SOW_3D CT Scanner_TAFB_18 November 2020.pdf

Statement of Work

(SOW)

MXDTAC-1 3D CT Scanner

H1WM04

1.0. Scope – This purchase description details the requirements for furnishing, shipping, installing, and verification/calibration of a commercially available 3 Dimensional Computed Tomography Scanner (3D CT

Scanner) for metal parts. Scan applications include various aerospace alloys from magnesium castings to nickel based super alloys. Part sizes, materials, geometry, and complexity will vary based on requirements. Parts such as engine disks and aircraft structures would be typical parts. The CT Scanner shall be utilized to inspect and measure surface and subsurface features of parts/assemblies without cutting or condemning the asset. The

CT scanner shall accomplish inspections via 3D CT & 2D X-ray scans using both micro and macro magnifications. The Contractor shall provide all labor, tools, equipment, materials, parts, personal protective equipment (PPE), transportation and any other incidentals to travel to Tinker AFB OK. Offloading and placement of the 3D CT Scanner will be assisted by Tinker AFB personnel with the guidance, planning and direction of Contractor technical personnel.

2.0. General Requirements and Specifications

2.1. Design – The CT Scanner shall be one of the manufacturer’s current production models and shall be new and unused. The CT Scanner and related components and accessories shall meet but may exceed the minimum requirements for design, construction, functional capability, size and performance as specified herein unless noted otherwise.

2.2. Measuring System – Either the U. S. Customary System of Units (US) or the International System of

Units (SI) may be used in the design and manufacture of the CT Scanner. The CT Scanner shall be inch/metric switchable with automatic conversion by the system between the two systems of measurement.

2.3. Construction – All parts and materials used in the construction of the CT Scanner shall be new. The quality of construction shall be provided to meet the strength, rigidity and wear resistance characteristics necessary to meet the standards for accuracy, performance and safety specified herein. All parts and mechanisms requiring adjustment, replacement or servicing shall be readily accessible. The CT Scanner shall be complete so that when installed and connected to the proper utilities it shall be ready for use. The construction of the CT Scanner shall be free from any defects – primarily, but not only – those which would affect the operation of the CT Scanner.

2.4. Maintenance –Parts lists/drawings, circuit diagrams and electrical/electronic schematics shall be provided for both preventative and limited remedial maintenance and troubleshooting.

2.5. Lubrication – All parts of the CT Scanner requiring continuous lubrication shall be automatically lubricated by a system that will ensure adequate lubrication of parts. Parts or mechanisms requiring periodic lubrication shall be provided with adequate means for grease or oil lubrication. Systems using recirculated oil shall be equipped with a replaceable or washable filter element. Each oil reservoir shall have an oil level gauge. Automatic processes of lubrication shall have a warning device to indicate when lube oil is low or empty.

2.6. System identification labels/plates – The system shall be identified with corrosion-resistant metal identification plates that are printed in English using plain bold-face letters. They shall be legible and permanent. Plate/label will contain Manufacturer’s Name, Manufacturer’s Model, Designation, Manufacturer’s Serial Number, Power Input (volts, total full load amps, phase, frequency), and Date of

Manufacture.

2.7. Safety and Health – Covers, guards, bellows, or other safety devices will be provided for all parts of the

CT Scanner that present potential safety hazards. Safety devices shall not interfere with the operation of the CT Scanner. The safety devices will prevent unintentional contact with the guarded part(s) and will be removable to facilitate inspection, maintenance and replacement of the part(s). All parts, components, mechanisms and assemblies furnished with the CT Scanner shall comply with applicable requirements of

OSHA. Additional safety and health requirements will be as specified herein:

2.7.1. The safety requirements and safety steps for the system must meet the requirements of T.O 33B-

1-1: Technical Manual: Nondestructive Inspection Methods, Basic Theory that includes, but is not limited to, that which is listed below:

2.7.2. “A radiation protection survey of all new shielded X-ray installations, or new equipment in existing installations, SHALL be made by a fully qualified Health Physicist, Bioenvironmental

Engineer, Nuclear Medicine Science Officer, or qualified Radiological Health Technician before the installation is placed into routine operation. The installation SHALL be inspected to verify adequacy of shielding, radiation protective devices and operational procedures.”

2.7.3. “Interlock System. The visible and audible warning beacons/signals SHALL be tied to an interlock system. The interlock system SHALL be placed on each door to interrupt power to the control box/tube head, stopping the irradiation process, when unauthorized access is attempted.”

