SOW_CT_FINAL_FEB26_2015_REV_1_PK_Edits.docx

Statement of Work Computed Tomography System

Summary This procurement is for a turn-key, state-of-the-art, 7-axis, 225kV micro-focus computed tomography (CT) system for the Naval Air Warfare Center Aircraft Division (NAWCAD) in Patuxent River, MD. The system shall be able to scan parts up to 30” in diameter and 48” in length. The system shall be fully shielded and interlocked cabinet-style unit. It shall comply with all applicable industry regulations. The overall maximum dimensions of the system shall permit the system to fit through the 70 inches wide x 95 inches high doorway into the building that will house the system. Figures 1 and 2 show the entrance to the facility where the system will be installed. The system shall include an acquisition workstation and a separate reconstruction workstation with RAID back-up, multiple dedicated GPUs, and all software to operate the system and reconstruct the data. The system shall include a turntable translation feature for increased scanning volume capability, automated measurement and surface extraction software, data correction algorithms, solid model and finite element model export capabilities, and dimensional comparison capabilities. The system shall be delivered to and installed at NAWCAD, Building 2188, Room 104 F, Patuxent River, MD 20670.

Background NAWCAD Patuxent River Nondestructive Engineering Branch is procuring a 225kV microfocus CT system to support upcoming work on additive manufacturing, failure analysis, ceramic matrix composites and reverse engineering.

Technical Requirements:

Salient System Characteristics X-ray tube: The x-ray tube shall have the following characteristics:

· Tube Voltage …25 - 225kV microfocus

· mA Range …0-3 mA

· Power …320 W max

· Focal Spot Size < 6 microns

· Detail Recognition …< 2 microns

· High Voltage Cable(s)

· Closed Loop Water Cooler

· X-ray Control Unit

· Workstation with Windows operating system

· Automatic tube warm-up ... High voltage, filament current

· Automatic focusing, electron beam alignment and target loading control

· Copper filters (QTY)

(3) 0.005” Thick

(2) 0.015” Thick

(2) 0.025” Thick

(1) 0.075” Thick

(1) 0.125” Thick

· Spare parts and service kit including at least 10 spare filaments and spare o-rings.

X-ray detector: The x-ray detector shall have the following characteristics:

· Monolithic flat panel

· 200 micron pitch

· Cesium Scintillator Screen

· 15 frames per second at full resolution. 30 frames per seconds at 2x2 binning

· Total area: 16" x 16" (409.6mm x 409.6mm)

· Fiber optic interface

· 2048 x 2048 pixels

· 200 μm pixel pitch

· 16 bit resolution (65.536 grey levels)

· Ultra high sensitivity

· Suitable for a wide range of X-Ray energies: 40 kV – 600kV (minimum range)

Manipulators: The manipulators shall have the following characteristics -7 Axis Manipulator

· All drives are motorized with variable speed joystick operation

· Tethered desktop control console.

· Detector Manipulator:

· Focal Distance: 0” to 48" (0cm to 122cm)

· Detector and Tube Vertical Axis – 48” (122cm)

· Part Manipulator:

- X Axis / front to back translation: 33” (84cm)

- Z Axis / focal distance tube to detector translation: 48” (122cm)

- Tilt: +20 /- 15 Degrees,

- CT precision rotation stage - 360 Degrees Continuous. Resolution 0.001 degree.

· 250lb (113kg) static capacity (not including tilt)

· Integrated electronics.

· Granite base for manipulator for system stability

· Cabinet

· Shielding: Shielding shall be adequate to limit radiation emitted from the cabinet not to exceed an exposure of 0.5 milliroentgen in one hour at any point five centimeters outside the external surface when operating at x-ray tube maximum output level.

· Dimensions: The system shall fit through a doorway that is 95” high by 70” wide. A modular system that can be partially assembled on-site is acceptable provided the system can be certified to meet all radiation safety requirements.

· Radiation safety features: The system shall be certified to meet all applicable federal and state (MD) regulations for cabinet x-ray systems.

· The system shall comply with all requirements of Title 21 Code of Federal Regulations (Volume 8, Parts 1010 and 1020) for cabinet x-ray systems.

· Environment controls: The cabinet shall contain any necessary climate (temp/humidity) controls required to ensure reliable/repeatable measurements. The vendor shall specify any facility requirement that must be supplied by the customer (power, ventilation, etc.) for proper installation of the proposed system.

