SOW_B3907 Pump Module.pdf

STATEMENT OF WORK (SOW)

FOR

Remote Pump Module System

BUILDING B3907

Oklahoma City Air Logistics Center Tinker Air Force Base

Prepared by

Joe Starwalt

76 CMXG/MXDEC

29 April 2022

Statement of Work

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Table of Contents

1. SCOPE OF WORK:

1.1 SCOPE:

1.2 BACKGROUND:

2. APPLICABLE GOVERNMENT AND INDUSTRY STANDARDS:

2.1 GOVERNMENT STANDARDS:

2.2 NON-GOVERNMENT STANDARDS:

2.3 ORDER OF PRECEDENCE:

2.4 APPLICABLE STANDARDS

2.5 PROHIBITED MATERIALS:

3. REMOTE PUMP MODULE SYSTEM:

3.1 REQUIREMENTS

3.2 CONSTRUCTION:

3.3 COMPONENT LABELING:

3.4 INTERCHANGEABILITY:

3.5 MAINTAINABILITY:

3.6 LUBRICATION:

3.7 UTILITIES AND MAINTENANCE ACCESS:

3.8 UTILITIES INTERCONNECTION:

3.9 SURGE PROTECTION:

3.10 MODERNIZATION PLAN:

3.11 RPMS CONTROLLED AREA:

3.12 PC AND PLC CONTROL SYSTEM:

3.13 RPMS PRELIMINARY/FINAL CALIBRATION:

3.14 RPMS AND AS-BUILT DRAWING REVIEW:

3.15 SOFTWARE:

3.16 EXECUTIVE SOFTWARE:

3.17 PC AND SOFTWARE SECURITY:

4. ACCEPTANCE TESTS

4.1 ACCEPTANCE TESTING WITH BASELINE DATA:

4.2 VIBRATION BASELINE TESTING:

4.3 MONTHLY STATUS REPORT:

4.4 TEST PLAN:

4.5 TRAINING PLAN:

4.6 WARRANTY:

5. QUALITY ASSURANCE PROVISIONS

5.1 RESPONSIBILITY FOR INSPECTIONS:

5.2 RESPONSIBILITY FOR COMPLIANCE:

5.3 EXAMINATION:

6. DESIGN REVIEWS

6.1 PRELIMINARY DESIGN REVIEW:

6.2 INTERMEDIATE DESIGN REVIEW:

6.3 CRITICAL DESIGN REVIEW:

6.4 FINAL ACCEPTANCE:

6.5 RPMS CALIBRATION:

6.6 EMERGENCY POC:

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7. TECHNICAL DATA REQUIREMENTS

7.1 MANUALS/DRAWINGS:

7.2 WORK PLAN DRAWINGS

7.3 AS-BUILT DRAWINGS

7.4 SOFTWARE DOCUMENTATION:

7.5 COMMERCIAL MANUALS:

7.6 CORRELATION TEST REPORT:

7.7 SYSTEM CLEANLINESS PARTICLE COUNT:

7.8 ACCEPTANCE TEST REPORT:

7.9 DOCUMENTATION:

8. TRAINING REQUIREMENTS

8.1 OPERATOR:

8.2 ELECTRICAL/MECHANICAL:

8.3 CALIBRATION:

8.4 SOFTWARE/PROCESS ENGINEERS:

9. SPECIAL PROVISIONS

9.1 GOVERNMENT OCCUPANCY OF FACILITIES & RESPONSIBILITIES:

9.2 GOVERNMENT INSTALLATION ACCESS:

9.3 WORKING HOURS:

9.4 SAFETY, FOREIGN OBJECT DEBRIS (FOD), DROPPED OBJECT PREVENTION (DOP) & QUALITY CONTROL

9.5 HOUSEKEEPING

9.6 TOOL CONTROL AND ACCOUNTABILITY:

9.7 FIELD VERIFY:

10. PROPOSAL BY CONTRACTOR:

10.1 PURPOSE:

10.2 REQUIREMENT:

11. OTHER WRITTEN SUBMITTALS:

11.1 REQUIRED SUBMITTALS

12. GOVERNMENT FURNISHED PROPERTY AND SERVICES

12.1 GFP:

12.2 GOVERNMENT FURNISHED SERVICES

12.3 INTANGIBLE GOVERNMENT PROPERTY

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APPENDICES

Appendix A: Equipment List Appendix B: Reliability Centered Maintenance and Vibration Severity Chart Appendix C: Safety Specifications Appendix D: Glossary and Definitions Appendix E: Environmental Appendix F: Certification Test Plan Appendix G: RPMS Technical Manual: Operation and Maintenance Instructions Appendix H: Drawings-Basis of Design and Component Locations Appendix I: UUT & Sub-component Test Specifications (Available Upon Request) Appendix J: Design Guidelines 450

