine and its related attachments and accessories shall conform to FED-STD-H28 or FED-STD-H28/21B.

2.4.15. Electrical Items: All electrical/electronic components located within the interior and footprint of test stand shall meet or exceed the minimum requirements defined by NFPA 70 Article 500 Class I, Division 1, Group D environment. Areas exterior to this region shall be Class I, Division 2 rated per NFPA 70, Article 500.

2.4.16. Electrical System: The machine shall be capable of running using the existing power supply source 480 VAC, 60 Hz, 3 Phase, Y Configuration.

2.5. Prohibited Materials:

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2.5.1. Mercury restriction: The machine shall contain neither mercury nor mercury compounds or be exposed to free mercury during manufacture.

2.5.2. Asbestos restriction: Asbestos and materials containing asbestos shall not be used on or in the machine.

2.5.3. Polychlorinated Biphenyl (PCB) restriction: The use of polychlorinated biphenyl on or in the machine is prohibited.

2.5.4. Lithium restriction: Lithium batteries used in the computer system are exempt from this requirement.

2.5.5. Ozone Depleting Chemicals (ODC) Restrictions: Class I ozone depleting substances in accordance with (IAW) section 602(a) of the Clean Air Act

Amendments 1990, 42 USC 7671a(a) as implemented by 40 CFR 82 Protection of

Stratospheric Ozone, shall not be contained within or used on this equipment.

2.6. Environmental Protection: Under the operating, service, transportation and storage conditions described herein the machine shall not emit materials hazardous to the ecological system as prohibited by federal, state or local statutes in effect at the point of installation.

2.6.1. Other Environmental Compliance: Contractor shall comply with all environmental requirements as stipulated in Appendix D.

3. TEST STAND REQUIREMENTS:

3.1. General: The RSTS shall be new and unused (not a prototype) and constructed using cutting-edge technology. RSTS design specifications shall be based on Unit Under Test

(UUT) requirements as noted in associated UUT Technical Orders (T.O.’s), which are listed in Appendix H. Any provided documents/manuals associated with existing test equipment are for reference only. RSTS particulars are noted below:

3.1.1. RSTS construction and layout shall be of new design.

3.1.2. RSTS construction and layout shall be no more than 100 ft2, with maximum overall length no greater than 12’ and maximum overall width no greater than 10’.

RSTS shall be located in shop to ensure a minimum walkway width of 4’ between

RSTS workstation and existing test stand workstations and a minimum walkway width of 4’ between back of RSTS and back of existing test stands.

3.1.3. Original RSTS technical documentation are the property of the USAF and relevant sheets are attached in Appendices F, G, and J. These technical documents are for reference only and shall not be used for derivation of RSTS test specification requirements.

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3.1.4. All RSTS components shall be available as commercial off the shelf (COTS) items.

3.1.5. New equipment shall be enclosed, and enclosure shall include access to all repairable components and doors large enough to repair & replace without major disassemble.

3.1.6. Any connection adaptors and/or cables shall be provided by Contractor.

3.1.7. Test Stand Shall Include:

3.1.7.1. Forklift pockets

3.1.7.2. Door switches with lighting

3.1.7.3. Plexiglass (or equivalent) protective viewing windows.

3.1.8. Supporting documentations should include operational manual, troubleshooting guide, calibration procedures, illustrated parts breakdown, and all schematics and drawings in Adobe and AutoCAD format.

3.1.9. Electrical and mechanical level 3 drawings as per MIL-STD3100B of the RSTS test stand shall be provided to the government in .dwg (AutoCAD 2024 or newer) and Adobe format.

3.1.10. The RSTS test stand shall be a completely standalone unit, fully capable of successfully testing every electrical test for the UUT and subcomponents IAW their respective T.O.’s.

3.1.10.1. Equipment shall have at minimum five (5) independent drive systems capable of multiple speeds:

3.1.10.1.1. Three (3) 29,000 RPM

3.1.10.1.1.1. NSN 2925-01-423-3002JU Stator (T.O. 8A3-5-46-3)

3.1.10.1.1.2. NSN 2925-01-435-9057PR Stator (T.O. 8A3-5-57-3)

3.1.10.1.1.3. NSN 2925-01-425-7087PN Stator (T.O. 8A6-2-8-3)

3.1.10.1.1.4. NSN 2925-01-204-0392JF Stator (T.O. 8A3-5-43-3)

3.1.10.1.2. One (1) 15,200 RPM

3.1.10.1.2.1. NSN 2925-01-206-7723NZ Stator (T.O. 8E1-11-3-3)

3.1.10.1.3. One (1) 8,000 RPM

3.1.10.1.3.1. NSN 6680-01-191-9345PN Speed Sensor (T.O. 8D21-6-13)

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3.1.10.2. Equipment shall be able to display the speed, voltage, current, and resistance results.

