EDDY_CURRENT_Specification_Rev_2.20.18.docx

Specification for a Eddy Current Non-Destructive Inspection Equipment

1. SCOPE. This specification describes the minimum performance requirements for design, manufacture, delivery, installation, and acceptance testing of a new, not used, Eddy Current Non-Destructive Inspection system. The contractor shall deliver the eddy current inspection system, part number ETC 2000 based on the Uniwest ETC (engine titanium consortium) platform or equivalent, with capability to inspect bolt hole and surface features of various turbine engine disks for defects.

2. APPLICABLE DOCUMENTS. The following specifications, standards, drawings and other publications of the issue in effect on date solicitation, or request for quotes, form a part of this specification to the extent specified herein. Unless otherwise noted the contractor shall ensure the latest edition is used.

2.1 Government Documents.

FLEET READINESS INSTRUCTION (FRCEASTINST)

FRCEASTINST 5090.1 – Environmental Compliance FRC EAST 5090/20 - Maintenance Contractor Hazardous Material Inventory FRC East Instruction 5000.1A, Enclosure 1 – Contract Performance Requirements

MIL STANDARDS

SPECIFICATIONS

MIL-DTL-31000 – Technical Data Packages (Copies may be ordered online at http://dodssp.daps.dla.mil/ or from DODSSP, Building 4D, 700 Robbins Avenue, Philadelphia, PA 19111-5094)

NAVAL AIR SYSTEMS COMMAND (NAVAIR)

NAVAIR 17-35TR-04 – Requirements for Preparation and Submission of Instrument Calibration Procedures (A copy of these instructions are available upon request by contacting the contracting officer.)

US ARMY CORPS of ENGINEERS

EM 385-1-1 - US Army Corps of Engineers Safety and Health Requirements Manual (A copy of this instruction can be acquired at http://www.publications.usace.army.mil/Portals/76/Publications/EngineerManuals/EM_385-1-1_2008Sep_Consolidated_2011Aug.pdf)

U.S. DEPARTMENT OF LABOR

(U.S. Department of Labor, OSHA Publications, P.O. Box 37535, Washington, D.C. 20013-7535 “www.osha.gov”)

U.S. NAVY

OPNAVINST 5100.23 – Navy Safety and Health Program Manual (Ashore) (“www.safetycenter.navy.mil/instructions/default.htm” or Commander, Naval Safety Center 375 A Street, Norfolk, VA 23511)

JOINT SERVICE TECHNICAL MANUAL (Air Force, Army, and Navy)

NAVAIR 01-1A-16 Series – Nondestructive Inspection Methods, Basic Theory (Application for copies should be addressed to the FRC East, Plant Engineering Branch (Code 6.3.1), PSC Box 8021, Cherry Point, NC 28533-0021)

2.2 Non-Government Documents.

AMERICAN NATIONAL STANDARDS INSTITUTE, INC. (ANSI)

ANSI B11/STD 11.19 - Machines-Performance Criteria for Safeguarding ANSI Z41 – Personal Protection – Protective Footwear ANSI Z87.1 – Practice for Occupational and Educational Eye and Face Protection ANSI Z89.1 – Personal Protection – Protective Headwear for Industrial Workers ANSI/ASQC D1160 – Formal Design Review (Address application for copies to the American National Standards Institute, Dept. 969, 1430 Broadway, New York, NY 10018)

AMERICAN SOCIETY OF MECHANICAL ENGINEERS (ASME)

ASME HST-1– Performance Standard for Electric Chain Hoists

(American Society of Mechanical Engineers, Three Park Avenue, New York, NY 10016 or www.asme.org)

AMERICAN SOCIETY FOR TESTING AND MATERIALS (ASTM)

ASTM A-36 – Standard Specification for Carbon Structural Steel (American Society for Testing and Materials, 100 Barr Harbor Drive, West Conshohocken, PA 19428-2959 or www.astm.org)

NATIONAL ELECTRICAL MANUFACTURERS ASSOCIATION (NEMA)

NEMA ICS-1 – Industrial Control and Systems General Requirements NEMA ICS-6 – Industrial Control and Systems Enclosures NEMA MG-1 – Motors and Generators Errata (National Electrical Manufacturers Association, 1300 North 17th Street, Suite 1752, Rosslyn, Virginia 22209 or www.nema.org)

NATIONAL FIRE PROTECTION ASSOCIATION (NFPA)

NFPA 70 – National Electrical Code (2014 Edition) NFPA 70E – Standard for Electrical Safety in the Workplace (Current Edition) NFPA 72 – National Fire Alarm and Signaling Code NFPA 79 – Electrical Standard for Industrial Machinery NFPA 101 – Life Safety Code (NFPA, 1 Batterymarch Park, Quincy, Massachusetts 02169-7471)

UNITED FACILITIES CRITERIA (UFC)

UFC 1-200-01 - General Building Requirements (Whole Building Design Guide, National Institute of Building Sciences, 1090 Vermont Avenue NW, Suite 700, Washington, DC 20005 or www.wbdg.org)

2.3 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 is obtained. The listed documents in this specification are a minimal list but not limited to regulations for industrial safety pertaining to industrial equipment design and installation. Under no circumstance shall these regulations not be applied to the manufacture and installation of the equipment.

