SOO.doc

U.S. Coast Guard Aircraft Engine Test Cell Upgrade

Statement of Objectives

1.0

BACKGROUND

The U.S. Coast Guard Aviation Logistics Center, (ALC), operates one (1) T-700-GE-401 Engine Turboshaft Test Cell at its facility in Elizabeth City, NC. This facility was established in 1986. This Test Cell was designed to operate the General Electric T-700-GE (series) engine through its entire operational range. The Test Cell is of a basic “U” shape and utilizes an Air Dynamometer P/N 1314AS100-1. The Test Cell was adapted from a Portable Outdoor configuration that was modified to fit in an Indoor facility. The Air Dynamometer is attached to a Portable Trailer, P/N 1289AS101-1 and the engine to be tested is mounted to the trailer. The Controls and Monitoring system are fixed to the facility in a Control room attached to the Test Cell. The T-700-GE-401 Engine Turboshaft Test Cell currently uses a proprietary data reduction program from CMR Technologies Inc to verify engine performance. The throughput of the cell is estimated to be 69 T-700 engines, with variation based on yearly demand.

The U.S. Coast Guard Aviation Logistics Center, (ALC), operates one (1) ATF3-6-4C Jet Engine Test Cell at its facility in Elizabeth City, NC. This facility was established in 1986. This Test Cell was designed to operate the Honeywell ATF3-6-4C engine through its entire operational range. The Test Cell is of a basic “U” shape with the engine installed into an ATF3-6 engine adapter, P/N ASE/501445-001. The adapter secures and positions the engine into the ASE 50K thrust stand, P/N ASE/501327-001. The thrust stand provides services to the engine through a coupling plate and measures engine thrust utilizing a load cell P/N 206209, type U3G1 from BLH Electronics, Inc. The Controls and Monitoring system are fixed to the facility in a Control room attached to the Test Cell. The ATF3 Test Cell currently uses a proprietary data reduction program from Honeywell to verify engine performance. The throughput of the cell is estimated to be 36 ATF3 engines, with variation based on yearly demand.

2.0

SCOPE

The U.S. Coast Guard Aviation Logistics Center’s objective is to:

1. Obtain services for the Design, Upgrade, Modification, and Sustainment of the ATF3 Jet Test Cell.

2. Obtain services for the Design, Upgrade, Modification, and Sustainment of the T-700-GE-401 Engine Turboshaft Test Cell to included T-700-701c, and the CT7-9C3

This specification defines the minimum requirements for the upgrade of the Automatic Data Acquisition System (ADAS), Data Reduction System, Display and Control System (DADCS) for both Test Cells located in Building 100 at Coast Guard Aviation Logistics Center, Elizabeth City, NC. The ADAS is used to acquire, display and record all physical parameters required for depot testing of the ATF3 and T-700 engines. This upgrade shall consist of replacement of the existing antiquated computer hardware, software, and equipment as well as replacement of existing sensory sub-systems such as:

· ATF3 System:

· Neff Data Acquisition System

· Data General CPU and Printer

· Data Reduction Computer and Printer

· Throttle Control System

· Engine Monitoring Sensor System

· Temperature

· Pressure (Hydraulic and Pneumatic)

· Vibration

· Displays/Controls

· Video Monitoring/Camera System

· Repositioning of the control console.

· Upgrade System Power

· T-700 System:

· CMR ADAS System

· Mistic Controller System

· OPTO 22 Interface System

· Throttle Control System

· Air Dynamometer System

· Engine Mounting

· Engine Monitoring Sensor System

· Temperature

· Pressure (Hydraulic and Pneumatic)

· Vibration

· Displays/Controls

· Video Monitoring/Camera System

· Repositioning of the control console.

· Replace T700 CPU and Printer Systems

· Upgrade System Power

The objective is to enable ALC to have a modernized test cell facility to meet OEM Standards and support the United States Coast Guard engines for the next decade. Our goal is to utilize the latest versions of sustainable "Commercial-off-the-shelf" (COTS) technology. Award recipient should project sustainability of selected equipment, hardware, software, and spare parts for a term of at least 5 years from Test Cell Upgrade Acceptance.

Test Cell component Inter-Changeability between the two Test Cells is required. There is a test cell (Cell #2) between the two cells to be upgraded. Cell #2 is not to be modified in any way. The water tower used for Cell #2 would be available for use and or upgrade provided it can be operated simultaneously with any upgrades to other cells. The water tower has been maintained, but not used for 2 years. The water system should be a closed loop system to re-circulate water from a dynamometer back to the cooling system. The facility currently has a drain system that feeds back to the oily-water separator. Any construction must be identified and priced separately. Only minor construction integral to the work may be authorized.