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1. SCOPE OF WORK:

1.1 Scope:

The Contractor shall repair & modify one (1) Remote Pump Module System (RPMS) mechanical operation as written in the requirements section of this document. The contractor shall also make modifications to enhance performance, maintainability, and increase RPMS operational life span.

Modifications and Upgrades include replacing a networked pump control Human Machine Interface (HMI) laptop computer with a panel mount touchscreen computer. Electrical modifications include removing an electrical enclosure and installing a new enclosure with components meeting Class I Div. I requirements. Mechanical upgrades include modification of main motor pump assemblies and associated valves to ensure components can be replaced with minimal modification, without require cutting or welding. Contractor shall utilize only new commercial-off-the-shelf (COTS) components and parts, except where specified to reuse existing equipment. The modified pump module shall meet all of the performance specifications listed in this Statement of Work (SOW) and most current available commercial data used for calibration, maintenance, and operation with Main Fuel Control (MFC) & Augmenter Fuel Control (AFC) production technical orders. The RPMS shall be repaired and modified for successful of testing MFCs and AFCs used in support of F-15 & F-16 aircraft equipped with F100-220 and F100-229 jet engines. The Contractor shall supply all engineering, labor, materials, parts, tools, equipment, supplies, transportation, software, and incidentals necessary to upgrade the RPMS.

The government shall supply the fuel controls required for acceptance testing of the upgraded RPMS. The majority of work and all acceptance testing shall be performed in Building 3907 at the Oklahoma City Air Logistics Center (OC-ALC), Tinker Air Force Base, OK. All work performed in B3907 test areas shall be performed in accordance with National Electric Code, Class I, Division II. All work associated with this contract shall not have any impact on production unless agreed upon – ahead of time, and on a case-by-case basis – by production management. Any requested production outages must be approved by production management and government point of contact with the earliest possible advance notice.

1.2 Background:

The remote pump module system supplies MIL-PRF-7024 Type II aviation calibration fluid to four jet engine fuel controls test stations located in building 3907 at Tinker Air Force Base.

Presently the remote pump module system does not deliver sufficient calibration fluid supply and pressure to allow four test stations to perform simultaneous testing of fuel controls. The remote pump module system is 25 years old. The original manufacture was Allied Signal but the RPMS has been modified from its original configuration by Electrical Manufacturing and Distributors Inc. (EMD) in Feb 2008. Some of the EMD upgrades included installing Siemen’s S7-300 PLC series programmable logic controller (PLC) for data acquisition and Digital Input & Output (DIO).

2. APPLICABLE GOVERNMENT AND INDUSTRY STANDARDS:

Contractor, at a minimum, is required to comply with the current editions of the following requirements for design, construction, installation and safety as applicable. The term “most recent edition” shall be understood to mean, “most recently released edition as of date of issuance of contract.”

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2.1 Government Standards: The following documents form a part of this purchase description to the extent stipulated herein.

2.1.1 U. S. DEPARTMENT OF LABOR

2.1.1.1 29 CFR 1910 – General Industry, OSHA Safety and Health Standards (29 CFR

1910), 2010 or most recent edition (available at http://www.osha.gov/)

2.1.1.2 (Application for copies should be addressed to the U.S. Department of Labor, 200

Constitution Ave, Washington, D.C. 20210)

2.1.2 ENVIRONMENTAL PROTECTION AGENCY

2.1.2.1 40 CFR 82 – Protection of Stratospheric Ozone, 2010 or most recent edition

2.1.2.2 (Application for copies should be addressed to the U.S. Department of Labor, 200

Constitution Ave, Washington, D.C. 20210)

2.1.3 FEDERAL STANDARDS

2.1.3.1 FED-STD-H28A – Screw Thread Standards for Federal Services, 1994 (R2001) or most recent edition

2.1.3.2 FED-STD-H28/21B – Screw Thread Standard for Federal Service, Metric Screw Threads, 1984 (R2006) or most recent edition

2.1.3.3 (Application for copies should be addressed to Superintendent of Documents, Government Printing Office, Washington, D.C. 20402-001).