3.1.10.2.1. Perform insulation resistance testing utilizing 500 VDC and capable of reading up to 10 GOhms.

3.1.10.2.2. Perform stator/sensor continuity testing.

3.1.10.2.2.1. Functional Testing:

3.1.10.2.2.1.1. Open circuit voltage testing.

3.1.10.2.2.1.2. Closed circuit voltage testing – short circuit and electronic variable loads.

3.1.10.2.2.1.3. Output to oscilloscope for speed sensor functional test.

3.1.10.3. Requirements are listed in Appendix H, the UUTs T.O.’s Test Section, and are also available to the Contractor upon request.

3.1.10.4. Contractor shall verify latest Technical Order in use prior to software development.

3.1.10.5. No modification/tweaking, by operator, of any testing control loop shall be required regardless of UUT being tested.

3.1.10.6. Test Parameters: The Contractor shall consult with Government engineering and production POCs throughout design process and at design reviews to ensure test procedures as implemented in Test Stand adequately reflect UUT

T.O. requirements and sufficiently test each UUT. The Contractor will provide the following deliverables at the indicated design reviews, which will be returned with comments for correction at the end of the Government review period as noted for each review.

3.1.10.6.1. PDR: A document cataloguing all relevant test parameters for each

UUT and UUT test with clear reference to the UUT T.O. requirements.

3.1.10.6.2. IDR: A draft of a general test flowchart indicating how the Test Stand’s planned components will meet UUT test requirements.

3.1.10.6.3. CDR: The final draft of a general test flowchart indicating how the

Test Stand’s planned components will meet UUT test requirements, including any adjustments made to design between design reviews.

3.1.10.7. Test Procedure: Step by step test instructions for each UUT shall be displayed on the test stand PC screen (if multiple screens are used, on the in-use screen at minimum). A draft of these test steps shall be provided by the contractor to the government POC for review NLT four (4) weeks prior to factory acceptance testing for review by government engineering and

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Government POC will provide any necessary revisions NLT two (2) weeks prior to factory acceptance testing.

3.1.10.8. Time to test requirement (including hookup to stand) for each known good

UUT, as tested by a certified Tinker mechanic, shall not exceed the following:

3.1.10.8.1. NSN 6680-01-191-9345PN Speed Sensor (T.O. 8D21-6-13): 1.19 hours

3.1.10.8.2. NSN 2925-01-206-7723NZ Stator (T.O. 8E1-11-3-3): 1.8 hours

3.1.10.8.3. NSN 2925-01-425-7087PN Stator (T.O. 8A6-2-8-3): 3.16 hours

3.1.10.8.4. NSN 2925-01-423-3002JU Stator (T.O. 8A3-5-46-3): 3.3 hours

3.1.10.8.5. NSN 2925-01-435-9057PR Stator (T.O. 8A3-5-57-3): 1.4 hours

3.1.10.8.6. NSN 2925-01-204-0392JF Stator (T.O. 8A3-5-43-3): 1.59 hours

3.1.11. The test stand shall be modular in design (i.e., constructed with multiple test chambers/sections as needed for end items. All connections between chambers/sections shall be designed such that the test stand can be taken apart and relocated without damaging connections and without requiring special training.

3.1.12. No proprietary software or technical data shall be used. The USAF shall have unlimited rights for all technical data and non-COTS software developed for this effort. All non-COTS source code and technical data developed shall be delivered to the government along with the COTS licenses at the end of the contract.

3.1.13. The Data Acquisition (DAQ) system shall utilize LabVIEW (2018 or newer) to develop a test program to communicate with Siemens S7 Programmable Logic

Controller (PLC).

3.1.14. Test variables shall be indicated one of three ways: red if out-of-limits (OOL)-high, green if in limits, and yellow if OOL-low. Substitutions to colors may be used if approved by government POC.

