AFATS 02-02 and Calibration Cart Upgrade Statement of Work

27 April 2026

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Table of Contents

1. SCOPE OF WORK

1.1 SCOPE

1.2 BACKGROUND

2. APPLICABLE GOVERNMENT AND INDUSTRY STANDARDS

2.2 GOVERNMENT STANDARDS

2.3 NON-GOVERNMENT STANDARDS

2.4 ORDER OF PRECEDENCE

2.5 APPLICABLE STANDARDS

2.6 PROHIBITED MATERIALS

2.7 ENVIRONMENTAL PROTECTION

2.8 OTHER ENVIRONMENTAL COMPLIANCE

3. GENERAL REQUIREMENTS

3.1 MINIMUM DESIGN PARAMETERS

3.2 INTERIOR ELECTRICAL ITEMS

3.3 EXTERIOR ELECTRICAL ITEMS

3.4 COMPONENT LABELING

3.5 COMPONENT ELECTROMAGNETIC COMPATIBILITY AND INTERFERENCE (EMI) REQUIREMENTS

3.12 CONSTRUCTION

3.14 RELIABILITY-CENTERED MAINTENANCE ACCEPTANCE TESTING W/ BASELINE DATA

3.15 CYBERSECURITY REQUIREMENTS

3.16 CODE COMPLIANCE

3.17 SAFETY ANALYSIS

3.18 WARRANTY

3.19 PERSONNEL

4. TEST STAND REQUIREMENTS

4.1 GENERAL

5. CALIBRATION CART REQUIREMENTS

5.1 GENERAL

6. ACCEPTANCE TESTS

6.1 ACCEPTANCE TESTING WITH BASELINE DATA

6.2 SOFTWARE TEST REPORT

6.3 CORRELATION TEST REPORT

6.4 MONTHLY STATUS REPORT

6.5 TEST PLAN

7. QUALITY ASSURANCE PROVISIONS

7.1 RESPONSIBILITY FOR INSPECTIONS

7.2 RESPONSIBILITY FOR COMPLIANCE

7.3 ENVIRONMENTAL CONDITIONS

7.4 VISUAL EXAMINATION

8. DESIGN REVIEWS

8.1 PRELIMINARY DESIGN REVIEW

8.2 INTERMEDIATE DESIGN REVIEW

8.3 CRITICAL DESIGN REVIEW

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8.4 TEST READINESS REVIEW

8.5 TEST PLAN

8.6 TEST STAND FUNCTIONAL TEST

8.7 CALIBRATION CART FUNCTIONAL TEST

8.8 TEST STAND CORRELATION

8.9 FINAL ACCEPTANCE

8.10 EMERGENCY POC

9. TECHNICAL DATA REQUIREMENTS

9.1 MANUALS/DRAWINGS

9.2 WORK PLAN DRAWINGS

9.3 AS-BUILT DRAWINGS

9.4 SOFTWARE DOCUMENTATION

9.5 COMMERCIAL MANUALS

9.7 DOCUMENTATION

10. TRAINING REQUIREMENTS

10.1 TRAINING PLAN

10.2 OPERATOR TRAINING

10.3 ELECTRICAL/MECHANICAL TRAINING

10.4 CALIBRATION TRAINING

10.5 SOFTWARE/PROCESS ENGINEER TRAINING

11. SPECIAL PROVISIONS

11.1 GOVERNMENT OCCUPANCY OF FACILITIES & RESPONSIBILITIES

11.2 GOVERNMENT INSTALLATION ACCESS

11.3 WORK HOURS

11.4 CONTRACTOR USAGE

11.6 SAFETY, FOREIGN OBJECT DEBRIS (FOD), DROPPED OBJECT PREVENTION (DOP) & QUALITY CONTROL

11.7 HOUSEKEEPING

11.8 TOOL CONTROL AND ACCOUNTABILITY

11.9 FIELD VERIFY

12. PROPOSAL BY CONTRACTOR

12.1 DESCRIPTION

12.2 REQUIREMENTS

13. OTHER WRITTEN SUBMITTALS

13.1 REQUIRED SUBMITTALS

Table of Tables Table 1- Summary of Required Submittals

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APPENDICES

Appendix A: 76CMXG Design Guidelines Appendix B: Safety Specifications Appendix C: Glossary and Definitions Appendix D: Environmental Language Appendix E: List of Parts to Be Replaced Appendix F: Unit Under Test Technical Orders Appendix G: Certification Test Plan Appendix H: Calibratable Items to be Utilized Appendix I: Reliability-Centered Maintenance Appendix J: Original Unmodified AFATS Test Stand Manuals and Drawings Appendix K: EMD-Modified AFATS Test Stand Commercial Manuals and Drawings Appendix L: Bauer-Modified AFATS Test Stand Commercial Manuals and Drawings Appendix M: AFATS Calibration Cart Manuals and Drawings Appendix N: AFATS Pump Module Manuals and Drawings Appendix O: AFATS Hydraulic Module Manuals and Drawings Appendix P: Contract Data Requirements List (CRDL)

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1. SCOPE OF WORK:

1.1 Scope: The following establishes the minimum requirement for the upgrade of Advanced Fuel Accessories Test System (AFATS) 02-02 (P/N 8230001-0501), and training on the maintenance, calibration, programming, and use of said test stand. The test stand will primarily be used to test fuel flow proportioners and float valves in accordance with their relevant Technical Orders (T.O.’s), but will also be used as needed to test refueling receptacles, transfer pumps and other similar components as per their relevant T.O.’s. The following also includes the minimum requirement for the upgrade of a currently nonfunctional calibration cart (P/N: 8231300-0501) for use in calibrating flowmeters and electrical parameters on this system and other existing AFATS configurations. The overall project will 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.