3. REQUIREMENTS.

3.1 General.

3.1.1 Measuring and Indicating Device Graduations. The US Customary System of Units (US) shall be used in the design and construction of the system. In this specification, all measurements, dimensions, sizes, and capacities are given in the US system. All measuring and indicating devices on the system shall be graduated to display the units referenced in the technical documentation.

3.1.2 Safety and Health Requirements. All machine parts, components, mechanisms, and assemblies furnished on the equipment, whether or not specifically required herein, shall comply with all of the requirements of OSHA 29 CFR 1910.

3.1.3 Safety Guarding. Covers, guards, or other safety devices shall be provided per ANSI B11.19. The safety devices shall not interfere with the operation of the equipment. The safety devices shall prevent unintentional contact with the guarded part, and shall be removable to facilitate inspection, maintenance, and repair of the parts.

3.1.4 Human Engineering. The equipment shall be ergonomically designed in accordance to MIL STD 1472G, as to reduce/eliminate injury to the operator while operating the equipment. All points of operation shall be easily accessible to the operator from the front of the tanks and tables with minimal motion and there shall be no overextending conditions. The system shall be designed and manufactured to minimize the possibility of human error or injury (i.e. back injury) and to ensure human/machine compatibility. Adequate access to support maintenance functions and personnel shall be provided as part of the design.

3.1.5 Noise Restriction. Noise transmitted from the equipment furnished shall not exceed 85 dBA at the source in accordance with OPNAVINST 5100.23. Noise generated by the work piece shall be excluded in determining compliance of the equipment with the 85 dB requirements.

3.1.6 Environmental Protection. The equipment shall meet all applicable US Environmental Protection Agency (EPA) and OSHA restrictions for materials classified as hazardous to the environment in effect on the date of contract. During the operation of the machine at the final location, the equipment shall comply with all applicable US EPA and OSHA regulations in effect on the date of contract regulating the emission of materials hazardous to the environment.

3.1.6.1 Mercury Restriction. The equipment shall not contain mercury or mercury compounds nor be exposed to free mercury during manufacture. Fluorescent light bulbs may be excluded in this restriction.

3.1.6.2 Asbestos Restriction. Asbestos and materials containing asbestos shall not be used on or in the equipment.

3.1.6.3 PCB Restriction. Equipment or materials containing polychlorinated biphenyl (PCB) shall not be used in the equipment.

3.1.6.4 ODS Restriction. Equipment or materials containing Class 1 Ozone Depleting Substances (ODS) shall not be used.

3.2 Equipment Components & Structure. The Contractor shall design and install equipment that meets the following design requirements. The equipment shall be assembled of parts that are new, without defects, and free of repairs. The structure shall withstand all forces encountered during operation of the equipment to its maximum rating and capacity without distortion.

3.2.1 Fastening Devices. All screws, pins, bolts, and other fasteners shall be installed to prevent unintentional loosening. Fastening devices subject to removal or adjustment shall not be permanently installed.

3.2.2 Surfaces. All surfaces shall be clean and free of harmful or extraneous materials. All edges shall be either rounded or beveled unless sharpness is required to perform a necessary function. The condition and finish of all surfaces shall be in accordance with the manufacturer's commercial practice.

3.2.3 Welding, Brazing, or Soldering. Welding, brazing, or soldering shall be employed only where specified in the original design. None of these operations shall be employed as a repair measure for any defective part.

3.2.4 Materials. Direct contact between dissimilar metals, especially brass, copper, or steel in contact with aluminum or magnesium, shall be avoided. When dissimilar materials are used a dielectric barrier is required preventing the metals from contacting each other.

3.2.5 Painting. The equipment shall be painted in accordance with the manufacturer’s standard commercial practice. Prior to painting, surfaces shall be properly prepared and primed. All paint and coatings used shall not degrade or be susceptible to chemical reactions of the machine processes. Manufacturer’s standard color shall be used. Machine guards shall be painted yellow. The inside of electrical panel doors shall be painted white and inside the electrical panels shall be painted white.

3.2.6 Workmanship. Workmanship of the equipment shall meet all requirements specified herein and shall be of a quality equal to that prevailing among manufacturers producing equipment of the type covered by this specification.

3.2.7 Standard Equipment. All standard equipment normally provided with the equipment system components, shall be furnished.

3.2.8 Dimensions. The equipment shall fit within a 10 feet X 15 feet space.

3.2.9 Interlocks. The equipment shall be provided with door interlock switches, which instantly remove power from equipment where a hazard exists when doors/panels providing access to those hazardous areas are opened (i.e. electrical cabinet, etc).

3.2.10 Electrical outlets. The Contractor shall provide an electrical plan and install a 125 V, 3-wire electrical plug to connect with existing wall outlet in area. This connection shall be permanent and only used for this equipment.

3.2.11 Moveable Cabinet. The cabinet shall be equipped with lockable casters to allow movement.

3.3 System Components. The system shall contain all stations and ancillary equipment necessary to perform semi-automated eddy current inspection.