3.1.15. The screen display readings shall be defined by the testing requirements for all

UUTs. The display screen shall be able to display all the monitored parameters, organized in logical groups. The display default parameter display sizes shall be large enough to be seen by the operator and inspector during testing.

3.1.16. Delivery date for the RSTS shall be no later than eighteen (18) months after date of contract.

3.1.17. The Contractor shall attend monthly collaboration meetings (conference calls acceptable) with Government POC for the purpose of specifying progress to date, SOW-2025-RSTS Page 16 any changes to estimated completion date and sharing information to ensure accurate completion of all major milestones to meet performance requirements.

Government POC includes but is not limited to 76 CMXG Engineering and 76

CMXG Production.

3.1.18. Prior to acceptance, test stand and subcomponents shall be cleaned to adhere to cleaning guidelines as defined in existing test stand manuals. Cleanliness of the test stand is important to satisfactory operation and to promoting a longer life for test stand equipment and components.

3.2. Construction: The RSTS shall be constructed of parts that are new, without defects, COTS, and free of repairs. Quality of materials used in construction shall be equivalent to or superior to those used in construction of existing RSTS located in B9001. Metals shall be of corrosion-resistant materials unless suitably protected to resist corrosion. The machine construction shall include all components, parts, and features necessary to meet the performance requirements specified herein. All parts subject to damage from environmental hazards shall be sealed or otherwise protected. The machine shall be capable of withstanding all forces encountered during operation of the machine at its maximum rating and capacity without distortion or failure. Welding, plugging, or filling with solder or paste shall not be employed as repair or reclamation measures for defective parts. All screws, pins, bolts and similar parts shall be installed with means of preventing loss of tightness. All parts subject to removal or adjustment, shall not be swaged, peened, staked, or otherwise permanently deformed. Test stand shall be built in compliance with Design Guideline 450 as shown in Appendix I. The final design of the

RSTS test stand shall be neat, tidy, and be Lista Blue.

3.2.1. Component Labeling: All test stand components shall be labeled with an embossed metal tag denoting part number as per the Illustrated Parts Breakdown (IPB). All hoses shall also be labeled with an embossed metal tag and hose schedule included in the IPB that details required pressure rating of hose, hose size, length, fluid compatibility requirements, maximum temperature, and nominal location. All electrical wiring shall have heat shrink labels (or equivalent) placed on either end of wire and labels and lettering shall suffer no degradation when subjected to any fluids associated with the RSTS.

3.2.2. Test Stand Anchoring: If RSTS is required to be anchored to the slab, anchors shall be no longer than three and three-quarter inches (3.75”) in length. All holes required to be drilled into the slab shall be no more than four inches (4”) deep.

Any damage to the existing vapor barrier due to holes deeper than those allowed shall be fully repaired by the Contractor. Repair method and final repair shall be reviewed and approved by Tinker AFB Civil Engineering.

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3.3. Interchangeability: To provide for replacement of worn parts, all parts bearing the same part number shall be functionally interchangeable and dimensionally identical within the manufacturer’s tolerance limits. Parts shall be the latest version available by the equipment supplier so that any replacement parts are available to the customer throughout the life of the equipment.

3.4. Maintainability: The machines shall be designed and constructed to permit effective maintenance. The machines shall be equipped with access covers (if applicable) to facilitate inspection, cleaning, repair, and replacement of parts.

3.5. Lubrication: Means shall be provided to ensure adequate automatic lubrication for all moving parts. Recirculating systems shall include filters which are cleanable or replaceable. Each lubricant reservoir shall have visible or mechanical means for determining fluid level. All oil holes, grease fittings and filler caps shall be accessible.

Parts consuming fluids shall be clearly identified as such along with the recommended periods of additions and the type of fluid that should be used. Contractor shall recommend a remedial maintenance schedule for servicing the lubrication system of the test stand.

3.6. Utilities and Maintenance Access: The Contractor shall provide maintenance access to the control panel and other parts requiring periodic maintenance or repair. All equipment access doors, control panels, and process sensitive areas shall be lockable. Keying configurations and methods of locking shall be discussed in the design reviews. The

Contractor shall label each breaker pulled from the main electrical panel. Electrical schematic(s) shall be attached inside of the control panel with all components labeled and identified. A listing of all components and their ratings shall be provided. Catwalks, ladders, platforms, and other access considerations shall be the responsibility of the

Contractor. Ladders exceeding twelve (12) feet in height shall contain fall protection.