2.2 Non-Government Standards: The following documents form a part of this document to the extent stipulated herein.

2.2.1 NATIONAL FIRE PROTECTION ASSOCIATION (NFPA)

2.2.1.1 NFPA 1 – Fire Code, 2010 edition or most recent edition

2.2.1.2 NFPA 70 – National Electrical Code, 2014 edition

2.2.1.3 NFPA 70E – Standard for Electrical Safety in the Workplace, 2011 edition or most recent edition

2.2.1.4 NFPA 79 – Electrical Standards for Industrial Machinery, 2007 or most recent edition

2.2.1.5 (Application for copies should be addressed to National Fire Protection

Association, Battermarch Park, Quincy, MA 02269)

2.2.2 TELECOMMUNICATIONS INDUSTRY ASSOCIATION (TIA) STANDARD

2.2.2.1 EIA/TIA-232-F – Interface Between Data Terminal Equipment and Data Circuit- Terminating Equipment Employing Serial Binary Data Interchange, 1997 (R 2002) or most recent edition

2.2.2.2 (Application for copies should be addressed to IHS International Inc., http://www.ihs.com, or call 1-800-854-7179 for U.S. and Canada)

2.2.3 NATIONAL ELECTRICAL MANUFACTURERS ASSOCIATION

2.2.3.1 NEMA MG 1 – Motors and Generators, 2009 (R2010) or most recent edition http://www.osha.gov/ http://www.ihs.com/

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2.2.3.2 NEMA ICS 6 – Industrial Control and Systems: Enclosures, 1993 (R2006) or most recent edition

2.2.3.3 (Application for copies should be addressed to National Electrical Manufacturers Association, 1300 N 17th Street, Suite 1752, Rosslyn, VA 22209)

2.2.4 AMERICAN NATIONAL STANDARD INSTITUTE

2.2.4.1 ASTM SI 10 – American National Standard for use of the International System of

Units (SI): The Modern Metric System, 2010 or most recent edition

2.2.4.2 (Application for copies should be addressed to American National Standards

Institute, Attn: Sales Department, 1430 Broadway, New York, NY 10018-3363)

2.2.5 AMERICAN WELDING SOCIETY INC (AWS)

2.2.5.1 AWS D14.4 – Specification for Welded Joints in Machinery and Equipment, 1997 or most recent edition

2.2.5.2 (Applications for copies should be addressed to the American Welding Society Inc., 550 North LeJeune Road, Miami, FL 33126)

2.2.6 INTERNATIONAL ORGANIZATION FOR STANDARDIZATION

2.2.6.1 ISO 4413 – Hydraulic Fluid Power – General Rules and Safety Requirements for

Systems and Their Components, 2010 or most recent edition

2.2.6.2 (Application for copies should be addressed to International Organization for

Standardization, 1, Ch. de la Voie-Creuse, Case postale 56, CH-1211 Geneva 20, Switzerland, e-mail central@iso.ch or IHS International Inc., http://www.ihs.com, or call 1-800-854-7179 for U.S. and Canada)

2.3 Order of Precedence: In the event of a conflict between the test of this specification and the references cited herein, the test of this specification takes precedence. Nothing in this document, however, supersedes applicable laws and regulations unless a specific exception has been obtained.

2.4 Applicable Standards

2.4.1 Dimensional Systems: U.S. Customary System of Units (US) shall be used in the design and construction. In this specification, all measurements, dimensions, sizes, and capacities are given in the U.S. Customary System of Units (US).

2.4.2 Measuring/Indicating Devices: All measuring and indicating devices, such as dial indicators, pressure gauges, temperature indicators, depth stops, and other similar devices used on the machine, shall be graduated in inch-pound units. Marking on all measuring and indicating devices shall be permanently and legibly engraved or etched on a non-glare background. All dials and other type indicating devices shall be securely mounted in place. Such devices shall be located so as to allow reading from the operator’s normal workstation.

