N68335-17-R-0192_SYSTEM_SPECIFICATION_RevC_-_FedBid.pdf

NAVAIR LAKEHURST

A COMPUTED TOMOGRAPHY (CT) X-RAY

NON-DESTRUCTIVE INSPECTION (NDI) SYSTEM

SPECIFICATION

Naval Air Warfare Center Aircraft Division Prototype and Manufacturing Division (PMD)

Joint Base McGuire-Dix-Lakehurst, New Jersey 08733-5000

10 July 2018

DISTRIBUTION APPROVED FOR PUBLIC RELEASE

1.0 Scope

System Overview

CT X-Ray NDI is a computer-aided tomographic process that uses irradiation to produce three-dimensional representations of the scanned object both externally and internally. This technology is a core capability that will provide cross-competency support for the NAWCAD LKE mission in the areas of SE and ALRE Design/In-Service Engineering, Production and Quality Assurance, and Materials Engineering. Optimization of parts and systems will be enabled when the fusion of design and inspection data in complex regimes is realized, enabling next-generation design. Future mission success depends on insertion of new materials and design techniques to improve efficiency of future designs and provide capable equipment to the warfighter. Currently used inspection methods are not capable of data fusion and resultant reports are merely simple representations of data – rather than providing robust digital interpretation of the component under investigation. For welding applications, this will enable engineers to evaluate the structural impact of defects compared with a Finite Element Analysis (FEA) of the design. Due to fatigue uncertainty, many ALRE/SE components are service life limited. There is a need for a non-destructive inspection technique that could justify a service life extension of supply ‘head hurters’ based on the current state of the part. CT provides a unique capability to accurately qualify high value parts with complex topologies produced by advanced manufacturing methods. Current NDI methods, such as dye penetrant and X-Ray, are insufficient for future complex parts manufactured by processes such as Additive Manufacturing (AM). Current Materials Engineering techniques include methods which may be destructive to the original part. This often destroys not only the information being sought, but destroys any re-usability of the part.

Future parts will be unique, directly manufactured, and expensive. Non-intrusive evaluation technologies will enable gathering vital materials engineering data with minimal economic impact. In addition, this technology will allow the Navy to develop inspection and reverse engineering capabilities that can be expanded across multiple projects and fold into the Enterprise Qualification/Certification Solutions needed to operationalize Additive Manufacturing (AM) solutions.

The CT X-Ray NDI system shall be in accordance with this system specification.

This system shall be a turn-key, 7-axis, Dual Tube 225 kV micro-focus directional and 450kV mini-focus CT system capable of scanning parts up to a 32” in diameter and 48” in height. The system must include an acquisition workstation and a separate reconstruction workstation with RAID back-up, multiple dedicated GPUs, and all software required to operate the system, reconstruct the data, and perform the analysis and visualization of the data. Products such as a prototype unit, pre-production model, or experimental unit do not qualify as meeting the requirements specified herein. This equipment shall be required to have the capability of connecting to our existing network.

Document Overview

This document provides the performance and verification requirements for the Computed Tomography X-Ray NDI System.

2.0 Applicable Documents

a. Code of Federal Regulations (CFR), Title 21, Chapter I, Subchapter J, Part

1020.30 Diagnostic X-Ray Systems and their Major Components

b. Code of Federal Regulations (CFR), Title 21, Chapter I, Subchapter J, Part

1020.31 Radiographic Equipment

c. Code of Federal Regulations (CFR), Title 21, Chapter I, Subchapter J, Part

1020.33 Computed Tomography (CT) equipment

d. Code of Federal Regulations (CFR), Title 21, Chapter I, Subchapter J, Part

1020.40 Cabinet X-Ray Systems

e. Nuclear Regulatory Command (NRC) Regulations (10 CFR), Part 19 - Notices, Instructions and Reports to Works: Inspection and Investigations

f. Nuclear Regulatory Command (NRC) Regulations (10 CFR), Part 20 - Standards for Protection Against Radiation

g. Nuclear Regulatory Command (NRC) Regulations (10 CFR), Part 30 – Rules of General Applicability to Domestic Licensing of Byproduct Material

h. Nuclear Regulatory Command (NRC) Regulations (10 CFR), Part 31 – General Domestic Licenses for Byproduct Material

i. NFPA 70, National Electrical Code

j. ASTM E2597: Standard Practice for Manufacturing Characterization of Digital

Detector Arrays

k. DODI 8500.2, Information Assurance (IA) Implementation

l. DODI 60.55.8, Occupational Ionizing Radiation Protection Program

m. NAVSEA 0420-AA-RAD-010, Radiological Affairs Support Program Manual

n. NAVAIRWARCENACDIVINST 5104.1C, Radiation Safety Program

3.0 System, Hardware, and Software Requirements

System Capabilities and Requirements

The CT X-Ray NDI system shall be capable performing the following operations:

Advanced 2-Dimensional X-ray inspection

2-Dimensional CT Slice visualization

CT volume reconstruction for 3-Dimensionsal inspection

3-Dimensional internal feature and external surface inspection and visualization

Single-pass acquisition method for elongated objects:

The system shall be capable of performing automated acquisition for elongated objects that typically do not fit in a single exposure without requiring volume stitching. The object length is only limited by the system scanning area. This method reduces or eliminates the cone angle artifacts caused by flat, planar features common in non-spiral CT techniques. This method must support continuous scan operation.

Method for expanding imaging field beyond detector panel size to cabinet size:

The system shall be capable to completely scan a part that is larger than the detector panel. The system shall be capable of scanning in step and continuous modes while moving the detector to a series of locations to increase the scanned volume without changing the system geometry.

Measurement, Analysis, and Visualization

Method for achieving resolution beyond detector panel resolution:

The designed motion of the manipulator and the software shall be capable of displaying and analyzing scan data utilizing sub-pixel analysis routines.

Resolution shall be at least triple the detector native resolution. This method must support continuous scan operation.

Time and motion analysis:

The system shall be capable of analyzing and capturing moving or changing parts as dynamic, time-based data sets.

The CT X-Ray NDI system shall have following characteristics at a minimum.

3.1.1 Nominal Part envelope

The system shall be capable of scanning parts up to a 32” in diameter and 48” in height.

3.1.2 Nominal sample weight

The system shall be capable of scanning parts up to 500 lb in weight (static capacity, not including tilt).

Software Requirements

3.2.1 Supporting Software

Any and all software required to set up, scan, analyze, and visualize data shall be provided. This shall include, but is not limited to, software needed to:

1) User-interface

2) Acquisition

a) Technique sheet creation for operator record

b) Performance monitor and alert system

c) Continuous acquisition mode

3) Archival

4) Image Processing/Analysis

a) Non-proprietary multiple image format output/input

b) Live imaging

c) Live averaging

d) Video capture

e) Automatic Statistical Process Control calculations and export to spreadsheet

5) Combination of 2 or more datasets regardless of initial acquisition settings

6) Measurement Functions on voxel, point cloud, mesh, and CAD data

a) Geometry element fitting optimized for voxel, CAD, and mesh data

b) Registration of boundary conditions

c) Alignment and registration of scan data

d) Generation and creation of datum systems

7) Porosity/Inclusion Detection and Analysis

a) Calculation of various defect parameters (e.g. position, size, geometry)

8) Wall Thickness Analysis

9) 3-Dimensional Volume Rendering

a) Real-time rendering

b) Export slices at any angle

c) Video creation

d) Localized reconstruction

10) Image Reconstruction

a) Cone-Beam reconstruction

b) Fan-Beam reconstruction

11) CAD Import and Compare

a) Import CAD files with PMI (PTC CREO)

b) Import STEP files (ISO 10303)

c) Nominal/Actual Comparison

i) Perform alignment of acquired data to nominal model based on datum systems IAW ASME Y14.5-2009.

ii) Compare acquired data to nominal model with applied Geometric and Dimensional Toleranceing IAW ASME Y14.5-

iii) Perform reporting of surface deviation from virtual condition with pass/fail indication based on permissible tolerance range.

12) Export

a) STL (Stereolithography), cloud points, OBJ, DXF, WRL, PLY

b) 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. A single dataset shall be able to be saved as an executable and viewed on up to 10 computers with each operator being able to separately slice through the data at the time.

13) Automatic Detector Roll, Pitch, Yaw Measurement and Calibration: The system shall have a method for automatically calculating and compensating for detector roll, pitch, and yaw. This technology will provide precise measurements needed for metrology and reverse engineering capabilities.