1.2 Background: The test stand and calibration cart described in this document are intended for use in the Aerospace Repair Industry. The existing test stand is installed in , at Tinker AFB, OK and the completed upgrade will remain installed in said location.

This shop runs on a 24 hour basis Monday through Friday with possible overtime hours during the weekend. Test stands will be installed in a National Electric Code, Class I, Division II, Group D environment, as per NFPA 70, Article 500. The AFATS 02-02 Test Stand is 28 years old and primarily tests the following components:

• Fuel Flow Proportioner P/N 44143 (T.O. 6J15-13-11-3)

• Float Valve P/N 1321-575030M2 (T.O. 6J15-3-44-63)

The test stand also has capability to test the following items, though it is not their primary test station.

• Fuel Transfer Pump Housing P/N 381300-7 (T.O. 6J10-3-136-3)

• Fuel Transfer Pump P/N 381400-24 (T.O. 6J10-3-136-3)

• Fuel Transfer Pump P/N 380200-14, -15, -17 (T.O. 6J10-3-137-3)

• Fuel Transfer Pump P/N 390000-1 (T.O. 6J10-3-146-3)

• Refueling Receptacle P/N 2652021-101, -102 (T.O. 6A6-16-3)

• Refueling Receptacle P/N 4011-51 (T.O. 6A6-19-3)

• Refueling Receptacle P/N 2730526M5-1 (T.O. 6A6-19-3)

• Slipway Receptacle P/N 2761117-102 (T.O. 6A6-20-3)

All end items are tested on the AFATS 02-02 Test Stand using a set of removable test carts that connect to and receive test fluid/electrical supply from the test stand via paired Staubli Plates.

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The stand is supplied calibration fluid (MIL-PRF-7024 Type II) at 100-400 psig, 102-612 gpm, 75-95°F from a remote centralized pump module that also supplies two other test stands in the same bay. The upgraded test stand must be designed to interface with the pump module via the existing fiber network and communicate with its Siemens S7 PLC.

Current computer hardware/software follows:

o VAX 4000 Model 200 o 2-Graphic Cards RGB (Operator Display & Process Data Display) o RS232 Interface – Touch Screen Communication for the above monitors o IEEE583 Interface – Communication to Kinetic Systems/Dynamic Signals

(CMAC) Data Acquisition & Control System (1502-P3E) o Crate Controller Card – 2922-Y1B, DEC Q-BUS Interface with DMA for

MicroVAX 3000 Series, Controls up to eight CAMAC Crates, RS-485 Balanced- Line Signaling between 2922 and 3922, Supports 8,16, & 24-Bit Data Words, Four DMA Operating Modes: Ignore-Q, Q-Stop, Q-Scan & Q-Repeat.

Crate Includes: 3665-Z1A Freq. to Digital Converter, 3516-S017 Analog to

Digital Input, E100 Digital Input, 2755 Doser Controller, 3559-D1A Resolver to Digital Converter, 3072-A1B 48-Channel Digital Input, 3116- V2A Digital to Analog Output, 3130-D1A DC Variable Current Driver Output.

o IEEE488 Interface – Communication to DMM, Switch Matrix, 2-Variable DC Power Supplies, Function Generator, Power Analyzer & Variable AC Power Supply.

o VMS, ADA Test Language

The calibration cart to be upgraded is located in at Tinker AFB. It is nonfunctional and is currently being used for spare parts for the in-use cart that moves as needed. When fully functional, the calibration carts had the capability to calibrate all measuring devices installed on all AFATS test stands (including electronics, pressure sensors, flowmeters, etc.) in-place without requiring their removal from the test stand or use of alternate external calibrators. The current configuration for the in-use cart is only capable of calibrating electrical signals and flow measurements, with all other calibrations being performed using external calibration standards. The cart calibrates the stand components in-place via a set of externally calibrated flowmeters (cascaded to allow for calibration of multiple flow ranges) and electrical calibration standards installed on the calibration cart that are calibrated separately and provide comparison to values generated by the test stand measuring devices. The calibration carts connect to and receive test fluid/electrical supply from the test stand via paired Staubli Plates.

2. APPLICABLE GOVERNMENT AND INDUSTRY STANDARDS:

2.1 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

SOW-2027-AFATS Upgrades Page 7 recent edition” will be understood to mean “most recently released edition as of date of issuance of contract.”