3.0 GOVERNMENT DOCUMENTS

ORDER OF PRECEDENCE: In the event of a conflict between the text of this document and the references cited herein, the text of this document takes precedence. Nothing in this document, however, supersedes applicable laws and regulations unless a specific exemption has been obtained.

Specifications, standards, and handbooks. The following specifications, standards and handbooks form a portion of this document to the extent specified herein. Unless otherwise specified, the issues of these documents are those listed in the issue of the Department of Defense Index of Specifications and Standards (DODISS) and supplement thereto, cited in the solicitation.

FEDERAL

Code of Federal Regulations (CFR): Federal Communications Commission

Title 47, Parts 15.101 to 15.109

Code of Federal Regulations (CFR): Occupational Safety and Health Standards

Title 29, Parts 1910.301 to 1910.399.

(Copies of the above standard may be obtained from the U.S. Government Printing Office Superintendent of Documents, Mail Stop: SSOP, Washington DC 20402-9328)

FAA Advisory Circular AC 43-207 Correlation, Operation, and Modification of turbofan/jet engine test cells.

(Copies of FAA publications are available from the Federal Aviation Administration, 800 Independence Avenue, S.W., Washington, D.C., 20591 or www1.airweb.faa.gov)

MILITARY OVERHAUL PUBLICATIONS

AFT3 Jet Test Cell Publications

2J-ATF3-10

POWER PLANT BUILD-UP MANUAL

2J-ATF3-2-1

TURBOFAN AIRCRAFT ENGINE – LIGHT ENGINE MAINTENANCE MANUAL

2J-ATF3-2-2

TURBOFAN AIRCRAFT ENGINE – HEAVY ENGINE MAINTENANCE MANUAL

2J-ATF3-2-3

TURBOFAN AIRCRAFT ENGINE - REPAIR MANUAL

2J-ATF3-4

TURBOFAN AIRCRAFT ENGINE - REPAIR MANUAL

TI-8084H

Test Instructions for Model ATF3-6 Engines T-700-GE-401 Engine Turboshaft Test Cell Publications

A1-T700A-MMI-200

TURBOSHAFT ENGINE MODELS T-700- GE-401 & 401C

A1-T700A-MMI-210

TURBOSHAFT ENGINE MODELS T-700- GE-401 & 401C

AG-240AC-OMP-000

TURBOSHAFT ENGINE TEST SYS – ORGAN & INTERMEDIATE MAINTENANCE MANUAL w/IPB

AG-240AC-OMP-100

TURBOSHAFT ENGINE TEST SYS – ORGAN & INTERMEDIATE MAINTENANCE MANUAL w/IPB

AG-502BA-MDB-000

AIR DYNAMOMETER T58/T700 – INTERMEDIATE MAINTENANCE & DEPOT INSTRUCTIONS w/IPB 03-1-641

TURBOSHAFT ENGINE TEST SYS, A/F3– ORGAN & INTERMEDIATE MAINTENANCE MANUAL w/IPB

03-01-642

T700 ENGINE TEST SYS, A/F37T-16(V)3 – ORGAN & INTERMEDIATE MAINTENANCE MANUAL w/IPB

CT7-93C TEST CELL PUBLICATIONS

SEI- 576 GE-Aircraft CT7 Turboprop engine maintenance Manual

SEI-578 Aircraft CT7 turboprop engine shop manual

All GE and Honeywell technical manuals are proprietary to the OEM.

The Contractor must be able to obtain independently. The Government will not be responsible for obtaining or providing these manuals.

(Requests for more information will be sent to the Contracting Officer at the address below)

Contracting Officer

USCG Aviation Logistics Center Aviation Logistics Division Ginger Woodington, Building 63 Elizabeth City, NC 27909

DRAWINGS

Copies of the Facilities Drawings will be provided to the contractor through the Contracting Officer.

4.0 DISTRIBUTION STATEMENT

Approved for public release; distribution is unlimited.