14) System Geometry Verification: The system shall have a tool that verifies system measurement performance through a combination of hardware and software.

15) Noise and Ring Artifact reduction: The system shall have ring reduction based on detector movement. Ring reduction technology shall add no more than 20% of time increase to the scan.

16) Dead Pixel Compensation: The system shall have mechanism for compensation of dead pixels to preserve full detector capabilities even after some individual pixels stop working.

17) Motion Control Programming

3.2.2 Computer(s)

The system shall include a computer(s) workstation meeting or exceeding the following specifications:

Image Analysis workstation:

1) OS: Windows 10

2) Processor: Six-Core Processor (at minimum)

3) RAM: 4 GB (at minimum)

4) Hard Drive: 3 TB Hard Drive with Raid capabilities (at minimum)

5) Disk Drive: DVD +/- RW

6) Interface: 10/100/1000 Network

7) High resolution monitor, keyboard, and mouse

CT Reconstruction workstation:

1) OS: Windows 10

2) Processor: Dual Six-Core Processors (at minimum)

3) RAM: 256 GB (at minimum)

4) Hard Drive: 24 TB Hard Drive with High Speed Raid 5 capabilities (at minimum)

5) Disk Drive: DVD +/- RW

6) GPU: 4 GPU NVidia Supercomputer, including, at minimum:

a) 11,520 total processing cores

b) 48 GB of GPU Memory

c) 3D Rendering capabilities

7) High resolution monitor, keyboard, and mouse

3.2.3 Embedded Operating System

Any operating system shall incorporate an IA-Enabled Operating System that has been validated or is being evaluated by NIAP or CC scheme and is:

1) Configurable in accordance with applicable DoD Security Technical Implementation Guides (STIGs). DoD Security Technical Implementation Guides (STIGs) are available at http://iase.dis.mil.

2) Able to incorporate the DoD Information Assurance Vulnerability Management Program (IAVMP) in accordance with DoDI 8500.2.

a) Supportable for the expected lifecycle of the system.

http://iase.dis.mil/

Hardware Requirements

3.3.1 Equipment Size

Based on the location chosen this equipment, including all space required to operate and maintain the system and process data, shall not exceed the following maximum parameter (see Appendix A for building layout):

Parameter Requirement

Overall Max Size 200”L X 156”W X 112”H

It is the responsibility of the offeror to ensure that the proposed system layout is in compliance with all Current Occupational Safety and Health Regulations (OSHA), Radiological Affairs Support Program Manual “NAVSEA 0420-AA- RAD-010”, and provides adequate means of personal egress all of which is subject to review and approval by the government. See Section 3.2 of the Statement of Work.

3.3.2 Equipment Weight

The weight of the CT X-Ray NDI system shall not exceed the maximum loading capacity of a 6.5” thick concrete slab. The contractor/manufacturer shall provide the weight of the equipment as well as a drawing detailing the feet/support system.

3.3.3 Cabinet

3.3.3.1 Shielding

The system cabinet shall have radiation shielding to prevent all radiation from leaking from the cabinet when operating at X-ray tube maximum output levels (energies of a maximum 450kV constant potential). Radiation emitted from the cabinet X-ray system shall not exceed an exposure of 0.5 milliroentgen (mR) in one hour at any point five centimeters outside the external surface.

3.3.3.2 Labeling

The cabinet shall have a tag or label certifying that the cabinet X-ray conforms to CFR 21 Part 1020.40.

3.3.3.3 Environment Controls

The cabinet shall contain any necessary climate (temperature/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.

3.3.4 X-Ray Source/Detectors

3.3.4.1 X-Ray Tube Types and Configuration

The system shall have a dual-tube configuration consisting of a 225 kV micro-focus & 450kV mini-focus tube.

3.3.4.2 Voltage Range

The system shall have a voltage range of 10 kV - 450 kV.

3.3.4.3 Voxel Resolution

The system shall be able to achieve a scan with an effective voxel resolution of 6 µm or better on a part 0.5 inches in diameter while maintaining a geometric unsharpness at the detector of less than 200 µm (1 pixel).