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

2.2.1 U. S. DEPARTMENT OF LABOR

2.2.1.1 29 CFR 1910 – General Industry, OSHA Safety and Health Standards (29

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

2.2.1.2 (Application for copies should be addressed to the U.S. Department of Labor, 200 Constitution Ave, Washington, D.C. 20210)

2.2.2 ENVIRONMENTAL PROTECTION AGENCY

2.2.2.1 40 CFR 82 – Protection of Stratospheric Ozone, 2010 or most recent edition

2.2.2.2 (Application for copies should be addressed to the U.S. Department of Labor, 200 Constitution Ave, Washington, D.C. 20210)

2.2.3 FEDERAL STANDARDS

2.2.3.1 FED-STD-H28A – Screw Thread Standards for Federal Services, 1994 (R2001) or most recent edition

2.2.3.2 FED-STD-H28/21B – Screw Thread Standard for Federal Service, Metric Screw Threads, 1984 (R2006) or most recent edition

2.2.3.3 UFC 3-600-01 – Fire Protection Engineering for Facilities

2.2.3.4 UFGS 07 84 00 – Firestopping

2.2.3.5 UFGS 21 13 13 – Wet Pipe Sprinkler Systems

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

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

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

2.2.3.9 UFGS 28 31 64 – Fire Detection and Alarm System

2.2.3.10 (Application for copies should be addressed to Superintendent of Documents, Government Printing Office, Washington, D.C. 20402-001).

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

2.3.1 NATIONAL FIRE PROTECTION ASSOCIATION (NFPA)

2.3.1.1 NFPA 1 – Fire Code, 2010 edition or most recent edition

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

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

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2.3.1.4 NFPA 16 – Standard for the Installation of Foam-Water Sprinkler and Foam- Water Spray Systems, 2019 edition or most current

2.3.1.5 NFPA 70 – National Electrical Code, 2014 edition

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

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

2.3.1.8 (Application for copies should be addressed to National Fire Protection

Association, Battermarch Park, Quincy, MA 02269)

2.3.2 TELECOMMUNICATIONS INDUSTRY ASSOCIATION (TIA) STANDARD

2.3.2.1 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

2.3.2.2 (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)

2.3.3 NATIONAL ELECTRICAL MANUFACTURERS ASSOCIATION (NEMA)

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

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

2.3.3.3 (Application for copies should be addressed to National Electrical

Manufacturers Association, 1300 N 17th Street, Suite 1752, Rosslyn, VA 22209)

2.3.4 AMERICAN NATIONAL STANDARD INSTITUTE

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

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

2.3.4.2 (Application for copies should be addressed to American National Standards

Institute, Attn: Sales Department, 1430 Broadway, New York, NY 10018- 3363)

2.3.5 AMERICAN WELDING SOCIETY INC (AWS)

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

2.3.5.2 (Applications for copies should be addressed to the American Welding

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

2.3.6 INTERNATIONAL ORGANIZATION FOR STANDARDIZATION

2.3.6.1 ISO 4413 – Hydraulic Fluid Power – General Rules and Safety Requirements for Systems and Their Components, 2010 or most recent edition

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

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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)

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

2.5 Applicable Standards:

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

2.5.2 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 will be graduated in inch-pound units. Markings on all measuring and indicating devices must be permanently and legibly engraved or etched on a non-glare background. All dials and indicating devices must be securely mounted in place. Such devices must be readable from the operator’s normal workstation. All measuring and indicating devices will be calibrated by OC-ALC PMEL (Precision Measurement Equipment Laboratory). The contractor will provide standards and procedures for calibration of any measuring or indicating device not found in the AFMETCAL (Air Force Metrology and Calibration) database.

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

2.5.4 Cautions-Warning Plates: Corrosion resistant “Caution” or “Warning” Plates must 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.

2.5.5 Noise Levels: The noise level emitted by the equipment under load must 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.

2.5.6 Instruction Plates: All words on instruction plates must be in the English language.

Words must be engraved, etched, embossed, or stamped in boldfaced letters on a contrasting background. Lettering must be a minimum of 18-point font and the plates must be sized accordingly to accommodate all standard text in this point size. Plates and lettering must be fully compatible with MIL-PRF-7024 Type II calibration fluid and MIL-PRF-83282 hydraulic oil and suffer no degradation when subjected to either fluid.

2.5.7 Nameplate: A corrosion resistant metal nameplate permanently and legibly marked with the following information must be securely attached to the machine in a readily visible location. Nameplate and lettering must be fully compatible with MIL-PRF-7024 Type II

SOW-2027-AFATS Upgrades Page 10 calibration fluid and MIL-PRF-83282 hydraulic oil and suffer no degradation when subjected to either fluid. Lettering must be a minimum of 18-point font.