2.4.3 Safety and Health: Covers, guards, and other safety devices shall be provided for all parts of the machine that present safety hazards. The safety devices shall not interfere with the operation of the machine. The safety devices shall prevent unintentional contact with the guarded part and shall be removable to facilitate inspection, maintenance and mailto:central@iso.ch http://www.ihs.com/

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SOW-H2WC10 Remote Pump Module Page 8 repair of the parts. All machine parts, components, mechanisms and assemblies furnished on the machine shall comply with all of the requirements of 29 CFR 1910.Cautions–Warning Plates: Corrosion resistant “Caution” or “Warning” Plates shall be securely attached to the equipment in visible locations with any safety precautions to be observed by the operator or maintenance personnel permanently marked on the plates.

2.4.5 Noise Levels: The noise level in the RPMS test station area emitted by the RPMS upgrade shall not exceed 80 dBA when measured at the operator’s workstation or at any other point at a distance of three (3) feet from any UUT test station located in B3907 Room 115 as measured on the “A” weighted scale of a standard Type II sound level meter.

2.4.6 Chemicals: The Contractor shall not transport, ship or use any chemical, material or substance used in the performance of this SOW on Tinker AFB prior written approval is provided by 72 ABW/CEIE, Natural Infrastructure Management (Environmental Compliance). The Contractor shall furnish to the Government POC a list of all chemicals used in conjunction with the modernization of the equipment, container sizes and quantities, and their Safety Data Sheets (SDS) ten (10) working days after contract award date. The government reserves the right to reject use of any chemicals and request alternative(s) be proposed for completion of the modernization. Proper use, storage and removal of any chemical required during modernization of RPMS shall be coordinated with the Tinker Unit Environmental Coordinator (UEC). UEC info shall be made available to Contractor by Government POC, as needed. Contractor shall remove all unused chemicals from Tinker AFB. Contractor shall comply with all chemical and environmental requirements as stipulated in Appendix E.

2.4.7 Instruction Plates: All words on instruction plates shall be in the English language.

Words shall be engraved, etched, embossed, or stamped in boldfaced letters on a contrasting background. Lettering shall be a minimum of 18 point font and the plates shall be sized accordingly to accommodate all standard text in this point size. Plates and lettering shall be fully compatible with MIL-PRF-7024 type II calibration fluid.

2.4.8 Nameplate: A corrosion resistant metal nameplate permanently and legibly marked with the following information shall be securely attached to the machine in a readily visible location. Nameplate and lettering shall be fully compatible with MIL-PRF-7024 type II calibration fluid and shall suffer no degradation when subjected to it. Lettering shall be a minimum of 18 point font.

2.4.8.1 Nomenclature of the Machine

2.4.8.2 Manufacturer’s Name and Address

2.4.8.3 Manufacturer’s Model Number

2.4.8.4 Manufacturer’s Serial Number

2.4.8.5 Date of Manufacture

2.4.8.6 Contract Number

2.4.8.7 Services Requirements – All service requirements to be included.

2.4.9 Castings and Forgings: All castings and forging shall be free from defects, scale, or mismatching. Processes such as welding, peening, plugging, or filling with solder or

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Such processes may only be used for enhancing surface finish and appearance.

2.4.10 Welding, Brazing, and Soldering: Welding, brazing, or soldering shall be employed only where those operations are included in fabrication of the original design. These operations shall not be employed as repair or reclamation measures for defective parts.

Any excess material used for such operations shall be thoroughly removed from the part(s) upon completion of the operations. Weldments shall comply with AWS D14.4.

2.4.11 Surface Finish: All surfaces of castings, forgings, molded parts, stampings, and welded parts shall be clean and free from sand, dirt film, sprues, flash, scale flux, and other harmful or extraneous materials. External surface edges shall be either rounded or beveled unless sharpness is required to perform a necessary function. Except as otherwise specified herein, the condition and finish of all surfaces shall be commensurate with the manufacturer’s standard commercial practice.

2.4.12 Gears: All gears and pinions, if applicable, shall be designed and manufactured of a suitable ferrous material with proper width and size to transmit full-rated torque and horsepower throughout the speed ranges without failure for the expected service life of the machine.