Contractor shall denote on the test stand main electrical device(s) the source panel name, location, and circuit breaker number(s) used to feed the electrical device even if using existing connections.

3.6.1. Utilities Interconnection: The Government will provide the required utilities to within twenty-five (25) feet of test stand location.

3.6.1.1. A single connection point will be supplied.

3.6.1.2. Contractor shall make final terminations of utilities to test stand. Contractor shall provide and run all conduit, conductors, and all other required electrical components from this connection point to the stand to make the stand fully operational electrically.

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3.6.1.3. All interconnections shall maintain the hazardous classifications for both inside and outside the test stand.

3.6.2. Electrical System: The machine shall be designed to operate from a single 480 volt (± 3%). 3 phase, 60-hertz (HZ) (± 1 hertz) power source. All electrical equipment shall comply with NFPA 79, NFPA 70 and NFPA 70E standards.

3.6.3. Surge Protection: All equipment shall utilize surge protection provided by

Contractor with Government approval.

3.6.4. Emergency Stop Buttons: The test stand shall include a minimum of one (1) emergency stop button to cut off all electrical power and utilities to the test stand in case of emergency

3.7. Installation Plan: Contractor shall submit an Installation Plan to the Government POC for review and approval. Installation Plan shall include:

3.7.1. Drawing denoting test stand location on existing floor plan.

3.7.2. Design drawing denoting general locations of major components including, but not limited to pumps, motors, pressure transducers, tanks, conduit sizes, conductor types and sizes, seal off locations, test stand electrical interconnect drawing, and over-current protection devices and sizes.

3.7.3. All subcontractor and partnership information.

3.7.4. Installation Plan shall be submitted to the Government POC a minimum of sixty

(60) workdays prior to initial work on test stand. Stand shall not be delivered until written approval of plan has been received by Contractor from the Government

POC. The government shall have 10 working days to review the Installation Plan and initiate contact with Contractor to discuss/review/resolve any issues.

Following resolution, Contractor shall have 5 working days to resubmit revised

Installation Plan to Government POC for review and approval.

3.8. PC and PLC Control System: RSTS test stand shall be controlled using a Professional

Computer (PC) / Programmable Logic Controller (PLC) configuration as noted below:

3.8.1. PLC shall be Siemens S7 (or better) or Government approved equivalent and controlled using LabVIEW, no earlier than 2018, no substitutes accepted.

3.8.2. New Computer System with the following requirements:

3.8.2.1. Latest Air Force approved Windows Enterprise version

3.8.2.2. CPU: Quad Core i7 (minimum)

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3.8.2.3. Redundant Array of Independent Disks (RAID) array based with a minimum of 1TB SSDs

3.8.2.4. 8GB Synchronous Dynamic Random - Access Memory (SDRAM) minimum.

3.8.2.5. Detachable, standard 101 key computer keyboard and mouse.

3.8.2.6. USB mass storage device ports.

3.8.2.7. Data Access. The Controller shall be equipped with Ethernet Interface (RJ45 port accessing on enclosure).

3.8.2.8. Account Privileges. At a minimum, privileges shall be configured for user and administrative accounts. User accounts shall be able to perform all machine functions without use of Windows administrative privileges.

3.8.2.9. Universal Serial Bus (USB) Communications. Use of any internal and external USB communications on the equipment shall be clearly documented and described within the contractor provided technical data. All external USB ports accessible to the user shall be able to be physically disconnected or rendered inoperable by non-permanent means.

3.8.2.10. Data Access Protocols. Equipment shall be able to communicate externally for machine monitoring and data collection purposes via Ethernet (RJ45 port) Interface using industry standard communication protocols. The controller shall be licensed and able to communicate, at a minimum, via

Fanuc Focas 2 and MTConnect for data access/collection. The installed

MTConnect adapter shall be version 1.3 or later. Specific data collection tags of interest acquired through Fanuc Focas 2 and MTConnect shall be discussed and determined at post award meeting. Contractor shall provide complete list of all TCP-IP ports and protocols utilized by the equipment.

3.8.2.11. Discrete Input/Discrete Output (Di/Do) Information. Contractor shall provide a complete Di/Do address (and/or tag) table with the machine technical data. The Di/Do table shall provide at a minimum the Di/Do signal address or tag name, signal or tag description, and any applied conditioning value or functions.