2.7.4. “Warning Beacons. Rotating or flashing strobe-type visible warning beacons SHALL be used at all entrances to the enclosure.”

2.8. Mercury Restriction –No mercury components may be added to the CT Scanner. Trace amounts of mercury naturally occurring in the granite slabs are acceptable as long as no additional mercury is added.

2.9. Asbestos Restriction – Asbestos and materials containing asbestos will not be used on or in the CT

Scanner and are strictly forbidden.

2.10. Ozone Depleting Substances - All Class 1 ozone depleting substances (ODSs) are strictly forbidden.

2.11. Environmental Protection – Under the operating, service, transportation and storage conditions described herein, the CT Scanner will not emit materials or radiation hazardous to the operator or ecological system as prohibited by Federal, State or Local statutes in effect at the time of installation.

3.0. CT Scanner – The CT Scanner shall consist of an X-ray source or an X-ray generator from a single or from multiple sources for macro and micro CT capabilities. Also, it shall consist of an X-ray focus controller, a digital detector, a sample table, and an automated specimen/part manipulation system to either move the detector and X-ray source or to move the sample during scanning such that sufficient data can be collected from complex geometries for the purpose of high-quality computed tomography.

3.1. Scanning Capability:

3.1.1. The CT scanner will automatically capture, render, and provide basic and real time analyses of standard 2D digital radiography and 3D X-ray computed tomography data at low and high magnification to include:

3.1.1.1. Live image video capture

3.1.1.2. Still image capture

3.1.1.3. Frame averaging

3.1.2. The CT scanner shall be capable of conducting time and motion analysis utilizing X-ray computed tomography.

3.1.3. The CT scanner shall be capable of capturing and automatically combining multiple CT volumes to demonstrate how objects behave or interact when loaded or in motion utilizing X-ray computed tomography software.

3.1.4. The CT scanner will be able to scan and automatically stitch together 2D and 3D CT scans to provide a montage or 3D model rendered view of parts larger than the detector window utilizing image acquisition and reconstruction software.

3.1.5. The CT scanner will be able to scan and automatically generate images of subpixel resolution utilizing image acquisition and reconstruction software.

3.1.6. The CT Scanner shall be capable of creating and exporting 2D CT slices.

3.1.7. The CT Scanner shall be capable of performing overall and local (small region within a volume)

CT volume reconstruction for 3D inspections.

3.1.8. The CT Scanner shall be capable of performing 3D internal and external surface scanning.

3.1.9. Automatic geometry corrections to reconstruction errors.

3.1.10. The CT Scanner shall utilize geometry tools to determine system geometry for reconstruction of

CT scans.

3.1.11. The CT Scanner shall utilize ring artifact reduction tools to eliminate artifacts in the CT scan that are the result of the nonuniform response of the pixels.

3.1.12. The CT scanner shall include Detector Qualification software which is a means of monitoring system performance over time. This software shall include a guided acquisition module to walk the user through obtaining system performance reports including a defective pixel report showing underperforming/over performing pixels as well and relevant/non-relevant CKPs including their size and location. This module shall also include statistical process control logs to allow long term monitoring of system performance to ASTM E2737.

3.1.13. The Contractor shall prove system capability prior to acceptance by successful non-destructive scanning of standard samples provided by the USAF requesting organization.

3.1.13.1. The CT scanner will, at a minimum, be capable of accurately and precisely capturing

95% of flaws in USAF unique 3D printed 17-4PH steel CT Standard Samples.

3.1.13.2. The CT scanner will, at a minimum, be capable of accurately and precisely measuring samples/revealing defects at a resolution of 0.001 inches +/- 0.0001 inches.

3.2. System Component Specifications – The following section details minimum specifications of the machine to be provided by the supplier:

3.2.1. X-ray tube configuration must be met with one or more X-ray tubes (may be interchangeable).

The X-ray tube and detector should be adjustable to provide a larger working volume for large parts. System should be capable of supplying 222 KV and 450 KV X-ray (Dual head) power source.