Computer hardware and Software:

The system shall include a computer(s) workstation to operate the system. The workstation shall include:

DR Workstation

· Windows® 7 operating system or newer

· Minimum Six-Core Intel® Xeon® Processor

· Minimum of 4 GB RAM

· Minimum of 3TB of Data Storage in RAID 0 Configurations

· DVD+/-RW Drive

· 10/100/1000 Network Interface

· NVidia High Performance Display Adaptor

· Minimum 30” (76cm) 4 Mega Pixel Color Display

· Keyboard and Mouse DR software High performance image analysis system with a comprehensive set of image analysis tools.

· Windows® based

· Non-proprietary image storage format.

· Multiple Windows interface

· High performance image processing and measurement functions utilizing GPU technology

· Automatic parallelization for systems with multiple CPU’s and GPU’s

· Live Imaging up to 30 frames per second

· Live Averaging

· Live Histogram

· Live line Profile

· Live Rotation between portrait and landscape modes

· Live Measurements with 1 pixel resolution

· Live image gain/offset calibration and defective pixel correction

· Automatic creation of Technique sheet for operator record

· Capture video into AVI files.

· Supports digital flat panel detectors, LDA’s and digital/analog cameras at 8, 10, 12 and 16 bits.

· Read and store images in TIFF 32 bit / 16 bit / 8 bit, BMP, JPEG, RAW

DR CT Acquisition Module The CT acquisition module shall provide automated CT acquisition capabilities.

· Capable of CT acquisition up to 10,000 angle steps.

· Technique sheet creator for operator record.

· Monitors x-ray performance and will pause the CT scan if x-ray interruption is detected.

· Capable of acquiring projections in a continuous mode for faster CT

Reconstruction Workstation (minimum) System shall be capable of reconstructing 30003 Voxel in less than 10 min and 3D rendering capabilities and shall include the following hardware.

· Windows® 7 or 8, 64 Bit Operating System

· 24 TB Hard Drive with High Speed Raid 5 capabilities

· 30” (76cm) high resolution flat panel monitor The computer workstation shall have adequate processing capability to meet the aforementioned reconstruction requirements. System shall meet or exceed the following:

· Dual Six-Core Processors (Total 12 Cores)

· 256GB RAM

· 4 GPU NVidia Supercomputer, including:

- 11,520 total processing cores

- 48 GB of GPU Memory

CT Computed Tomography Software CT software shall include:

· CT calibration, Cone-Beam reconstruction, 3D real time visualization and analysis tools in the same interface.

· The software shall not limit the size of the reconstruction

· The software shall be capable of the following:

· Combining 2 or more datasets (even if data is acquired at different current settings)

· Significantly improving CT quality of widely varying densities.

· Increasing the dynamic range of the CT dataset.

· Reducing noise and photon starvation in the CT reconstruction

· The software shall be able to perform local CT reconstructions of a small area of interest inside a larger object.

· Simplified processing - The software shall include a simplified, user-friendly mode that lets the user quickly navigate through the full CT scanning process, from the creation of the project to the final results. The simplified interface shall include features to guide the user through the calibration and reconstruction process.

· Automatic Calibration - To optimize cone-beam CT reconstruction process and to simplify CT and μCT equipment.

· Cone Beam Reconstruction –Reconstruction performed on GPU hardware.

· 3D Volume Rendering –

· Real time volume rendering

· Export slices at any angle

· Create movie animations

· Perform localized reconstruction.

· 3D Surface Rendering - Surface extraction to CAD compatible format:

· Export to STL (Stereolithography), cloud points, OBJ, DXF, WRL, PLY. Visualization in wireframe mode. Map textures with reflection.

· Export an executable viewer module with a dataset to allow others to view, slice, rotate, window and manipulate the dataset on a traditional laptop or desktop computer. Ideally, the viewer module is a fully capable and equivalent to the post-processing capabilities of the CT Workstation.

· Helical (Spiral) Acquisition

· The system shall be capable of performing automated helical (spiral) acquisition with a digital flat-panel detector for the scanning of elongated objects that traditionally cannot fit into a single exposure. The scan does not require volume stitching and the object length is only limited by the system scanning area. This reduces or eliminates the cone angle artifacts caused by flat, planar features common in non-spiral CT techniques.