2.5.7.1 Nomenclature of the Machine

2.5.7.2 Manufacturer’s Name and Address

2.5.7.3 Manufacturer’s Model Number

2.5.7.4 Manufacturer’s Serial Number

2.5.7.5 Date of Manufacture

2.5.7.6 Contract Number

2.5.7.7 Services Requirements – All service requirements to be included.

2.5.8 Castings and Forgings: All castings and forging must be free from defects, scale, or mismatching. Processes such as welding, peening, plugging, or filling with solder or paste must 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.

2.5.9 Welding, Brazing, and Soldering: Welding, brazing, or soldering must be employed only where those operations are included in fabrication of the original design. These operations must not be employed as repair or reclamation measures for defective parts.

Any excess material used for such operations must be thoroughly removed from the part(s) upon completion of the operations. Weldments must comply with AWS D14.4.

2.5.10 Surface Finish: All surfaces of castings, forgings, molded parts, stampings, and welded parts must be clean and free from sand, dirt film, sprues, flash, scale flux, and other harmful or extraneous materials. External surface edges must 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 must be commensurate with the manufacturer’s standard commercial practice.

2.5.11 Gears: All gears and pinions, if applicable, must 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.

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

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

2.5.14 Electrical Items: All electrical/electronic components located within the interior and footprint of test stand and calibration cart must meet or exceed the minimum requirements defined by NFPA 70 Article 500 Class I, Division I, Group D environment.

Areas exterior to these regions must be Class I, Division II, Group D-rated per NFPA 70, Article 500.

2.5.14.1 If purge air cabinets are utilized, purge air requirements must be limited to 200 scfm. Contractor must be responsible for tapping into existing supply duct

SOW-2027-AFATS Upgrades Page 11 in the Test Bay as necessary for any required feed to system and must include a manual volume damper for flow control.

2.5.14.2 Purge air system and enclosures must be protected from over pressurization.

The system must conform to NFPA 496 and International Society of Automation (ISA) 12.4 standards and be Underwriters Laboratory (UL) classified.

2.5.15 Electrical Systems: The AFATS 02-02 Upgrade must not require any alterations to the existing equipment’s facility power supply. The AFATS Calibration Cart Upgrade must maintain capability to receive necessary power from the test stand it is paired to.

2.6 Prohibited Materials:

2.6.1 Mercury Restriction: The machine must contain neither mercury nor mercury compounds or be exposed to free mercury during manufacture.

2.6.2 Asbestos Restriction: Asbestos and materials containing asbestos must not be used on or in the machine.

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

2.6.4 Lithium Restriction: Lithium and lithium compounds must not be used on or in the test stand except in the case of lithium batteries used in the computer system.

2.6.5 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, must not be contained within or used on this equipment.

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

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

3. GENERAL REQUIREMENTS:

3.1 Minimum Design Parameters: The AFATS 02-02 Test Stand Upgrade and AFATS Calibration Cart Upgrade must be designed such that all new/replacement parts are unused, without defects, commercial-off-the-shelf (COTS) and free of repairs/modification. The upgrades must be final designs (not prototypes) and must demonstrate verifiable improvement over equipment prior to upgrades.

3.2 Interior Electrical Items: All electrical/electronic components and connections located within the AFATS 02-02 Test Stand and Calibration Cart footprints, floor to ceiling, must be Class I, Division I, Group D-rated as defined in NFPA 70 Article 500 and NFPA 496.

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3.3 Exterior Electrical Items: All electrical/electronic components and connections outside the AFATS 02-02 Test Stand and Calibration Cart footprints must be Class I, Division II, Group D-rated as defined in NFPA 70 Article 500 and NFPA 496 and must be mounted in an enclosure(s). Enclosure interior(s) must only be accessible from outside the equipment envelopes.

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

3.5 Component Electromagnetic Compatibility and Interference (EMI) Requirements: Suitable items must have removable/replaceable electronic circuit modules that plug into an equipment rack or frame located on the interior of exterior of the given equipment, with electrical interconnections primarily through edge connectors that interface directly with a backplane. Electrical power input must be derived from the backplane power sources. EMI requirements of these REMs must be based on MIL-STD-461E system/equipment-level electromagnetic interference (EMI) controls.

3.6 Turn-key installation and start-up are required for both upgrades.

3.7 The upgrade designs must be created such that the government will have capability to perform similar upgrades on equivalent equipment.

3.8 Operator manuals, calibration procedures, and Illustrated Parts Breakdown manuals must be updated or rewritten to reflect the upgrades. The manuals for the individual pieces of equipment must remain separate and distinct from one another; no two manuals concerning different upgraded equipment will be combined.

3.9 The government will have unlimited data rights to provided items.

3.10 Safety and code compliance reports are required and must be compliant with the most recent versions of ASME B31.3, NFPA 70 Article 500, and relevant Technical Orders.