3.3.4.4 Focal Spot Size

3.3.4.4.1 225kV Micro-focus Tube

At a minimum, the 225 kV micro-focus tube shall have a continuously variable focal spot size capable of obtaining a 3 µm focal spot.

The tube shall be capable of operation at a power of at least 300 Watts.

The tube shall be an open tube design with user-serviceable parts including at minimum capability for user replacement of the target, window, and filament.

3.3.4.4.2 450kV Minifocus Tube

At a minimum, the 450kV mini-focus tube shall be capable of obtaining a focal spot size of 400 µm and 1000 µm.

3.3.4.5 X-Ray Control Unit

The system shall have an X-Ray control unit capable of the following:

Automatic tube warm-up

Automatic focusing

Electron beam alignment

Target loading control

3.3.5 X-Ray Detectors

The system shall have a dual-detector configuration that meets the following minimum requirements:

Digital Detector Array (DDA)

Size: 16” x 16”

Bit Depth: 16 bit

Pixels: 2048 x 2048

Pixel Pitch: 200 µm

Framerate: 15 frames per second (at full resolution)

Minimum Virtual Detector Size:

o Height: 46” o Width: 39”

Minimum Spatial Resolution (SRb) of 0.2mm or smaller measured per

ASTM E2597

Linear Detector Array (LDA)

Size: 24” active length

Bit Depth: 16 bit

Pixels: 1536

Pitch: 400 µm x 600 µm

Linear rate: 3000 hz

3.3.6 Manipulator

The system shall have a 7-axis manipulator with motorized drives with variable speed operation and tethered to the desktop control console.

3.3.6.1 Part Manipulator

X-axis (front-to-back) translation: 33”

Z-axis (focal distance tube to detector translation): 48”

Tilt: +20 / -20 Degrees

Stage: 360° continuous with 0.001° resolution

Static capacity: 500lb (not including tilt)

3.3.6.2 Detector Manipulator

Focal Distance: 0” to 48"

Detector and Tube Vertical Axis: 48”

3.3.7 Operational Environment

The Computed Tomography X-Ray NDI System shall operate in an environmentally controlled location meeting the following conditions:

Operational:

a) Temperature: 68°F to 85°F

b) Max. 60 % relative atmospheric humidity

Storage:

a) Temperature: 0°F to 100°F

b) Max. 80 %, Relative humidity non-condensing

3.3.8 Electrical Power Requirements

The Computed Tomography X-Ray NDI System shall be able to operate with the available power as listed (the system need not use all of these options; this is what will be available):

220 VAC 3~/PE

220 VAC 1~/PE

110 VAC

Voltage fluctuations: +6 % to -10 % Frequency: 50 / 60 Hz Max Nominal power: 15 kW Current consumption (max.): 50 A

3.3.9 Cooling Water

If required, cooling water systems shall be closed loop and shall conform to all other requirements of the system.

3.3.10 Compressed Air

If required, the CT X-Ray NDI system may utilize externally provided compressed air. Compressed air shall be provided by the government with a minimum flow rate of 15 cfm at 7 bar to the chosen location. The quality of the compressed air shall be in accordance with ISO 8573.

Supporting Documentation

The following documents shall be supplied with the CT X-Ray NDI system:

1) Operation/Radiation Safety Manual or Files

2) Maintenance Manual

3) Installation Manual

4.0 Safety Requirements

The CT X-Ray NDI system shall conform to radiation safety and labeling requirements as outlined in Reference m of 2.0 Applicable Documents.

Each door of the cabinet CT X-Ray NDI system shall have a minimum of two safety interlocks. The key switch shall be made to prevent the initiation of X-Ray production when in the “OFF” position. It must comply with all applicable Code of Federal

Regulations, DODINST 60.55.8 Occupational Ionizing Radiation Protection Regulations.

The CT X-Ray NDI system shall have emergency stop latching switches IAW Reference m. At a minimum, emergency stop switches shall be available in the following locations:

a. Mounted to the CT X-Ray NDI system

b. Wall mountable with wire tether no less than 30ft in length

The work station shall have a control or controls to initiate and terminate the generation of X-rays other than by functioning of a safety interlock or the main power control.