3.8.2.12. Minimum Sensing Requirements. All sensors and sensor components shall be integrated into the machine control system and readable through

MTConnect. All discrete outputs for data collection purposes shall be conditioned to display meaningful values. All sensor data shall be available as a discrete output for data collection purposes.

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3.8.3. Minimum 17” color flat screen (touch screen) HMI with adjustable StrongArm

(or equivalent) mount to test stand.

3.8.4. No custom proprietary software shall be used.

3.8.5. Local Area Network (LAN) connection capability to existing LAN system allowing full interface with and backup capability of test stand PC and PLC.

3.8.6. System addressing of LAN hardware will be set with guidance from system administrators to comply with existing network standards.

3.8.7. Hardware shall be chosen, where feasible, that has error handling capabilities and be tied back through LabVIEW for pre-test verification of operation.

3.8.8. PLC software shall be password protected at three separate levels as noted below:

3.8.8.1. Operator level: allows access for testing of UUTs alone. Software changes and access to calibration data are NOT allowed at this level.

3.8.8.2. PMEL Tech level: allows access to Operator level as well as Calibration level to permit test stand calibration including entry of calibration data.

Software changes are NOT allowed at this level.

3.8.8.3. Administrative level: allows access to all previous levels as well as capability to modify any test stand software as necessary. Any changes to software shall cause the associated Rev level of the software to change to the next logical level, i.e. Rev. levels shall not be check sum based.

Administrative level shall also include troubleshooting mode that allows the user to manipulate test set points in real time to determine possible fault locations.

3.9. Calibration Equipment: Required calibration features for test stands are detailed below:

3.9.1. Design shall include provisions for connecting test stand calibration equipment currently located in Tinker AFB.

3.9.1.1. Appendix F contains a list of items requiring calibration based on the RSTS designs. This list is for reference only; new RSTS design may have more or fewer items requiring calibration.

3.9.1.2. All items requiring calibration shall be currently listed in Air Force

Metrology and Calibration Program (AFMETCAL) (Air Force TO 33K-1-

100-2) as approved devices.

3.9.1.3. HMI shall display real-time feedback of item being calibrated.

3.9.1.3.1. Raw signal and final units shall both be shown on HMI.

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3.9.1.4. As Found and As Left data shall be available on HMI during calibration with an option to save data to hard drive during calibration.

3.9.1.5. A minimum of 20 data points must be available for each item requiring calibration.

3.9.1.5.1. Five (5) alignment points minimum.

3.10. Test Stand Preliminary/Final Calibration: The first draft of the calibration process shall be delivered by Contractor for review at Intermediate Design Review. Calibration process shall include distinct procedures for both alignment (full adjustment of calibrated instruments when out of spec) and verification (regular checks to determine whether instruments are in spec). Review comments will be delivered via the

Government POC back to Contractor within 10 working days. Contractor shall fully incorporate comments as necessary and resubmit revised procedure prior to Critical

Design Review.

3.10.1. Preliminary Calibration process shall be carried out as follows:

3.10.1.1. Contractor shall be present for initial calibration of the test stand and shall remain present until calibration of the stand is complete.

3.10.1.2. Calibration support shall be provided and be responsible for resolving any calibration issues that may arise from the modifications above within 10 days of identification.

3.10.1.3. Following installation of RSTS at Tinker AFB, Contractor shall complete and prove out the entire approved calibration process prior to contacting

PMEL personnel.

3.10.1.4. Preliminary calibration process shall include a Calibration Summation spreadsheet completed by Contractor detailing the following:

3.10.1.4.1. Each item calibrated and calibration results (Pass or Fail).

3.10.1.4.2. Initials of technician who performed item calibrated and date the calibration was completed.

3.10.1.4.3. As Left values for each item calibrated.

3.10.1.4.4. Any alignments or adjustments performed during calibration.

3.10.1.4.5. Technical documentation revision history (if applicable).

3.10.2. Final Calibration process shall be carried out as follows:

3.10.2.1. Contractor shall have appropriate personnel present during the entire Final

Calibration process.

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3.10.2.2. Final calibration process instructions shall be written to accurately reflect new test stand port and connection labels as applicable.

3.10.2.3. Review and perform entire calibration process, step-by-step, with PMEL personnel present.

3.10.2.4. Modify calibration procedure and software as recommended and agreed to by PMEL personnel, as necessary.

3.10.2.5. Once the calibration procedure is finalized, revised, and resubmitted by

Contractor, PMEL will formally calibrate the test stand.