3.2.1.1. 225 kV micro focus range

3.2.1.1.1. <10 micron focal spot

3.2.1.1.2. Adjustable energy: 20kV – 225KV

3.2.1.1.3. Adjustable current: 0 mA – 3 mA

3.2.1.2. 450 kV mini focus range (minimum)

3.2.1.2.1. 0.4 and 1.0 mm focal spot per EN 12543

3.2.1.2.2. Adjustable energy: 50kV – 450KV

3.2.1.2.3. Adjustable current: 0 mA – 14.0 mA (3.3mA at 450kV)

3.2.1.3. Fast tube switching if multiple tubes are used. (No hardware or electrical disconnects required)

3.2.2. Detector – Best grade available for detector model

3.2.2.1. Type: Flat panel digital detector

3.2.2.2. Minimum imaging window: 16 inch x 16 inch array

3.2.2.3. Maximum detector pixel size: 200 micron

3.2.2.4. Minimum Resolution:16 bit

3.2.2.5. Minimum frame rate: 4 FPS @ full resolution (15fps @ 2x2 pixel binning)

3.2.2.6. Gadox scintillator screen

3.2.2.7. Sensitivity: Ultra High

3.2.2.8. Ability of the system to finely divide detector pixel pitch so as to augment/optimize image resolution

3.2.2.9. Ability to scan an array of metal types to include alloys such as aluminum, steel, and nickel based superalloys of different thicknesses (up to 1 inch).

3.2.3. System Motion

3.2.3.1. System motion shall provide at least 7-axis of motion that allows:

3.2.3.1.1. Minimum of 65 inches of vertical and 36 inches of horizontal travel.

3.2.3.1.2. Minimum tilt of 20 degrees.

3.2.3.1.3. The distance between the source and detector must be variable to accommodate various part sizes, geometries.

3.2.3.1.4. Minimum focal distances:

3.2.3.1.4.1. 450kV - 90 inches

3.2.3.1.4.2. 225kV – 80 inches

3.2.4. Manipulator control

3.2.4.1. Automated control of all axis for CT imaging

3.2.4.2. Manual control of all axis for component positioning during setup and real-time 2D imaging

3.2.4.3. Manual control of manipulator to position component stage for ease of loading and unloading parts

3.2.4.4. Manual control of all motorized axes shall be provided utilizing push-button control or joystick operation. Axes positions shall be displayed on the monitor as well as the

HMI.

3.2.5. Interior Lighting

3.2.6. X-ray tube control and monitoring

3.2.7. Complete control and monitoring of all manipulation axes

3.3. Chamber Size - The CT Scanner must be able to accommodate a part size of up to and including

60x60”.

3.4. Weight Capacity and Loading Capacity of Specimen Table - The sample table must be able to hold a minimum weight of 400 lbs without interfering with/or compromising the general operation of the scanning apparatus while loaded.

3.5. Radiation Enclosure - The CT Scanner will be encased in a radiation-proof cabinet. Radiation proofing on the cabinet shall be adequate such that the standard operation would NOT require the operator to wear a dosimeter per APA and OCIA guidelines.

3.6. Remote Sample Actuation - The CT Scanner cabinet shall have a means to provide electrical, pneumatic, and hydraulic utility connections to samples for the purpose of operation/actuation of the sample during operation of the CT scanner. Proper use of these ports or connecters, for this purpose, shall not compromise the radiation shielding of the cabinet.

3.7. Safe and Ergonomic Loading - The CT scanner system will be supplied with an automated loading system to facilitate ergonomic loading of large and heavy samples. The loading table must be less than

30 inches tall and be able to extend out of the chamber for part loading/positioning and retract for scanning. The automated loading system will be integrated within CT scanner system, and fully supported for maintenance by the Contractor. Walk-in enclosures with other means of load assist mechanisms (such as gantry system or robot arm) for safe loading of parts onto the scanning stage will be acceptable as long as scan volume is not inhibited and enclosure does not extend out of the available footprint for the system described in 3.8.

3.8. Utility requirements -

3.8.1. Power input: 208 VAC, 60 Amp, Single Phase, 50/60 Hz

3.9. Enclosure – Max footprint for system – 25’ X 12.5’ area (312.5 ft sq), with a maximum allowable height of 12’.

3.9.1. Radiation enclosure shall be no larger than 10’ deep by 15’ wide by 11.5’ tall. 36” space for electrical enclosure will be required. A minimum of 180” of overhead clearance will be required for assembly. A minimum of 18” will be required around the perimeter for assembly with 36” on the electrical enclosure side. Max 12’ X 5’ footprint for ancillary hardware for the system.

3.9.1.1. Due to limited entry and access restrictions, if the radiation enclosure shipping crate is larger than the dimensions listed in 8.0, the enclosure MUST be delivered disassembled and reassembled on site. This must be included in the quotation provided if necessary.