3.3.1 Data acquisition and analysis. Two workstations shall be provided to run the operation of the Eddy Current Non-Destructive Inspection Equipment. One in accordance with (IAW) the below and one exact spare workstation computer IAW paragraph 3.3.2. The workstation computer shall meet the minimum requirements

a) 32 GB (8GBx4) of DDR3 RAM capable of running at least 1866 MHz

b) 1TB or larger Hard Drive non-RAID configuration.

c) 256 GB Solid State Drive (SDD)

d) Minimum 16x DVD ± RW Blue Ray Optical Drive

e) One unused standard serial port

f) QWERTY, US Layout, corded keyboard

g) Corded optical mouse

h) Two unused USB ports

i) One spare PCI slot

j) Software shall operate with less than 50% usage of CPU and memory.

k) Enterprise class Hard Drive

l) Passive Cooling when available

3.3.1.1 Architecture / Processor. The system shall use x86 based, high performance, 32nm node, multi-core CPU. Examples include Intel’s Core i7 and AMD’s FX series. The processor shall be capable of running a minimum clock speed of 3.2 GHz in normal (non turbo) mode.

3.3.1.2 Operating System. Microsoft® Windows 7 Professional with the latest available Service Pack shall be used as the operating system or newer stable OS.

3.3.1.3 Productivity and Utility Software. The system shall include the following:

a) Microsoft® Office Professional 2013

b) Norton Ghost or equivalent disk imaging utility

3.3.1.4 Control and Display software. The control and display software shall provide:

a) Motion Control for the axis, looping, scanning, analysis, commenting, messaging, and external program control.

b) Windowing a post-procession algorithm that scans data for thresholds exceeding scan-plan parameters

c) Command lines to include motion control for axis, looping scanning, analysis, commenting, messaging, and external program control.

d) Software capable of external post processing programs that may be used for data analysis and decision modeling.

e) Software capability for off-line personnel training, analysis of data, and scan plan development

f) Auto Calibration that integrates automated system calibration against a known standard

g) Auto Decision Making: pass/fail decision that is performed by the software by comparing indication sizes to the acceptable indication limits.

h) Return-to-Indication re-scans regions previously found to have threshold parameters. The tool shall automatically show the locale of any found indication regions in scans for bores, webs, slots, and bolt- holes

i) Software capable of analysis/interpretation of slot and broach scan data for possible indications. Incorporates threshold, nominal length, and edge neglect parameters.

j) Integration of existing XXXX.prg(G-code files).

k) The ability to edit program files.

3.3.1.5 Display and Graphics Adapters. The system shall utilize a 24 inch (or larger) flat panel Thin Film Transistor (TFT) or Active-Matrix Liquid Crystal Display (LCD). The display shall provide at least 1920 x 1080 resolution and possess at least 24-bit color. This monitor shall be driven by a high end graphics adapter equivalent to or better than NVIDEA GeForce GTX 760. A second identical graphics adapter shall be provided and installed for future use. These two adapters shall not be interconnected in SLI configuration.

3.3.2 Spare data acquisition and analysis workstation computer. An exact spare workstation computer shall be provided. The operator control station shall provide space to store the exact spare workstation computer. A Norton Ghost image of the computer’s hard drive shall be provided on CD, DVD, or external HDD.

3.3.3 Inspection System.

3.3.3.1 Capability. The inspection system shall be capable of inspecting individual Bolt holes and surfaces in order to minimize the total inspection time for a given part.

3.3.3.2 Inspection Platform. The ETC 2000 or equivalent shall be manufactured upon the Uniwest ETC (engine titanium consortium) platform and shall include the following components and specifications.

a) Uniwest Eddy Current Instrument (Eddy View Pro) or equivalent

b) ETC 4004 large interface module or equivalent

c) Integrate Fixtures referenced in QTC-D2885.006

d) Vertical translation axis X-axis: 17 inches

e) Horizontal translation axis Y-axis: 13 inches

f) Probe height translation axis Z-axis: 12 inches

g) Radial translation axis: 10 inches configurable at different zero offset points

h) Inspects vertical, horizontal, and angled

· Bolt holes

· Surfaces

i) Rotational axis

· Rotational speed: continuously variable and up to 12 rpm

j) Precision/Accuracy of Robotic Axes Translation axes positioning:

· Vertical axis: +/- 0.005"/foot

· Radial axis: +/- 0.005"/foot Resolution

· Vertical axis: 0.001"

· Radial axis: 0.005" Backlash

· Vertical axis: < 0.001"

· Radial axis: < 0.001" Repeatability

· Vertical axis: 0.005"

· Radial axis: 0.005" Straightness

· Vertical axis: < 0.010"/foot

· Radial axis: < 0.010"/foot Rotational axis

· Vertical axis perpendicularity - +/- 0.010"/foot

· Angular positioning accuracy - < +/-0.1 pc/revolution

· Angular repeatability - < +/- 0.1

· Backlash - < 0.1

· Horizontal axis parallelism +/- 0.010"/foot

· Resolution: 0.01

3.3.3.3 ETC 2000 Probe Kits. The contractor shall deliver general inspection kits for the eddy current inspection of Bolt holes and surfaces of the FRCE engines.

a) The bolt hole probe inspection kits shall contain probes that range in diameter from .095-.809 inches.

b) The surface probe inspection kits shall contain pencil probes capable of rabbet fillet radii and flat surfaces.