3.10.2.6. Limitations on the calibration are not acceptable and any limitations noted by PMEL shall be fully resolved by Contractor.

3.11. Code Compliance: The Test Stand shall be compliant with the latest American Society of Mechanical Engineers (ASME) and the National Fire Protection Association (NFPA)

70 Article 500, Hazardous Locations. The Contractor shall provide Code Compliance

Reports signed by a licensed engineer. The Code Compliance Reports shall be provided to the COR as part of the Critical Design Review.

3.12. Safety Analysis: The Contractor shall provide a Cause and Effect Matrix (Alarms and

Shutdowns) and a Test Stand Safety Analysis which has been verified by a disinterested third party. The Contractor shall provide one (1) each hard copy and one (1) each electronic copy of the Cause and Effect Matrix and Test Stand Safety Analysis. The electronic copy shall in PDF format and compatible with the latest version of Adobe

Acrobat. The Cause and Effect Matrix and the Test Stand Safety Analysis shall be provided to the COR as part of the Critical Design Review.

3.13. Test Stand IVV and As-Built Drawing Review: Prior to government calibration, contractor shall provide the latest data package to the government. The government will verify the accuracy of all As-Built drawings, to include but not limited to IPB and all drawings associated with the project. Following review, the Government shall list all deficiencies noted and submit list to Contractor for correction. All deficiencies shall be corrected by Contractor prior to final As-Built drawing submittals. Once finalized, the

Government shall submit a signed and dated document noting that As-Built drawings are 100 percent accurate. Please note that Level 3 drawings as per MIL-STD-31000B are required. Document shall include a detailed list of As-Built drawings including each drawings name, date, and revision level.

3.14. UUT Fixtures, Tooling, and Power Cables: Contractor shall provide all fixtures and tooling necessary for mounting and testing each UUT on the RSTS. Tools and fixtures may be reverse engineered and fabricated, or authentic from Original Equipment

Manufacturer (OEM).

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3.14.1. Legacy fixtures do not need to be reproduced.

3.14.2. If tools and fixtures are reverse engineered, manufacture drawings shall be included for all tools and fixtures that are reverse engineered and fabricated.

Manufacture drawings shall be such that local manufacture of any item can be achieved without further engineering. Requirements for tooling and fixtures can be found in UUT T.O.s (Appendix H).

3.14.3. Fixtures may be incorporated into new test stand design.

3.15. Software: The Contractor shall develop a Test Executive as well as individual UUT

Computer Software Configuration Items (CSCIs) so that they can have separate configuration management at the completion of the contract. The software shall be developed utilizing an object-oriented design such that there is an Executive piece that calls independent pieces for each UUT.

3.15.1. Software assurance shall be designed into the software.

3.15.2. Stands shall have a software Administrative Level ON/OFF option to allow UUT test results/reports to be automatically uploaded to the existing LAN system only when turned ON.

3.15.3. Self-Test: The Contractor shall develop self-test software to identify faulty equipment in the test stand and be used for troubleshooting of the stand.

3.15.4. Executive Software: Contractor shall develop executive software that is common to all UUT types tested.

3.15.4.1. The Executive Software shall run on the latest Air Force approved Windows

OS platform.

3.15.4.2. Occasionally, a Windows OS may freeze or lock up when a software program performs an illegal operation, or it may include an Interrupt

Request line (IRQ) conflict, incompatible device driver, virus, etc. To prevent such problems, all software updates to OS, device drivers, or anti-virus software and the addition of hardware shall be performed by an authorized software maintainer.

3.15.4.3. A password protected Administrative level shall be used to limit user access to executive software including drives, read/write access, and OS privileges.

3.15.4.4. In the event of Windows OS lock ups, a manual E-stop switch shall allow the operator to bring the UUT to a safe condition.

3.15.5. UUT Software: Contractor shall develop menu screens that shall be used for UUT test screens.

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3.15.5.1. Before executing selected UUT test the software shall capture and archive the UUT specifications including, but not limited to: weapon system, Individual Tracking Number (ITN), UUT serial number, test stand’s On-

Condition (OC) number, date, and time.

3.15.5.2. Test results in PDF format shall also be capable of being printed out in hard copy for every UUT and every required test point (see Appendix G for minimum content required).