3.9.1.2. A detailed description of the dimensions of the cabinet will be needed at least 60 days in advance to perform an analysis of the movements to get the system into the correct location.

3.9.2. Radiation enclosure, interlock, and warning lights to meet all state and federal x-ray safety regulations.

3.10. CT Scanner Control Computer – The following minimum hardware and software capabilities/functions will be required (items may be exact or equivalent to; verification of equivalency is required):

3.10.1. Hardware:

3.10.1.1. High End Workstation Computer System that meets the recommended requirements to run the CT Scanner software and acquisition of data from the CT scanner. Minimum requirements include:

3.10.1.2. Eight-Core Intel Xeon Processor (or equivalent)

3.10.1.3. 32 GB RAM

3.10.1.4. 3TB hard drive (or total combination of drives)

3.10.1.5. Blue Ray and DVD+/-RW Drive,

3.10.1.6. USB 3.0 ports

3.10.1.7. 31.5” 4K Color display

3.10.1.8. Wireless Keyboard and Mouse

3.10.1.9. High End Reconstruction Workstation Computer System that processes and models

CT Scanner data and runs all applications detailed in the Software section. Minimum requirements include:

3.10.1.10. Minimum 4 GPUs

3.10.1.11. 96 GB Video RAM

3.10.1.12. 256 GB RAM minimum

3.10.1.13. 64-bit Windows operating system

3.10.1.14. Multiple monitors via Display port or HDMI type connectors

3.10.1.15. 8 TB min of storage

3.10.1.16. Blu-Ray compatible internal optical drive

3.10.1.17. Two (2) 31.5” minimum, LCD/LED Monitors with cable

3.10.1.18. Wireless Keyboard

3.10.1.19. Wireless Mouse

3.10.1.20. CT Scanner Controller Suite

3.10.2. Software:

3.10.2.1. Windows 10-based Operating System for both acquisition and processing workstations.

3.10.2.2. Digital 2D Radiography Features

3.10.2.3. Live/Real-time image integration, frame averaging, contrast/brightness adjustments

3.10.2.4. Sharpening, smoothing, edge enhancement, and other user definable filters

3.10.2.5. Image archival in TIF (multiple resolutions), BMP, RAW, and JPEG formats

3.10.2.6. Text annotation (text, arrows, shapes) on captured or live measurements

3.10.2.7. Profile analysis function: Line and histogram-based analysis functions for contrast adjustments

3.10.2.8. 3D and 2D scan stitching software; capturing and stitching scans larger than the detector window

3.10.2.9. Subpixel imaging: allowing smaller steps sizes than the smallest pixel size to allow for higher resolution

3.10.2.10. Spatial calibration and measurements in all axes

3.10.2.11. Pseudo colorizing and thresholding of density variations

3.10.2.12. Video rendering of 3D scan

3.10.2.13. Recording of projectionsImage processing tools and projection filtering to allow cropping of multiple planes/angles (slicing)Video rendering of time and motion analysis of 3D scans

3.10.2.14. 2D capturing and Graphical rendering from 3D scans

3.10.2.15. Beam hardening and ring artifact reduction.

3.10.2.16. Automatic detector correction (offset, gain, missing pixels)

3.10.2.17. DICONDE data format compliant as described in ASTM E 2767

4.0. Peripheral Devices

4.1. Computer System Table/Workstation – A table or workstation for the operating system shall be provided by the supplier. Table must at a minimum approximately 48” wide x 30” deep x 29” tall. An appropriate full adjustable/ergonomic office task chair that is compatible with the provided desk setup will be supplied as well.

5.0. Additional Equipment

5.1. Air Filter / Regulator – If pressurized air is required, the CT Scanner will operate using at most 100 psi shop air supply in the existing area, or provide a regulation system to step up the supply to required pressure. The supply line will include a moisture/water purge trap to prevent moisture introduction. The contractor shall supply a means to remove contaminants and regulate the pressurized air entering into the

CT Scanner.

5.2. Vibration Dampening System – The contractor shall supply (if required) any means necessary to reduce external environmental vibratory inputs/excitations not directly associated with the CT Scanner operation, effects associated with operation in both an industrial manufacturing and airport type environment. Vibration analysis will be included if necessary in the procurement contract. Active, passive, or combination systems with demonstrated effective system performance at a similar and the final location are acceptable.