2.4.13 Painting: Yellow or orange safety color-coding shall be used for designated physical hazards.

2.4.14 Screw Threads: All threaded parts used on the machine and its related attachments and accessories shall conform to FED-STD-H28 or FED-STD-H28/21B.

2.4.15 Electrical Items: All electrical/electronic components located within or outside the pump RPMS area, detailed in immediately preceding paragraph shall meet or exceed the minimum requirements defined by NFPA standards starting in paragraph 2.2.1 of this document.

2.4.16 Electrical System: The machine shall be capable of running using the existing power supply source.

2.5 Prohibited Materials:

2.5.1 Mercury restriction: The machine shall contain neither mercury nor mercury compounds, or be exposed to free mercury during manufacture.

2.5.2 Asbestos restriction: Asbestos and materials containing asbestos shall not be used on or in the machine.

2.5.3 Polychlorinated Biphenyl (PCB) restriction: The use of polychlorinated biphenyl on or in the machine is prohibited.

2.5.4 Lithium restriction: Lithium batteries used in the computer system are exempt from this requirement.

2.5.5 Ozone Depleting Chemicals (ODC) Restrictions: Class I ozone depleting substances in accordance with (IAW) section 602(a) of the Clean Air Act Amendments 1990, 42 USC 7671a(a) as implemented by 40 CFR 82 Protection of Stratospheric Ozone, shall not be contained within or used on this equipment.

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2.5.6 Environmental Protection: Under the operating, service, transportation and storage conditions described herein the machine shall not emit materials hazardous to the ecological system as prohibited by federal, state or local statutes in effect at the point of installation.

2.5.7 Other Environmental Compliance: Contractor shall comply with all environmental requirements as stipulated in Appendix E.

3. Remote Pump Module System:

3.1 Requirements

3.1.1 The contractor shall repair and upgrade one (1) remote pump module system to continuously recirculate MIL-PRF-7024 Type II calibration fluid from a tank reservoir, through a supply manifold that supplies four (4) test stations. Upon project completion calibration fluid shall be supplied to the test station supply manifold at a minimum pressure of 1400 Pounds per Square Inch (PSIG) to a maximum pressure of 1800 PSIG.

Calibration fluid shall be supplied at a variable demand flow rate from 0 to 400 Gallons per Minute (GPM). Calibration fluid shall be supplied through the existing 150 ft. 4” pipe used as a supply manifold, and returned from test stations through existing 115 ft.

6” pipe outlet manifold back to the tank reservoir. Any modifications to the supply or return manifold required to fulfill requirements shall be supplied and performed by the contractor. Any required modifications to the supply or return manifold shall fall under the same advance notice policy as the RPMS.

3.1.2 All existing safety features including pressure relief valves and Emergency Stop Features (ESTOP) shall be kept operational.

3.1.3 The contractor shall replace 4 test station calibration fluid inlet regulators with new inlet regulators that are rated for use with MIL-PRF 7024 Type II calibration fluid. The inlet regulators shall be tolerant of calibration fluid particulate contamination allowances per the standards set forth in Appendix G. The inlet regulators shall supply test stations delivery rates below:

3.1.3.1 OC12898, 130 GPM @ 1200 PSIG

3.1.3.2 OC13034, 130 GPM @ 1200 PSIG

3.1.3.3 OC12895, 60 GPM @ 1300 PSIG

3.1.3.4 OC13033, 60 GPM @ 1300 PSIG

3.1.4 The contractor shall modify all main motor pump assemblies and associated manifold connection fluid inputs and outputs, changing them from plumbed pipe manifold connections to flexible hose connections. All supplied hoses shall be conductive covered and electrically grounded. Hoses shall be appropriate for use with MIL-PRF 7024 Type II.

3.1.5 The contractor shall remove, refurbish, and reinstall all Main Pump & motor assemblies and all boost pump and motor assemblies currently in use. New equipment may be added to the RPMS at the contractor’s discretion to meet the flow and pressure requirements set forth in this document. Any new equipment shall be interchangeable

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SOW-H2WC10 Remote Pump Module Page 11 with the existing pump and motor assemblies and be able to be classified as a suitable replacement.

3.1.6 All motor pump assembly inlet and outlet valves on the current configuration shall be replaced with flanged valves which do not require welding or cutting for maintenance or replacement.