3.3.4 Electrical System. The machine shall conform to NFPA 79. The existing source voltage available at the facility is 125 VAC, Single phase, 60-hertz power service. The machine’s electrical system shall be tolerant of fluctuation of ± 10 percent. The electrical system shall be complete. This shall include any electrical transformer(s) that may be required to modify the existing source voltage to the proper operating voltage of the equipment. A properly rated and fused single disconnect device shall be utilized on the machine with means of lockout in the off position only. Graphic symbols for logic diagrams shall be in accordance with applicable requirements of NEMA ICS1.

3.3.4.1 Electrical Enclosures. Manufacture of the enclosure shall conform to all applicable standards NEMA ICS-6. The enclosure shall be a NEMA 250 Type 12, providing ventilation utilizing an A/C unit for cooling of components.

3.3.4.2 Motors. Motors shall be rated for continuous duty and shall have ball or roller bearings of the sealed and permanently lubricated type. Alternating-current (AC) motors shall be designed to operate on 60-Hz and each motor enclosure shall meet the requirements for a drip-proof enclosure. All motors shall meet the requirements of NEMA MG-1. Each motor shall have an identification plate to identify manufacturer, model identification, serial number, voltage, amperage, horsepower, phase, and frequency. Motor horsepower shall be the manufacturer’s standard or standard optional horsepower as indicated on the manufacturer's design and drawing(s).

3.3.4.3 Fail-Safe Operation. All electrical systems shall be designed for fail-safe operation and shall be insulated, isolated, shielded, and grounded for operating safely.

3.3.4.4 Emergency Stop. The equipment shall include several emergency stop buttons throughout the system, within the reach of the operator to remove all energy sources in a safe manner for the termination of the operation, per NFPA 79.

3.3.4.5 Lockout/Tagout. A single point disconnect for lockout/tagout shall be provided for the equipment per 29 CFR 1910.147. A written procedure for locking out all energy sources shall be provided in accordance with 29 CFR 1910.147.

3.3.5 Operating Conditions. The equipment shall be capable of 16 hours of continuous, efficient and safe operation in a factory environment of 80 degrees Fahrenheit ±20 degrees, atmospheric pressures between 25.5 and 30.5 inches of mercury, and relative humidity of 95% or less without exceeding the designed operating limits of any of its components.

3.3.6 Space Constraints. The equipment shall be designed to require the minimum amount of floor space possible. The equipment shall be designed and positioned allowing access to all serviceable components. The contractor shall provide a preliminary equipment layout showing length, width, and height as well as how the equipment fits within the allowed floor space with their proposal.

3.4 Marking on Instruments, Control Panels, and Plates. All alphanumeric symbols on instruments, control panels, charts, and plates shall be in the English language. Characters shall be permanently marked in boldface on a contrasting background and shall be clearly and legibly marked for function and identification on a corrosion resistant material.

3.4.1 Lubrication Chart or Plate. A corrosion resistant lubrication chart or plate shall be permanently attached to the machine. The following information as a minimum shall be furnished: points of lubricant application, servicing interval, type of lubricant, viscosity, military or federal specification for each lubricant (if applicable), and size and type of each lubricant filter.

3.4.2 Nameplate. A nameplate shall be permanently and securely attached to each machine. The nameplate shall contain the information listed below. If the machine is a special model, the model designation shall include the model number of the basic standard machine and a suffix identified in the manufacturer's permanent records. The nameplate shall contain the following information: nomenclature, manufacturer's name, manufacturer's model designation, manufacturer's serial number, power input (volts, total amps, phase, and frequency), contract number, date of manufacture, cage, part number, contract order number, blank space for plant account number, date of manufacture, and IUID data matrix contract II.

3.5 Post Award Conference. The Post Award Conference (PAC) shall be held at the Government’s facility no later than 30 calendar days after contract award. Representative(s) from the contractor’s plant who are familiar with both the equipment to be furnished and the requirements of the specification shall attend the PAC. The contract is responsible for taking minutes during PAC. During the PAC a Plan of Action and Milestone (POA&M) (see Sect 3.6.4) chart shall be submitted to the Government in hard copy and electronic format. During the PAC, the contract and all requirements regarding regulatory compliance, equipment, layout, delivery, demolition, installation, disposal, training, and warranty shall be discussed.

3.6 Technical Data. Technical data shall contain technical information, specifications, instructions for the operation, maintenance of the machine and recommended spare parts list. All copies of technical data shall be legible and written in the English language.

3.6.1 Manuals. The contractor shall provide two (2) complete printed sets and one (1) electronic copy (CD-ROM) of the Eddy Current Inspection system Operation, Software, and Maintenance manuals. Documentation shall include at a minimum, operations, installation, maintenance, routine service schedule, calibration, preventive maintenance, lockout/tagout procedures, illustrated parts break down, recommended spare parts list including part numbers, vendor’s literature, mechanical design drawings, pneumatic schematics, and electrical/electronic schematics. All original software manuals and registration keys/codes shall be provided, along with original software installation disks. The maintenance procedures section of the technical manuals shall address procedures required for the corrections of faults occurring with each piece of equipment. The manuals shall contain diagnostic procedures for isolating faults, correcting the faults, and replacing parts. The technical manuals shall provide an engineering approach to the determination of preventive maintenance tasks. Preventive maintenance tasks shall be clearly outlined, with specified periods/cycles for performance of tasks. Technical data packages shall be provided for all special fixtures, tooling, gauges, and master setting equipment. All technical data, drawings, and prints furnished shall be written in the English language. Review by the Government of all technical data and manuals furnished will be accomplished during the preliminary acceptance testing at the contractor's facility. Final manuals are due at completion of installation of the equipment.