· Image stitching

· Larger parts may require multiple scans to completely scan the part when it is larger than the detector panel. The software shall be able to stitch multiple images into one seamless image of the part or assembly.

· Sub-pixel resolution

· The software shall be capable of displaying and analyzing scan data utilizing sub-pixel analysis routines.

· Time and motion analysis

· The system shall be capable of creating and analyzing moving or changing parts as dynamic, time-based data sets. The system shall be able to acquire time-based data in either a continuous or stepped mode. Continuous scan mode refers to repeatedly scanning the part while motion or change is occurring at a speed that is slow relative to the time it takes to complete a full scan. Stepped scanning refers to re-scanning the part multiple times after the part is removed from the CT unit, subjected to some condition that will cause motion or change in the part. The system shall be able to generate time-sequenced images (videos) showing the motion or change in the part resulting from the continuous or stepped scans.

· Programmable CNC Motion Control

· The system shall utilize programmable CNC motion control.

· Detector Lateral Shift

· Lateral shift allows for up to 16” (40cm) of lateral x-ray detector travel.

· Automated-analysis Perform automated fiber analysis, porosity analysis, and geometric measurements and comparison of scan data with solid model requirements using VG Studio Max.

· Solid model export

· Auto-generate and export Solid model data in standard formats like CATIA and SolidWorks. Software shall be Geomagic Design X.

Installation and Training

System Installation:

The system shall be delivered to and installed at NAWCAD, Building 2188, Room 104 F, Patuxent River, MD 20670. Building access to room 104F is through a doorway that is 70 inches wide x 95 inches high. The contractor shall specify any utility or facility requirements (such as power or ventilation requirements) that must be met by the government prior to the delivery of the system to enable the contractor to properly install the system in Building 2188 Rm 104F. The overall footprint of the system shall be 14 feet x 7.5 feet or less. The maximum height shall be less than 9 feet.

DR / CT System Training:

The offeror shall provide 4 Days On-Site training for up to 8 NAWCAD AIR 4.3.4.3 employees that includes the following topics: digital radiography, computed tomography, and operation/maintenance/safety of the delivered CT system operation. This training shall be provided as part of the system delivery and acceptance.

Digital Radiography & Intro to CT Training (40 hour course) The offeror shall provide one 40 hour ASTM/ASNT Certified DR/CT training course for at least 2 NAWCAD AIR 4.3.4.3 employees. This course follows the recommended curriculum of FWG-IDR, MAI, ASTM and ASME in a format for compliance with NAS 410 Qualification/Certification program. It is preferred that it be held at NAWCAD Patuxent River, but may be held at an alternate location. This training shall be provided 3-6 months after the system is accepted.

Advanced CT Training The offeror shall provide one 4-day Advanced CT Training class for at least one NAWCAD 4.3.4.3 employee. The course may be held at NAWCADPAX or at an alternate site selected by the vendor. The class shall focus on the advanced capabilities of the delivered system and Industrial CT technology. The course shall include CT Technique Development training and CT Reconstruction. This training shall be provided 9-12 months after the system is accepted.

Maintenance

· 12 Month Hardware Warranty The offeror shall replace or repair any system hardware components that fail within 12 months of the government acceptance of the fully installed and operational system at no cost to the government. The offeror shall identify any consumable items that are not covered under this warranty.

· Two-Year preventative maintenance services The offeror shall provide at least two preventative maintenance visits to NAWCADPAX to verify and optimize system performance and to perform any system maintenance required. The offeror shall include the scope for this maintenance in the proposal. The maintenance schedule shall include at least one visit per year for the first two (2) years after government acceptance of the fully installed and operational system at no additional cost to the government.

· Two-Year Software Maintenance/Updates The offeror shall provide all software updates released within two years of the date when the government acceptance of the fully installed and operational system at no additional cost to the government.

Technical Manual The system shall include a user’s guide technical manual(s) that covers system operation, system safety, data processing/viewing, routine maintenance and basic troubleshooting information. The standard commercial user/technical manual(s) for the hardware and software should meet this requirement.

Delivery Schedule The equipment shall be delivered and installed within 20 weeks of receipt of the contract.

Figure 1, CT Laboratory Entrance (70” wide x 95” high)

7.5 feet 14 feet

Figure 2. Location of CT Equipment (ceiling is 9 feet, other equipment/cabinets shown in picture will be removed, required utilities will be supplied) image1.jpeg image2.jpeg