3.11 Work on the test stand and calibration cart must have no impact on production.

3.12 Construction: The AFATS Upgrades must be constructed of parts that are new, without defects, commercial-off-the-shelf (COTS), and free of repairs and modification. Metals must be corrosion resistant materials unless suitably protected to resist corrosion. The AFATS Upgrade construction must include all components, parts, and features necessary to meet the performance requirements specified herein. All parts subject to damage from environmental hazards must be sealed or otherwise protected. The upgrades must be capable of withstanding all forces encountered during operation of the test stand and calibration cart at their maximum ratings and capacities without distortion or failure. Welding, plugging, or filling with solder or paste must not be employed as repair or reclamation measures for

SOW-2027-AFATS Upgrades Page 13 defective parts. All screws, pins, bolts, and similar parts must be installed with means of preventing loss of tightness. All parts subject to removal or adjustment must not be swaged, peened, staked, or otherwise permanently deformed. The upgrades must be built in compliance with 76CMXG Design Guideline as detailed in Appendix A.

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

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

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

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

3.13 The Contractor will assume full responsibility for all equipment and materials required in the conduction of this project. The Government will not be liable for lost or stolen items.

3.14 Reliability-Centered Maintenance Acceptance Testing w/ Baseline Data: Following Final Calibration of the test stand and calibration cart and prior to Correlation Testing, RCM acceptance testing and baselining (including Equipment Health Checkout) must be completed by personnel from 76MXSG/MXDEQ as described in Appendix I. This effort will be attended by the Contractor’s technical representative. Additional information requested in Appendix A will be provided by the Government POC for distribution.

Repeated RCM attempts using Government employees may be subject to Government consideration.

3.15 Cybersecurity Requirements

3.15.1 General Requirements

3.15.1.1 The contractor must ensure that all delivered items have been developed and sourced in a manner consistent with a Cybersecurity Supply Chain Risk Management (C-SCRM) program aligned with NIST SP 800-161. All deliverables must be free from prohibited telecommunications and video surveillance services or equipment as defined by Section 889 of the 2019

NDAA.

3.15.1.2 During the contract’s period of performance, prior to final Government acceptance, the contractor must report any cybersecurity incidents affecting the development, integrity, or delivery of the product to the OC-ALC within five (5) business days of identification. Similarly, during the period of

SOW-2027-AFATS Upgrades Page 14 performance, the contractor must maintain an insider threat detection program for all personnel with access to government systems or data related to this contract.

3.15.1.3 To satisfy the requirement for current, secure network authentication standards, all delivered systems and devices capable of network communication must support, at a minimum, the following protocols and configurations:

3.15.1.3.1 Network Access Control: The device must support IEEE 802.1X for port-based network authentication.

3.15.1.3.2 Data-in-Transit Encryption: All communication sessions must be encrypted using Transport Layer Security (TLS) version 1.2 or higher (TLS 1.3 is preferred). Insecure legacy protocols such as SSL, TLS 1.0, and TLS 1.1 must be disabled.

3.15.1.3.3 Secure Management Protocols: Remote administrative access must be provided exclusively via Secure Shell (SSHv2). Web-based management interfaces must use HTPPS. If Simple Network Management Protocol (SNMP) is used, it must be SNMP version 3 with authentication and privacy features enabled.

3.15.1.3.4 Insecure Protocol Disablement: All insecure and legacy plaintext protocols must be disabled by default. This includes, but is not limited to, Telnet, FTP, TFTP, and SNMP versions 1 and 2c.

3.15.1.4 The Contractor may contact ocalc.cyber.support@us.af.mil to obtain Government Furnished Information (GFI), such as the necessary digital certificates and network-specific configuration parameters (e.g. RADIUS server addresses) required for implementation.

3.15.2 Hardware Requirements

3.15.2.1 All hardware and physical components must be Trade Agreement Act (TAA) compliant, and any system or component containing cryptographic mechanisms must use cryptographic modules that are FIPS-140 validated. For specialized industrial systems that utilize an internal IP-based network, the product must provide a clear point of connection to the government network, either through an internal router capable of 1:1 Network Address Translation (NAT) with an open RJ-45 port, or via an open RJ-45 port leading directly to the system's internal switch. These industrial systems must also be capable of communication utilizing the Open Platform Communications Unified Architecture (OPC UA) protocol. As part of the delivery, the contractor must provide a complete technical data sheet for all delivered hardware. For industrial systems, this documentation package must also include a comprehensive data point explanation table. This table must, at a minimum, define every available machine data tag, its data type (e.g., integer, string), units of measure (e.g., PSI, degrees Celsius), and a plain-language description of the data point it represents.

3.15.3 Software (SW) Requirements

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3.15.3.1 The delivered operating system must comply with one of the following conditions: 1) It is the Government-provided “Gold Image” OS; 2) It is a secure, enterprise-version OS configured in accordance with all applicable DISA STIGs; or 3) It is a secure OS delivered with a detailed security requirements guide for maintaining its security.

3.15.3.2 The software must be designed to be fully functional when run by a standard, nonprivileged user account. Day-to-day operator functions must not require administrative privileges. The use of administrator-level accounts must be restricted solely to authorized personnel performing specific system administration and maintenance tasks.

3.15.3.3 All delivered software executables must be digitally signed, and the public keys used for these digital signatures must be provided to the Government.

Furthermore, a complete Software Bill of Materials (SBOM) for all delivered software and firmware must be provided. All software must be fully compatible with Government-specified and supported operating systems.