3.6.1.1 Software Application Program Manual. The contractor shall provide complete documentation of the software environment, reports, database, design, and program language. The documentation shall include instructional information on how to troubleshoot, maintain, test, modify, back-up, and install the software through its life cycle. This document convers all software, firmware and configurable items, components, or devices in the system. It shall provide all configurations as delivered, including default values and version numbers. This document shall describe how to adjust alarms and calibration standards. It shall describe how each unique system component integrates with the control and monitoring software. The document shall have a list of all known developed errors message, alarms and the state that created them. The documentation shall give steps for error recovery procedures. The submission of this manual shall be before the start of final acceptance testing. FRC East will review and provide comments for the contractor to incorporate into the final submission.

3.6.2 Engineering Documentation. The contractor shall provide complete drawings of all systems and subsystems for the Eddy Current Non-Destructive Inspection System. These drawings shall include block diagrams, signal flow diagrams, physical system layout, electrical/electronic schematics, and mechanical drawings. All diagrams shall be cross-referenced to each other, and include component, identity, location, and I/O channel entry points. The documents shall further break down the system diagrams into the lowest component reference, I/O channels, signals, power distribution, and wiring connections. Wiring tables shall be provided for all plugs, jacks, and terminal boards with their associated signal designation. The documents shall provide a list of all switches, relays, indicators, motors, and controls and how it relates to the above diagrams and their locations. The contractor shall provide the drawings in .dwg format. Each drawing shall have the drawing number, part number, and bill of material (BOM). The contractor shall apply ASME Y14.100-2000 “Engineering Drawing Practices” drawing standards. The documents shall be delivered to the government prior to final acceptance testing for review and comments to be incorporated for final submission.

3.6.3 Site Preparation and Installation Plan. The contractor shall provide a clear and concise site preparation and installation plan. The plan shall include a detailed description of all installation work, a detailed site layout, general equipment specifications (i.e. size, weight, etc.), any required structural modification or additions, utility requirements and location, pertinent electrical details, and any other details required for site preparation and layout. As part of the site preparation and installation plan the contractor shall include facilities preparation instructions, including detailed information concerning any equipment that applies a load to a facility structure, wall, or roof. The site preparation plan shall be submitted at least 90 calendar days prior to installation for Government review and be presented at the Critical Design Review for concurrence ( para 4.6.3 ) .

3.6.4 Plan of Action and Milestones. The contractor shall provide a Plan of Action and Milestones (POA&M) to identify contractor performance dates of all major events from contract award to completion of all contract requirements. The initial POA&M shall be delivered 30 calendar days After Contract Award (ACA). The milestones shall be prepared using a recognized project management technique (preferably Microsoft Project). The Government and the contractor shall review the report on a monthly basis. The contractor shall notify the Government prior to making any changes to the POA&M. All changes to the POA&M must be accepted in advance by the Government. The POA&M shall detail such items as system design concept, system development, software design concept, software development, engineering, procurement of major hardware, assembly, operational debug, factory acceptance, shipment, installation, training, and final acceptance test. For the POA&M to be acceptable all action items requiring contractor changes shall be resolved to an acceptable level.

3.6.5 Acceptance Test Plan. The contractor shall prepare an acceptance test plan. The plan shall be a step-by-step written instruction on how to verify that the equipment is in accordance with this specification. The contractor shall submit draft copies to the Government in accordance with the contractor submitted and Government approved POA&M and final copies are due 90 calendar days prior to final acceptance testing.

3.6.6 Calibration Requirements. The contractor shall provide technical data for any and all components requiring calibration. These requirements shall be in accordance with MIL-STD-1839. Calibration Procedures shall be provided in accordance with NAVAIR 17-35TR-04

3.6.6.1 Equipment Calibration and Alignment Procedures. If calibration is required, the contractor shall provide specific instructions describing how to fully calibrate and align the system, using equipment, procedures, and methods approved by the Navy METCAL program and the OEM or governing authority for the component assembly. The calibration procedure shall include specific instructions necessary to power-up/down the system, navigate the software, locate components and a functional description of calibration software and file locations. The calibration procedure shall be written in standard NAVAIR 17-20 Instrument Calibration Procedure (ICP) format, as specified in NAVAIR 17-35TR-04. The document shall be delivered to FRC East prior to calibration and final acceptance for review. The calibration procedure must be approved in accordance with Navy METCAL Program requirements prior to Final Acceptance Testing. Supplemental manuals or copies shall be provided during training on the materials presented to demonstrate how to use the manual to perform Calibration of the system. Calibration and alignment procedures can be documented in the Maintenance, if the number of components or parameters are not significantly high. Alignment instructions and procedures from COTS equipment may be referred to, but the documents must be delivered, and have clear, concise, step by step instructions.