Beneficial comments (recommendations, additions, deletions) and any pertinent data which may be of use in improving this document should be addressed to:

Contracting Officer

USCG Aviation Logistics Center Aviation Logistics Division Ginger Woodington, Building 63 Elizabeth City, NC 27909 5.0

REQUIREMENTS

This Up-grade will require the Test Cell to be capable of testing repaired engines in compliance with the Original Equipment Manufacture’s, (OEM), specifications of the engines. The Upgrade shall improve the Test Cell to meet or exceed Industry Standards In-Accordance-With, (IAW); Federal Aviation Administration Advisory Circular AC 43-207, the National Electrical Code (NEC) and federal regulations. This upgrade should include, but is not limited to, the following systems:

1. Structural changes required for the installation of upgrades

2. Load or Dynamometer System

3. Electrical: (Test Cell and Adapters)

4. Fuel System (From and Including Pumps to Test Cell)

5. Pneumatic: (Test Cell and Adapters)

6. Hydraulic: (Test Cell and Adapters)

7. Sensor: (RTD’s, Pressure, and Temperature)

8. Control

9. Display

10. Data Acquisition (Software)

11. Data Reduction (Software)

12. Alarm, Warning, Annunciation, and Indicators

13. Data Recording, Playback, and Storage

14. CCTV, Video Recording, Playback, and Storage

15. Computers and Peripherals (Hardware)

16. Intercom and Communications

17. FOD Screens

18. Bypass Ducting (ATF3 Only)

19. Hot Shrouds (ATF3 Only)

20. Test Bed (T-700 & CT7 use same test bed interchangeably)

21. Vibration and Trim Balance Analyzer

22. Load Cell (ATF3 Only)

23. System Power (Each Cell Isolated)

24. Hoist System and Controls (ATF3 Only)

25. Inlet Bell Refurbishment (ATF3 Only)

26. Test Cell Adapter Refurbishment (ATF3 Only) The Test Cells will be required to correlate a USCG jet engine to the OEM specifications and FAA Document AC 43-207.

1. The T-700 Test Cell utilizing the USCG “Gold Engine” that has been baselined by General Electric.

2. The ATF3 Test Cell utilizing an ATF3-6-4C engine provided by the USCG.

3. The CT7-9C3 engine will be provided by the USCG.

5.1

DATA COLLECTION

The system must fully integrate the test system component equipment, software, and Automatic Data Acquisition System to collect and distribute channel data. This includes, but is not limited to, temperatures, pressures, humidity, altitude, speeds, rated horsepower, thrust, air flows, fluid flows, and engine cycles. Collectively, these data points determine the operational performance of the Jet or Turboshaft engine being tested. The software must provide the capability to consolidate this data, present them to the operator in various display formats, and automatically compare them against adjustable limits for automated error control sequences and/or error annunciation.

5.2

GRAPHICAL USER INTERFACE (GUI)

The system must provide on-screen guidance and instructions for the operator to run a series of predefined tests to verify the operations and performance of the engines and their components. Visual displays must be in color, and capable of displaying selected data in various forms to include, but not limited to, Text, Raw Data, bar graph, simulated dials, simulated cockpit indicators, video, caution, warning indicators, and overspeed protection. User input will be via Touch screen, keyboard, and mouse driven menus.

5.3

DATA RECORDING AND STORAGE

The integrated system must be capable of recording continuous selected parameters and snapshots of the channel data on to the system hard drive, and utilize this data to generate specialized printed reports in color and Black and White for the completed tests, in electronic and hard copy formats. Selected Tests parameters and snapshots should be re-settable to allow for multiple snapshots of the same test for system troubleshooting.

The selected parameters, snapshot points, and reports must be adaptable and changeable to meet the changing and challenging documentation requirements. Reports must be generated and stored in Microsoft compatible formats.

The system must include means of voice communication between operator and mechanic during engine set-up, motoring checks, leak checks and low-power runs.

5.4

TEST CELL CAPABILITIES

The capabilities of the Test Cells are required to test the following engine types:

JET CELL

· USCG ATF3 engine

· ATF3-6-4C

All software must have the ability to be reprogrammed to accommodate a new engine type in the event the USCG re-engines the HU-25 Falcon.

TURBOSHAFT CELL

· USCG GE T-700 engines

· T-700-401C

· USAF, Navy, Marine, Army (JDLM)

· T-700-401C

· T-700-701C

· USCG CASA series General Electric CT7-9

· CT7-9C3

The T-700 Test Cell will be required to operate with both the 24-pin and 31-pin Digital Engine Control Unit, (DECU/ECU).

Inter-Service operability is highly desirable with Air Force, Navy, Army, and USMC systems and facilities.

5.5

DESIGN

Both Test cells are required to have interchangeable current versions of operating systems, hardware, software, peripherals and electronic devices. Interchangeable parts and components should be used wherever possible between the two test cells. They are also required to provide identical user interface and console set-up. All wiring used in the installation should be of aircraft grade whenever possible. Quick connects/disconnects shall be used wherever possible to allow for ease of maintenance and operation.

The Government reserves the right to perform pre-award on-site visits of contractor’s production facility to gain insight of manufacturing capabilities.