3.15.3.4 To ensure long-term Government sustainment, the contractor must enter into a Source Code Escrow Agreement with a neutral third-party escrow agent at the contractor's expense. The deposit materials must include, at a minimum, the complete software source code, all necessary build scripts, compilers, third-party libraries, and detailed documentation required to independently compile, install, and maintain the software. The release conditions for the escrow must include, but are not limited to, contractor bankruptcy, acquisition, or failure to meet the support and security update obligations outlined in this SOW.

3.15.3.5 Following final Government acceptance, the contractor is obligated to provide all necessary software and firmware security updates in a timely manner. This obligation must extend until the end of the product's warranty period or until the software is officially deprecated by the manufacturer, whichever is longer.

3.15.4 Maintenance and Support

3.15.4.1 In the event that contractor personnel require access to a Government facility to perform maintenance or support, they must be continuously escorted by a designated Government cybersecurity representative. Furthermore, any equipment brought by contractor personnel (including but not limited to laptops, diagnostic tools, or storage media) is subject to inspection, scanning for vulnerabilities and malicious code, and continuous monitoring by the Government. The Government reserves the right to deny facility or network access to any contractor-owned equipment that does not meet its security standards or poses a risk to Government information systems.

3.16 Code Compliance: All upgraded equipment must 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 must provide Code Compliance Reports signed by a licensed engineer. The Code Compliance Reports must be provided to the COR NLT fourteen (14) calendar days prior to the Critical Design Review.

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3.17 Safety Analysis: The Contractor must 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 must 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 must be in PDF format and compatible with the latest version of Adobe Acrobat. The Cause and Effect Matrix and the Test Stand Safety Analysis must be provided to the COR NLT fourteen (14) calendar days prior to the Critical Design Review.

3.18 Warranty: The Contractor must warranty all equipment, workmanship, and components free of defects for a period of no less than 730 calendar days. The Contractor will be notified of defects by the Government in writing via email. The Contractor must respond to all reported problems within 24 hours. Defects must be remedied at no cost to the government within ten

(10) calendar days. Contractor must be responsible for correcting any found defect or inconsistency with this SOW to the Government’s satisfaction. If the defect or inconsistency cannot be remedied within ten (10) calendar days, the Contractor must inform the Government POC before the initial requirement period expires and must define an estimated completion date (ECD) for the corrective action. If the defect or inconsistency persists beyond the 730 calendar day period or the standard warranty period, whichever is longer, the Contractor will still be responsible for corrective action until the issue is rectified.

Warranty will start after final payment in WAWF.

Any spills caused by an equipment defect during equipment installation must be cleaned up within 2 clock hours at no cost to the Government. Contractor will be responsible for damages to the new equipment, existing equipment, and the facility caused by the defect.

All materials and labor for corrective action, modifications, and defects will be supplied by the Contractor, including a tracking number and carrier name e-mailed to the Government POC as applicable. The warranty will not be considered null and void if Government personnel are required to perform emergency shutdown or repairs to the equipment due to a defect that presents a clear and present danger, including but not limited to potential grave damage to the environment (i.e. release of toxic chemicals), creation of a health hazard to personnel working in and around the equipment, and/or creation of a safety hazard to the building, personnel within the building, or other equipment surrounding the Contractor’s equipment.

Contractor must provide a method for reporting problems encountered with AFATS Test Stand 02-02 and AFATS Calibration Cart following installation and throughout the warranty period. This problem reporting method must contain clear conditions which, when met, will necessitate a site visit by Contractor personnel to directly perform corrective action. Said conditions will be discussed with Government personnel and agreed to in writing prior to the start of the warranty. Upon receipt of problem report, Contractor will analyze and respond with their planned corrective action and recommendations to the Oklahoma City Air Logistics Complex (OC-ALC) and will coordinate a site visit for Contractor personnel to perform corrective action if necessary. Problem reports must be classified as by the OC-ALC as urgent or routine. Initial response time for urgent problem reports must be forty-eight (48) clock hours or less. Initial response time for routine problem reports must be seven (7) calendar days or less. Contractor must provide contact information (phone, e-mail address at a minimum) for a primary and back-up POC for reporting problems.

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The Warranty must not be considered null and void for any component of the equipment or the equipment in its entirety if Government employees perform work on the equipment under the direction of Contractor personnel. The Contractor will remain liable for all defects that persist after Government work at Contractor request is completed.

3.18.1 Corrective Action Plan: The Contractor will provide the Government with a response plan for any issues discovered by Government POCs. This plan must include, at minimum

3.18.1.1 Timeline to mitigate issues found

3.18.1.2 Method for mitigating issues, e.g. all necessary expertise needed to resolve issues

3.18.1.3 Plan to substantiate that the issue has been successfully addressed prior to re-engagement of Government personnel

3.18.1.4 Mitigation process for any other remaining issues, whether discovered before or during effort to mitigate original issue

3.19 Personnel: The contractor must have the following minimum personnel on staff. These personnel must be used to perform this upgrade.