3.15.5.3. The Test Points (TPs) shall be formatted in accordance with (IAW) the target test equipment style requirements. The main test menu shall display a list each individual TP, matching the most current version of T.O. requirements.

3.15.5.4. Operator shall be prompted to select which semi-automated test to run as well as prompted afterwards to acknowledge that the selected test has completed.

3.15.5.5. Once an individual test section is complete, the display shall read, “Operator must confirm test IAW T.O.” and the operator will then confirm the action on the test screen.

3.15.5.6. All test points shall be programmed and carried out IAW the most current version of UUT T.O.s including applicable AF Form 202s.

3.15.5.7. Hardware and Operator Error handling shall be integrated into the software.

3.15.5.8. The Contractor shall provide a draft of a document denoting sensor usage and software code line versus testing procedure step for each UUT at factory acceptance testing for review by government engineering POC. A final draft of this document will be provided by the contractor at final acceptance testing.

3.15.6. Data Acquisition: The software shall use a data acquisition (DAQ) system for capturing data throughout the testing of each UUT. During testing of each UUT, data shall be written to the hard drive in the new computer system at regular intervals.

3.15.6.1. The DAQ system shall meet a minimum sampling rate of 1 sample per 10 milliseconds.

3.15.6.2. The data collected shall include all testing parameter requirements IAW T.O.

such as, but not limited to: voltage, current, resistance, power, temperatures, speeds, switch positions, etc..

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3.15.6.3. The data collected shall have the capability of being exported to the latest

Air Force approved Microsoft Excel Enterprise version.

3.15.6.4. The data from the last one hundred (100) tests, at a minimum, shall be captured and archived on the new computer system.

3.15.6.5. Data acquisition chassis, controllers, and cards shall have at least one (1) secondary, independent, manufacturer as identified by Contractor that provides a COTS functional replacement.

3.15.7. Test Report: Test results shall be used to generate and populate UUT test reports.

Test reports shall be archived electronically in the test stand’s computer system and be available for easy retrieval by Operator in PDF format. Test results shall also be capable of being printed out from the test stand to locally connected printer.

3.15.7.1. The test reports shall be searchable by, but not limited to, weapon system, ITN, serial number, Control number, and date.

3.15.7.2. The test reports and results shall not be allowed to be electronically changed in any way and may only be allowed to be removed from the PC at the

Administrative level.

3.15.7.3. Contractor shall verify UUT test reports can be printed using the

Government furnished printer and that test reports are complete and accurate.

3.16. PC and Software Security: The contractor shall take the following necessary steps to ensure Government data is safeguarded and secure.

3.16.1. The contractor shall protect Government data by implementing safeguards addressing, at a minimum, the 15 listed areas, which corresponds with the following National Institute of Standards and Technology (NIST) security controls: AC-6, AC-3, AC-20, CA-3, SC-7, AC-22, IA-2, IA-8, MP-6, PE-3, SI-

2, SI-3.

3.16.2. The contractor shall ensure that details about the safeguards for protecting critical program information are not disclosed or published without written consent of the Contracting Officer.

3.16.3. The contractor shall allow the Government access to facilities and resources necessary to execute an inspection program to verify that Government data is secured.

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3.16.4. The contractor shall Safeguard all DoD covered defense information in accordance with DFARS Clauses 252.204-7008, “Compliance with

Safeguarding Covered Defense Information Controls” (AUG 2015) and

252.204-7012, “Covered Defense Information and Cyber Incident Reporting”

(SEP 2015) on all information systems that are owned, or operated by or for, a contractor and that processes, stores, or transmits covered defense information

(SSE Guidebook V1.1, p. 41).

3.16.5. The contractor shall report cyber incidents in accordance with Defense Federal

Acquisition Regulation Supplement (DFARS) Clauses 252.204-7008, “Compliance with Safeguarding Covered Defense Information Controls” (AUG

2015) and 252.204-7012, “Covered Defense Information and Cyber Incident

Reporting” (SEP 2015) (SSE Guidebook V1.1, p. 59).

3.16.6. The contractor shall ensure cloud computing services adhere to the requirements in DFARS Clauses 252.239-7009, “Representation of Use of Cloud Computing”

(SEP 2015) and 252.239-7010, “Cloud Computing Services” (AUG 2015) (SSE

Guidebook V1.1, p. 46).

3.16.7. The contractor shall insure that…