All software must have the capability to be reprogrammed in the event of a re-engine project of the HU-25 ATF3 engine package.

The vibration and trim balance analyzer must have the ability to archive the vibration data.

6.0 WARRANTY

Upon Project completion, provide the designated Government personnel with the required training in system operation and maintenance.

The Contractor shall provide a minimum one (1) year warranty on all parts and labor from the day of Government acceptance with a desired 24-hour response time. This warranty shall cover ALL of the Test Cell System components specified in this document.

7.0 TECHNICAL documentation

Upon completion the contractor will provide manuals on electronic media and hard copy that cover Layout, Design, Maintenance, Testing, Troubleshooting, Operation, Calibration, and Illustrated Parts Breakdown (IPB’s). These manuals must contain design and wiring schematics, installation drawings, and must include component part numbers and OEM part numbers with manufacturer for installed equipment. Wiring diagrams must include wire type, size, connector ID number and Connector Part Numbers. The contractor shall provide written permissions that allow the USCG to reproduce these manuals and software/firmware either partially, or in their entirety for USCG use.

The system must include software programs, instructions with user interface and manuals to calibrate, troubleshoot, and maintain the test system and all system components.

The T700/CT7 and ATF3 systems shall include Test Procedures, Parameters, and Test Points IAW Appropriate Technical Publications.

The contractor shall provide Acceptance Data Sheets for each phase of the Up-grade to be inspected and accepted by ALC IOD Quality Assurance Personnel.

ANY EQUIPMENT, PROCESSES, SOFTWARE, DOCUMENTATION, AND EQUIPMENT DEVELOPED FOR THIS PROJECT WILL BECOME THE PROPERTY OF THE COAST GUARD.

7.1

TRAINING

The Contractor shall provide sufficient personnel on site for Installation and Assistance, Start-up/Acceptance, Operator Training (Equipment Operation), Maintenance Training. A priced line item is requested for additional training on an as needed basis for new employees. The Government requires the contractor to perform an initial maintenance checks process with USCG employees prior to final acceptance.

7.2 SERVICE AGREEMENT

The contractor will agree to a service agreement to properly calibrate and service the complete test cell system on-site, once per year. The Government desires the contractor to provide a 24 hour response time for on-site service for any emergency situation designated by the Coast Guard.

7.3 SERVICE BULLETINS

All service bulletins if not previously accomplished, shall be identified to the contracting officer. All future Service Bulletins for equipment and software installed pursuant to this contract shall be made available to the Contracting Officer for possible incorporation in to the Coast Guards’ test cell. Incorporation of these Service Bulletins will be at the discretion of the USCG, and will be negotiated on a case-by-case basis.

8.0

DELIVERABLES

Contractor shall provide system designs, manuals, and schematics in an electronic media format that allows for one copy to be locked, to preserve original design, and format; the other copy to be unlocked to allow for future system upgrades, modification, and expansion.

All illustrations will be originated in “Autotrol Technical Illustrator” software and delivered as a “.dg” and “.cgm” file. The existing ALC illustration database will be utilized to generate and store filenames and metadata for these graphics. The generated filename will be placed in 6 pt font in the lower right hand corner of the illustration and shall also be used as the electronic filename for the graphic.

All technical drawings will be originated in “CoCreate One Space Designer” or “ProEngineer” and delivered in the native format for each. The existing ALC drawing database will be utilized to generate and store filenames and metadata for these drawings.

9.0

PERIOD OF PERFORMANCE

The upgrade to the test cell system should be completed within 12 months of contract award. This will include design, purchase and modification of all hardware, software, and manuals. Shutdown, disassembly of the existing system, upgrades, and correlation is desired to be completed within 90 days to avoid serious production delays. The upgrades will be done consecutively; the ATF3 will be dropped and upgraded first. When those upgrades are completed the T700 Cell will be dropped and upgraded. The 90 days is for each cell independently.

All efforts shall be made by the Contractor to complete the installation as soon as possible after the start of the contract. Installation, as long as it does not interfere with the U.S. Coast Guard production operations, can begin as soon as the Government program manager has approved the proposed design and received approval from the Government. Any Contractor tasks that will require extensive interruption of the U.S. Coast Guard utilities or facility/equipment access must be scheduled with the Government prior to implementation.

10.0

GOVERNMENT FURNISHED PROPERTY

The USCG will make an engine T700-GE-401C and CT7 available for use in correlating the test cell following installation of the upgrade.

The USCG will also make available an ATF3-6-4C engine for correlating the test cell following installation of the upgrade.