3.19.1 At least one (1) National Instruments Certified LabVIEW Architect on staff with experience in LabVIEW and PLC systems.

3.19.2 At least one (1) member assigned as a Program Manager who will have overall responsibility for meeting the contract requirements stated within this SOW.

3.19.3 At least one (1) member assigned as a Field Service Engineer who will be available for technical direction during modification and testing of the test stand at Tinker AFB.

3.19.4 At least one (1) member assigned as a Mechanical Engineer who will have overall responsibility for piping/pump/hydraulic design as necessary to meet contract requirements within this SOW.

3.19.5 At least one (1) member assigned as an Electrical Engineer who will have overall responsibility for electrical design as necessary to meet contract requirements within this

SOW.

4. TEST STAND REQUIREMENTS:

4.1 General: AFATS 02-02 Test Stand Upgrade design specifications must be based on Unit Under Test (UUT) requirements as noted in associated UUT Technical Orders (T.O.’s), which are listed in Appendix F. Any documents/manuals associated with existing test equipment are for reference only and are intended to provide the Contractor with the functional basis to be exceeded by the completed upgrade. AFATS 02-02 particulars are noted below:

4.1.1 Configuration: AFATS 02-02 Test Stand Upgrade must use the design of the previously upgraded AFATS 02-03 Test Stand currently in use at Tinker AFB, as the minimum basis for all new upgrades, and must improve upon/modernize said design wherever possible. AFATS 02-02 and AFATS 02-03 are not configured for the same end

SOW-2027-AFATS Upgrades Page 18 items; as such, the upgraded test station must not be a direct copy of its minimum basis and must be tailored to all end items noted in this SOW. See Appendices J-L for general test stand configuration. Data acquisition chassis, controllers, and cards must have at least one (1) secondary, independent manufacturer as identified by the Contractor that provides a COTS functional replacement. The upgraded configuration must have complete capability to test all listed end items in accordance with their associated Air Force (AF) Technical Orders (T.O.’s).

4.1.2 Calibrated Items: See Appendix H for minimum required calibratable items. Note that this list only includes items currently calibrated on the non-upgraded test stand; any additional items that are calibrated on other AFATS test stands are indicated in Appendices J-L. Any items found to require calibration other than those given in Appendix H must be added to the calibration procedure to be used by the Government after Final Acceptance.

4.1.3 Contractor must verify latest T.O. in use prior to software development.

4.1.4 No modification/tweaking by the operator will be required for any testing control loop regardless of the UUT being tested.

4.1.5 Test Requirements: Test Requirements for each UUT test are given in their associated

T.O.’s, which are listed in Appendix F and available to the Contractor on request. The Contractor must consult with Government engineering and production POCs throughout the design process and at all design reviews to ensure test procedures as implemented in the test stand sufficiently reflect the T.O. requirements and completely test the UUT. The Contractor must provide the following deliverables at the indicated design reviews as part of their associated deliverable packages for Government POC review. Comments noting any needed corrections will be returned to the contractor for review after the associated design review period.

4.1.5.1 PDR: A document cataloguing all relevant test parameters for each UUT and UUT test with clear reference to the UUT T.O. requirements.

4.1.5.2 CDR: A general configuration flowchart indicating how the Test Stand’s planned components will meet UUT test requirements.

4.1.5.3 Time to test (including hookup to stand) requirement for each known good UUT, as tested by a certified Tinker mechanic, must not exceed the following:

4.1.5.3.1 Fuel Flow Proportioner (T.O. 6J15-13-11-3): 4 hours

4.1.5.3.2 Float Valve (T.O. 6J15-3-44-63): 4 hours

4.1.5.3.3 Fuel Boost Pump (T.O. 6J10-3-136-3): 5 hours

4.1.5.3.4 Fuel Boost Pump Housing (T.O. 6J10-3-136-3): 4 hours

4.1.5.3.5 Fuel Boost Pump (T.O. 6J10-3-137-3): 5 hours

4.1.5.3.6 Fuel Boost Pump (T.O. 6J10-3-146-3): 4 hours

4.1.5.3.7 Refueling Receptacle (T.O. 6A6-16-3): 3 hours

4.1.5.3.8 Refueling Receptacle (T.O. 6A6-19-3): 3 hours

4.1.5.3.9 Refueling Receptacle (T.O. 6A6-17-3): 3 hours

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4.1.5.3.10 Slipway Receptacle (T.O. 6A6-20-3): 3 hours

4.1.6 The Contractor may request the Contracting Officer (CO) to provide a copy of the end item T.O.’s listed in Appendix F and the test stand technical orders/commercial data listed in Appendices J-L. The request will be by email. The Contractor will sign a Non- Disclosure Agreement and must not disclose the data provided for any purpose or in any manner not specifically authorized or required by this SOW or the contract.