3.6.7 Data Rights. The Government requires unlimited rights to all technical data and drawings for equipment modified from Consumer of the shelf (COTS) equipment. The government requires limited rights to all technical data and drawings for Consumer of the shelf (COTS) equipment. These unlimited rights will allow it to maintain and upgrade the items throughout the planned lifecycle. In addition, the Government’s license to the technical data rights, license, and drawings if the Government chooses to do so, will allow future competitive procurement of replacements and upgrades. When an upgrade or re-procurement is contemplated, the Government will have the right to provide drawings and technical data to vendors. These data rights shall pertain to all documentation and drawings pertaining to the system to be acquired through this procurement and shall be delivered not later than the initiation of final acceptance testing.

0. Installation: Installation and Final Acceptance Testing (FAT) of the Eddy Current Non-Destructive Inspection Equipment shall be completed within 30 calendar days from delivery of the system equipment (180 calendar days after contract award). Installation shall be conducted during the FRC East’s normal working hours of 7:00 am to 3:30 pm (EST), Monday thru Friday unless authorization to work outside of normal working hours is requested by the contractor and approved in advance by the Government. Downtime as a result of the work to be performed shall be approved by the Government. Downtime shall be kept to a minimum.

0. Removal and Disposal. The contractor shall be responsible for all demolition necessary for execution of this installation. The contractor shall also clean up and dispose of any and all waste in accordance with all local, state, and federal regulations that was generated in the installation of the equipment at the facility. The area shall be kept clean at all times to prevent Foreign Object Debris or Foreign Object Damage (FOD). The contractor shall be responsible for removal of the existing equipment that is being replaced by the new equipment. The contractor shall move all removed components to the Hazardous Waste Berm (Building 4466) which is located behind Building 133. The contractor shall give the hazardous waste personnel a minimum of 24 hours’ notice prior to moving any equipment to the Berm. Relocation of equipment shall be performed only on normal working days Monday-Friday, 6:30 AM to 3:00 PM, excluding holidays. In addition, the contractor shall ensure NO metal is removed from the facility. All metal (i.e. hoist rails, etc) shall be recycled at the customer facility. The contractor’s demolition work shall be in accordance with EM 385-1-1, subpart 23, Demolition.

0. Government Responsibilities: Government will provide the following utilities with 100 feet of the installation site: 120/208 and 277/480 VAC; three (3) phase 60 Hz; compressed air of 85 psi. Contractor shall provide new disconnects on all energy sources used for the Eddy Current Non-Destructive Inspection Equipment.

0. Contractor Responsibilities: The contractor shall be responsible for installation of the Eddy Current Non-Destructive Inspection Equipment. The contractor shall also clean up and dispose of any and all waste generated during the installation of the Eddy Current Non-Destructive Inspection Equipment at the FRC East. The contractor shall also be responsible for the following:

1. Criminal Records Check: Working contractors shall have all their employees obtain and provide a two year Criminal Records Check (CRC). This also includes sub-contractors; the sub-contractor shall be required to provide the CRC on all their employee's that expect to work onboard this facility, or gain access. The contractor (employee) upon arrival at the MCAS front gate will provide their CRC on the spot per existing rules, regulations and policy.

1. Ensuring that all personnel directly or indirectly employed by the contractor and requiring entrance to this facility shall be English speaking. Appropriate documentation shall be submitted to the security pass office prior to entrance to this facility.

1. Obtaining all passes required for entry for manufacturers personnel entering FRC East, Cherry Point. In addition, the contractor shall be responsible for the conduct of all representative personnel while they are on station.

1. Giving advance notification of visits to the Government's facility. At least five (5) days notification is required for visits by US citizens and at least 60 days notification is required for visits by foreign nationals. This rule applies to all visits.

1. The installation shall be accomplished using materials and wiring methods required by NFPA 70 (NEC). All unloading, handling, and moving shall be performed to preclude damage to materials, equipment, and building facilities.

1. Equipment shall not be dragged on facility floors. Metal skid plates or wooden skids are acceptable for unfinished floors; however in areas with finished floors, equipment shall be moved by means of load spreading rollers, dollies, or shall be trucked clear of the floor.

1. The contractor shall be responsible for the installation of equipment covered by this specification and the connection of that equipment to Government furnished utilities provided at or near the installation site. The contractor shall locate the equipment within the boundary areas in a fashion that will provide a minimum working clearance of three (3) feet around the equipment, and the immediate work area. Sufficient space between the equipment and the boundaries shall be provided as required for performance of normal maintenance functions. All electrical control and power panels shall be located so as to provide a minimum safe working clearance immediately in front of the panel that is in compliance with Section 110-16 of the National Electrical Code.

3.7.4 Installation Work Schedule. All installation work shall occur during the Government’s normal daily work hours. Hours are between 6:30 am and 3:00 pm Monday through Friday, except Federal holidays. If the contractor desires to perform work outside of these hours the installation work schedule must be approved in advance by the Government. The contractor shall coordinate the work to minimize impact on facilities production operations.

3.7.5 Utility Shutdowns. Utility connection shutdowns shall be scheduled during weekends, or other non-normal Government hours, and shall be approved by the Government two (2) weeks prior to the requested shutdown.