5.3. Machine Manuals – Two (2) complete sets of technical data (or a single electronic file of all manuals) will be submitted upon contract approval prior to delivery to ensure proper shop footprint specifications and familiarity with the CT Scanner before delivery. This technical data will include items such as operating manuals, maintenance manuals, facilities requirements, parts catalogs, parts lists, wiring schematics, lubrication charts, machine accuracy, and power requirements. Applicable test results shall be written in English.

6.0. Electrical Equipment – The electrical system of the CT Scanner and all electrical components thereof, will conform to the requirements of NEC. All electrical equipment design and documentation is subject to final approval by the Government.

7.0. Contract Monitor Provisions

7.1. Quality Conformance Inspection – Quality conformance inspection shall be applied to each item prior to being offered for acceptance under the contract. Preliminary quality conformance inspection prior to shipment will be conducted at the facility chosen by the contractor. Final quality conformance inspection shall be conducted at the Government installation site, after installation, standard checkouts and after calibrations have been completed, and will consist of the examination in 7.2. and the tests in 7.3. under the supervision of Government representatives appointed by the contract administrator. The calibration data obtained in the preliminary and the final quality conformance checks shall be furnished with the machine in a standard certificate format. Failure of any item to pass any examination or test shall be cause for rejection. The 3D CT Scanner and all equipment associated with this purchase will remain the property of the contractor until all items of this quality conformance inspection have been passed and accepted by all government representatives.

7.2. Examination – The 3D CT Scanner and all associated equipment shall be examined for compliance with design, construction, materials, components, electrical equipment and workmanship requirements specified herein by the Contractor and customer.

7.3. Tests – In addition to the specific testing requirements of 2.7 and 3.2, the Contractor shall demonstrate that the 3D CT Scanner performs as required herein using accepted industry standards for testing and calibration provided these tests demonstrate all performance requirements stated in this purchase description. Failure of any test to demonstrate that the CT Scanner, related equipment and software, to meet the minimum requirements as specified herein, will be cause for rejection or delay of acceptance.

7.4. Certifications – Contractor shall be ISO 9001 certified.

8.0. Shipping and Installation–

8.1. The Contractor shall include all costs associated with shipping or transport to the final destination of

Tinker AFB, OK, as specified in the contract delivery schedule. Upon delivery, Tinker AFB personnel will assist with offloading the crated equipment. The equipment shall be moved to either the space allocated for the system or to a staging area until representatives of the contractor can be on site for uncrating and final installation. Prior to delivery, the Contractor shall provide to the Contracting Officer the data as specified in 8.1.1-8.1.4. This data shall be in the Contractor’s format.

8.1.1. Contract information to include Contract and CLIN numbers, Contractor identification, SOW reference(s), system name/information, date of submission, and appropriate distribution statement.

8.1.2. Utility, temperature, and space requirements for preparation of facility.

8.1.3. Methods of delivery to include shipping crates, etc., and special tools/equipment required for delivery, offloading, moving, etc.

8.1.4. Names and pertinent information of visitors, technicians, engineers, etc., who will be visiting

Tinker AFB for the installation of the system.

8.2. Crates and boxes must be able to fit through a 11’11” wide by 10’11” high roll down door with lifting/moving equipment under the crate or container. Staging of equipment will not exceed 14 calendar days upon receipt of equipment, unless negotiated and agreed upon by the Contractor and Contracting

Officer if changes from the original contract are deemed necessary.

9.0. Training – Upon delivery and inspection/acceptance of the CT Scanner, the Contractor shall train two (2)

Government personnel on all delivered hardware and software applications. The purpose of this training is to ensure safe and proper initial use of the system. Additional applications training shall be provided to the

Government upon request within one year of delivery. The Contractor shall provide training for two (2)

Government personnel, not to exceed 40 hours per person. This training shall be focused and advanced class-based applications training at the Contractor’s site or at the Customer’s site. The applications training, which shall consist of using and inspecting parts with the CT Scanner, shall be based on methods governed by industry standards such as the American National Standards Institute/American Society for Nondestructive

Testing (ANSI/ASNT®) CP-105 and NAS 410 and Department of Defense standards such as T.O. 33B-1-1, 33B-1-2. In advance to conducting classroom training, the Contractor shall deliver the training course content and material to the Contracting Officer to be approved by the OC-ALC NDI Program Manager (PM). This is required for the ALC PM to establish equivalent prerequisite for certification. The course content and material will be in the Contractor’s format.

10.0. System/Software Support – Contractor will provide standard commercial support to ensure proper functioning and operation of the 3D CT Scanner system.