4.1.7 The original Honeywell “doser” modules and obsolete instruments, sensors, and hardware listed in Appendix E must be replaced with COTS devices that meet or exceed original hardware for controllability, range, and accuracy. Any variations between original and replacement components must be clearly documented, and any variations must not compromise the equipment’s ability to complete tests. Government Engineering POC will approve all suitable substitute parts prior to purchase and installation by Contractor.

4.1.8 Upgraded test stand must be capable of providing the following electrical power supplies to UUTs as needed. Existing AC/DC power supplies must be replaced with COTS equivalents (See Appendix E).

4.1.8.1 200±2 VAC, 400±2 Hz, 15A AC Power

4.1.8.2 30VDC, 5A DC Power

4.1.9 Rusted drain and base pans must be replaced.

4.1.10 Contractor must inspect test stand internal and fixture hoses for damage and/or wear during equipment modification and present findings to the Government engineering POC for review. Contractor will replace damaged hoses as directed by Government POC.

4.1.11 All water line insulation will be replaced.

4.1.12 All AFATS test carts and fixturing currently in use must remain usable with upgraded test stand. No upgrades are required for these items.

4.1.13 TPS and UUT metadata will be stored locally at the upgraded machine.

4.1.14 Correlation testing is required between upgraded stand and “master” stand. Correlation testing will be performed as described in Appendix G.

4.1.15 All software source code developed by the contractor must be provided to the government prior to completion of contract.

4.1.16 IT Security:

4.1.16.1 PC operating system must be the latest USAF-approved version of Windows Enterprise.

4.1.16.2 The Contractor must ensure that system administrators have access to perform mandatory patch management and security scans to comply with current AFSC System Maintenance Plan and Information System Configuration Management.

4.1.16.3 The Contractor must ensure that any Windows operating system can be configured to be domain-joined and that contractor access will be restricted

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4.1.16.4 The Contractor must protect Government data by implementing safeguards addressing, at a minimum, the following 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.

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

4.1.17 Testing will be semi-automatic.

4.1.18 Test software will be LabVIEW or equivalent to be approved by Government POC.

4.1.19 The Contractor must provide new Test Program Sets (TPS) integrated into upgraded software for each UUT.

4.1.20 Communications between test stand and Central Computer will be maintained.

4.1.21 New PLC system must be designed to communicate with existing low pressure pump module Siemens S7 PLC for purposes of automatically activating pumps and directing flow/pressure as needed for end items. PLC system must also communicate with low pressure pump module as it communicates with existing hydraulic module. This PLC system must replace the existing VAX data acquisition system and all its associated components. VAX removal must be performed such that the VAX and its components can be utilized as spares for existing non-upgraded test equipment.

Technical information for the low pressure pump module and hydraulic module are located in Appendix N and Appendix O, respectively.

4.1.22 Professional Computer (PC) and Programmable Logic Controller (PLC) Control System:

Data acquisition system must, at minimum, be functionally equivalent to the data acquisition system of the upgraded AFATS Test Stand 02-03 and must improve this design wherever possible. Specific minimum PC and PLC system requirements include:

4.1.22.1 Cutting-edge COTS PLC using LabVIEW (functionally equivalent to or better than Siemens S7 PLC Controller)

4.1.22.2 Most up-to-date USAF-approved version of Windows Enterprise

4.1.22.3 CPU: Quad Core i7 (minimum)

4.1.22.4 Redundant Array of Independent Disks (RAID) array based with a minimum of 1TB Solid-State Drive SSD’s

4.1.22.5 8GB Synchronous Dynamic Random-Access Memory (SDRAM) minimum

4.1.22.6 19’ color flat screen (touch screen) HMI (minimum) with adjustable

StrongArm (or equivalent) mounted to test stand

4.1.22.7 Detachable standard 101-key computer keyboard and mouse, Class I, Division

II, Group D rated

4.1.22.8 Built-in DVD-ROM/CD-RW and USB mass storage ports

4.1.22.9 No custom proprietary software will be used

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4.1.22.10 LAN connection capability to existing LAN system allowing full interface with and backup capability of the test stand PC and PLC

4.1.22.11 System configuration such that flowmeter calibration data can be uploaded to test stand through USB port or similar (subject to Government POC approval).

Manual loading (keying in) capability of flowmeter calibration data will be provided for use if necessary, but no input must strictly require it.

4.1.22.12 Error-handling capabilities within hardware where feasible

4.1.22.13 PLC Software must be password-protected at three separate levels as noted below:

4.1.22.13.1 Operator Level: Allows access for testing of UUT’s. Software changes and access to calibration data must NOT be allowed at this level.

4.1.22.13.2 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 must NOT be allowed at this level.

4.1.22.13.3 Administrative Level: Allows access to all previous levels as well as capability to modify any test stand software as necessary. Any changes to software must cause the associated revision level of the software to change to the next logical level, i.e., revision levels will not be check-sum based.

4.1.23 Validation/Verification: Following Final Calibration, Contractor must provide guidance (hands-on) to the Government POC to complete Validation and Verification of software programming versus testing procedures as per each UUT T.O. Contractor must provide the Government a list of sensor usage and software lines of code versus testing procedures as per each UUT T.O.