3.8 Training for Government Personnel. The contractor shall furnish the services of competent instructor(s), fluent in the English language, who shall give full instruction to designated personnel in operation, maintenance, and pertinent safety requirements. The training shall cover the information in the Operations and Maintenance Manual. Each instructor shall be thoroughly familiar with all parts of the equipment and shall be trained in operation and maintenance. Instruction shall be given during the first regular work week following Government acceptance of the equipment for regular operation. Training shall be conducted at installation and set-up area or an area specifically designated by the TPOC identified within the contract. All materials, manuals, tapes, data, etc. shall be contractor furnished and shall become the property of the Government. Training shall be for the following types and numbers of personnel: four (4) operators, two (2) engineers/engineering technicians, two (2) mechanical maintenance mechanics, two (2) electrical/electronic maintenance mechanics, and two (2) calibration technicians. All training shall be conducted between regular working hours 6:30 AM to 3:00 PM Monday-Friday, excluding Government holidays. Training shall only start after Final Acceptance Testing. Training shall be completed within five (5) days.

3.8.1 Operator Training. Shall be for a minimum of two (2) eight hour days and shall thoroughly familiarize operators in operation the system through actual hands-on instruction with the equipment. The Operator and Maintenance Manual and the Software User Manual shall be used extensively as reference materials during this training.

3.8.2 Maintenance Training. Shall be for a minimum of two (2) eight hour days and shall include mechanical, electrical, and electronic instruction on the system and its components through actual hands-on instruction with the equipment. The Operator and Maintenance Manual shall be used extensively as reference materials during this training.

3.8.2.1 Mechanical Maintenance. Mechanical maintenance training shall include at a minimum:

a. Review mechanical and pneumatic schematics and drawings.

b. Component location and function.

c. Troubleshooting procedures and techniques.

d. Repair procedures including disassembly and assembly.

e. Adjustments, preventive maintenance procedures, including lubrication points, type lubricant, and frequency, predictive maintenance.

3.8.2.2 Electrical and Electronic Maintenance. Electrical and electronic maintenance training shall include as a minimum:

a. Review electrical and electronic wiring schematics and drawings.

b. Troubleshooting procedures and techniques.

c. Electrical and electronic equipment servicing.

d. Procedures for adjustments (i.e. locating equipment, adjustments to be made, equipment required to make adjustments).

e. Preventive maintenance procedures.

f. Controller programming and machine manipulation.

g. Engineering software programming instruction.

3.8.2.3 Calibration. Calibration training shall include complete review of the calibration procedure as well as walking through the procedure step by step including actual calibration of all components requiring calibration.

3.9 Warranty. The contractor shall provide an initial warranty of 12 months, to commence at the completion of final acceptance. During the warranty period, supplier shall assume responsibility for any and all defects in materials, equipment, workmanship and performance. Under this warranty, the labor necessary to repair the equipment and all associated travel expenses shall be provided by the vendor at no extra cost to the Government.

3.10 Delivery. All equipment shall have a delivery date not to exceed 180 Calendar days after contract award.

4. QUALITY ASSURANCE PROVISIONS.

4.1 Responsibility for Inspection and Compliance. The contractor shall be responsible for the performance of all inspection requirements specified herein. The Government reserves the right to perform any inspections set forth in the purchase description where such inspections are deemed necessary to assure supplies and services conform to prescribed requirements. All items must meet all requirements of Sections 3 and 4.

4.2 Contract Quality Assurance Inspection (Origin). Contract quality assurance inspection shall be performed at the contractor’s facility in accordance with the contractor submitted and Government approved POA&M (Section 3.6.4) prior to being provided for acceptance under the contract. Quality conformance inspection shall consist of the examination in 4.4, 4.5.1 and the Government approved test plans (see Paragraph 3.6.5). The machine shall pass the examination, all tests, and the contract quality assurance inspection to be acceptable.

4.3 Final Inspection/Acceptance Test (Destination). Final inspection and acceptance test shall be performed on the equipment in accordance with the contractor submitted and Government approved POA&M (Section 3.6.4) to ensure conformance with this specification. The acceptance test shall be performed only after the equipment is installed at its final location. The acceptance test shall consist of the examination in 4.4 and all tests in 4.5. The machine shall pass the examination, all tests, and the final inspection to be accepted. All acceptance testing shall be complete within (5) days after installation.

4.4 Examination. The equipment shall be examined by a Government representative for design, dimensions, assembly, materials, components, electrical equipment, and workmanship to determine compliance with the requirements of this specification. All pieces of equipment shall be of good quality and not physically damaged during or subsequent to their manufacture/assembly, shipment, or installation.

4.5 Tests.

4.5.1 Operational Test. The equipment and its control system shall be operated in accordance with the manufacturer’s standard operating test procedure for warm-up and runoff checks. Proper operation of all manual and automatic controls, motors, adjustment mechanisms and accessories shall be verified. Operation of the equipment shall be demonstrated to show conformance with this specification.