The CT X-Ray NDI system should provide an output signal indicating the system’s current status. Instructions for interpreting this signal shall be provided. The following status indications shall be available at a minimum:

1. Machine Idle

2. Machine Running (Radiation on light with proper labeling and X-Ray system in operation)

3. Machine Fault (Operator intervention required)

4. Emergency Stop

5.0 Verification

Requirement Applicability

The basic objective of verification is to ensure compliance with the applicable requirements of Sections 3, 4, and 5.

5.1.1 Required Verifications

For every requirement paragraph in the specification, a corresponding verification and verification method is given in Section 6.

5.1.2 Verification Requirements Matrix

Table 6.1-1 below lists the requirements paragraphs above and the corresponding required verification from Section 6 below. These verification methods are defined in Table 6.1-1 below:

Table 6.1-1 Verification Requirements Matrix

ITEM DESCRIPTION PARAGRAPH

NUMBER

Preferred Verification method

2nd Verification method

3rd Verification method

4th Verification method

5th Verificatio n method

X-Ray Energy Range 3.1.1 R1 D2 R2

Nominal Parts Envelope

3.1.2 R1 D2 R2

Supporting Software 3.2.1 R1 D2

Computer 3.2.2 R1 D1 D2

Embedded Operating System

3.2.3 R1 D1 D2

Equipment Size 3.3.1 R1 D2 R2

Equipment Weight 3.3.2 R1 D2 R2

Cabinet 3.3.3 R1 or D1

DS R2

X-Ray Tube Types 3.3.4.1 R1 or

DS

P

Voltage Range 3.3.4.2 R1 R2

Voxel Resolution 3.3.4.3 R1

Focal Spot Size 3.3.4.4 R1 R2

X-Ray Detector 3.3.5 R1 R2

Scan Travel 3.3.6.1 R1 R2 D3

Part Manipulator 3.3.6.2 R1 R2 D3

Detector Manipulator 3.3.6.3 R1 R2 D3

Operational Environment

3.3.7 D2 D3

Electrical Power Requirements

3.3.8 D2 D3

Cooling Water 3.3.9 D2 D3

Compressed Air 3.3.10 D2 D3

Supporting Documentation

3.4 D2

Safety Requirements 4.0 R1 or D2 R2, V or P

R3 R4 R5

Verification Methods

Verification of the Computed Tomography X-Ray NDI System requirements will be accomplished by 1) reference 2) documentation 3) demonstration samples, and 4) Video, or a combination thereof as defined below.

5.2.1 Reference

A Point of contact, with appropriate contact information, of someone operating (or in charge of the operation of) the system that can be used as a reference to validate a requirement

5.2.2 Documentation

Documentation refers to polished documents which provide verification of a vendor’s claims.

5.2.3 Demonstration Samples

Demonstration samples are defined as samples provided by the vendor which verify the claims that the requirement has been met. The vendor must supply in writing that these sample have been made by the CT X-Ray NDI system being proposed.

5.2.4 Video / Pictures

Video / Pictures is defined as a digital recording or picture which verify the requirements. The vendor must supply in writing that these are authentic.

Table 7.2-1 Verification Methods

METHOD DEFINITION

R1 Government Reference A point of contact at a US Government agency who can verify that the requirement has been met.

R2 Defense Industry A point of contact at a Major Defense Contractor who can verify that the requirement has been met. For the purposes of this document, a major defense contractor is one who has done $100 Million of work for the US Department of Defense.

R3 US academic A point of contact at a US accredited University who can verify that the requirement has been met.

R4 US industry A point of contact at a US business who can verify that the requirement has been met. The Point of contact must be a US citizen.

R5 Foreign Industry A point of contact at any business who can verify that the requirement has been met.

D1 3rd Party Certification A Certification provided from an independent organization documenting the requirement has been met.

D2 Vendor Manuals A manual currently supplied with the equipment which will document that the requirement has been met

D3 Vendor Brochure A published Brochure from the Vendor which will document that the requirement has been met.

DS Demonstration Samples Sample provided at the vendors expense with the proposal which can show that the CT X- Ray NDI system can meet the requirement.

V Video A digital video which can show the requirement has been met. Any video used to validate a time requirement must be of the entire process and of substantial detail such that the required time can be measured.

P Picture A digital picture in Jpeg format of the system or of an item the system has made which can show the specified requirement has been met.

Appendix A: Building Layout

Roll-up Door Opening = 10' ft W x 9' Height