4.5.2 Performance Test. Testing shall consist of a minimum of the manufacturer’s standard testing identified in the approved Acceptance Test Plan (see Paragraph 3.6.5). During these tests the equipment shall be operated continuously with no shutdowns for repairs or adjustments. All tests specified in the Acceptance Test Plan shall be performed.

a) The supplier shall perform a PAT at the contractor’s manufacturing location, following a test procedure that is agreed to by both the contractor and the FRCE.

b) The baseline will be established by inspecting FRCE notched engine parts (i.e. T58 and F402) to ensure 100% coverage of the inspection area. Results of the baseline will be stored in the inspection system for comparison purposes and a test report provided to the government.

c) The contractor shall allow government personnel to attend and witness the PAT at the contractor’s site. The Final Acceptance Test (FAT) shall be conducted at the FRCE using the same test procedure and notched part used in the PAT in order to have a one to one comparison. A final test report shall be issued upon successful completion. The contractor shall send performance of each scan with pictures after performance test if Government does not attend the Preliminary Acceptance Test (PAT). Scans must be reviewed and accepted by the Government prior to approval.

d) The supplier shall validate the performance of each scan plan and its associated support equipment following installation through appropriate system and station self-tests and any other means prior to the FAT.

e) The contractor shall provide engineering support service during the FAT at the FRCE.

4.5.3 Safety Testing. The contractor shall perform tests to ensure that all safety features including fail-safe devices, interlock switches, electrical/electronic shielding and grounding, power loss protection, and other applicable items are installed and are functioning properly. In addition, the contractor shall fully demonstrate all lockout/tagout procedures. Audible noise levels shall be measured after installation for conformance with this specification.

4.6 Design Reviews. The contractor shall conduct and participate in the specified reviews. The specific dates and duration of the reviews shall be as specified in the contract schedule and POA&M. Reviews shall be co-chaired by a Government and contractor representative. The contractor shall be prepared to explain the reasoning, assumption, and methodologies in arriving at any particular conclusion, recommendation, or alternative in the accomplishment of the tasks required by the contract. The contractor shall prepare drawings and other data, as required, to aid in the reviews. The contractor shall have key personnel and support available to carry out the reviews. Subcontractors, if any, shall attend reviews when required to address key elements. The contractor shall prepare and submit the Conference Agendas 15 calendar days prior to the conference and the Conference Minutes within 15 calendar days of completion of the conference. Except where noted herein, reviews shall be considered fulfilled when all of the following items are completed

a. A teleconference or formal meeting has been conducted and the reviews are presented to the Government.

b. All action items requiring contractor response have been resolved.

c. The minutes have been accepted by the Government

Reviews are not considered approvals by the Government that the contractor’s proposed design, if followed, will result in a properly functioning system. In addition, the design review process does not relieve the contractor from the obligation to provide a system that meets the performance requirements specified herein.

4.6.1 Joint Pre-Installation Review. A joint pre-installation review shall be conducted prior to installation. This review shall occur either during the Contract Quality Assurance Inspection at the contractor’s facility (Paragraph 4.2) or 30 calendar days prior to delivery of the equipment. The contractor shall not proceed to the installation phase until successful completion of this review as determined by the Government and the contractor. During this review installation will be completely reviewed, the equipment shall be inspected, as well as ensure any permits and inspections are in place.

4.6.2 Joint Requirements Review. The purpose of the Joint Requirements Review shall be to review and comment on the contractors proposed solutions. Reviews are not approvals and are no way binding to the Government. However, it is in the best interest of the Government and the contractor to review the work periodically. There will be no set dates for the subject review but they will be held when deemed necessary by either the Government or the contractor. This is intended to help eliminate potential problems before they have a chance to arise, or before much time, effort and cost is accrued. They are performed as required at various levels of depth. Acceptance of the equipment shall only be obtained through meeting the requirements of Section 4.0 of this specification.

5. PREPARATION FOR DELIVERY

5.1 General. The equipment shall be packed for shipment in a manner that will ensure acceptance by common carrier and safe delivery to the consignee. Preservation, packing, and marking shall be in accordance with best commercial practice. Preservation, packing, and marking shall be in accordance with MIL-M-18058.

5.2 Marking. Each shipping unit or crate shall be clearly, legibly, and permanently marked to show destination, contract number, gross weight, and number of units or crates in shipment. Marking shall be in accordance with standard commercial practices.

6. LABOR REQUIREMENTS

6.1 General. All work shall be accomplished in accordance with NAVFAC P-307, CMAA 78 and their referenced standards

6.2 Labor Hour Reporting: In accordance with the Navy Marine Corps Acquisition Regulation Supplement (NMCARS) Part 5237.102-90 relating to Enterprise-wide Contractor Manpower Reporting Application (ECMRA): The contractor shall report contractor labor hours (including subcontractor labor hours) required for performance of services provided under this contract the Fleet Readiness Center East, MCAS Cherry Point, NC 28533 via a secure data collection site. Contracted services excluded from reporting are based on Product Service Codes (PSCs). The excluded PSCs are:

(1) W, Lease/Rental of Equipment;

(2) X, Lease/Rental of Facilities;

(3) Y, Construction of Structures and Facilities;

(4) S, Utilities ONLY;

(5) V, Freight and Shipping ONLY.

The contractor is required to completely fill in all required data fields using the following web address https://doncmra.nmci.navy.mil. Reporting inputs will be for the labor executed during the period of performance during each Government fiscal year (FY), which runs October 1 through September 30.