3.1.7 The contractor shall install shut-off valves before and after existing Supply Header flowmeter to allow for isolation during removal of meter for calibration. Additionally, contractor shall procure and install a new and calibrated Supply Header flowmeter, equal to or better than existing 4”-CF-021-RE Vortex Flow Meter, for use during acceptance test.

3.1.8 The contractor shall replace the pump rack control laptop currently in use with a panel mount touchscreen computer. The fixed computer/touchscreen unit (control unit) shall be centrally located to the associated test stations located in test bay B3907 Room 115.

The control unit shall be connected to the dedicated RPMS via hardline connection. No wireless networks may be used in the performance of the upgrade. The touchscreen software shall be hosted with InTouch 2014 R2 & the latest USAF-approved Windows Enterprise version. The control unit shall meet or exceed all compatibility and functions of the laptop and local area network (LAN) it is replacing.

3.1.9 The contractor shall remove and replace the electrical enclosure in B3907 room 115 post D7. The new enclosure shall be rated for Class I Div. I applications. All existing hardware in the old enclosure shall be relocated and installed into a new electrical enclosure while maintaining a Class I, Division I, Group D workspace.

3.1.10 The 76 CMXG Commercial Manual for Operation & Maintenance (Appendix G) shall be updated to reflect changes. Contractor shall verify latest Manual version in use prior to making changes. Updated manual shall be provided to the government in Word 2016 or newer.

3.1.11 An Item Parts Breakdown manual shall be created for equipment changes or additions in the performance of this project and provided to the government in Word 2016 or newer. Any previously existing equipment that was not modified is not required to be identified in the IPB. Similarly, any parts of modified equipment that were not altered does not need to be identified in the IPB.

3.1.12 Electrical, hydraulic, and mechanical drawings for modifications made during the modernization of the RPMS shall be updated and provided to the government in AutoCAD 2018 or newer .dwg format.

3.1.13 Testing requirements for all UUTs and subcomponents are detailed in the RPMS commercial data and UUT Technical Order Test Section, provided in Appendix I Contractor shall verify latest Technical Order version in use prior to software development.

3.1.14 Prior to commencement of initial on site work, a pre-job safety meeting shall be conducted with the Contractor, to include but not limited to 76 CMXG Engineering, 76 CMXG Safety, and 76 CMXG Production.

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3.1.15 A pre-construction job review shall be conducted with Contractor prior to modification of any equipment to ensure any active workload in the area is not impacted. Meeting shall include but not be limited to 76 CMXG Engineering and 76 CMXG Production.

3.1.16 Design shall include provisions for connecting RPMS calibration equipment and be similar to existing RPMS configurations.

3.1.17 Appendix G contains a list of items requiring calibration. These items, exactly as listed, shall be provided and incorporated into the stand design. If calibration procedures change, the Contractor shall be responsible for writing and providing updated calibration procedures to the government. Contractor shall be present for initial calibration of the RPMS and shall remain present until calibration of the pump module system is complete. Calibration support shall be provided and be responsible for resolving any calibration issues that may arise from the modifications above within 10 days of identification.

3.1.18 The Contractor shall provide all components that are missing from the RPMS that are required by the modernized design, including any components needed to fulfill modern code and safety requirements set forth by US regulatory entities (Section 2) pertaining to equipment of this nature.

3.1.19 The RPMS shall remain modular in design.

3.1.20 No proprietary hardware, software, or technical data shall be used. The USAF shall have unlimited rights for all technical data and non-COTS software developed for this effort.

All non-COTS source code and technical data developed shall be delivered to the government along with the COTS licenses at the end of the contract.

3.1.21 Test variables shall be indicated one of three ways: red if out-of-limits (OOL)-high, green if in limits, and yellow if OOL-low. Substitutions to colors may be used if approved by government POC.

3.1.22 The footprint size of the existing pump module rack shall remain the same size.

3.1.23 The Contractor shall attend, or conference call, monthly collaboration meetings with

Government POC, including but not limited to 76 CMXG Engineering and 76 CMXG Production, for the purpose of specifying progress to date, any changes to estimated completion date and sharing information to ensure accurate completion of all major milestones to meet performance requirements. Any and all contract date changes shall come through the Contracting Officer for final approval and be submitted by 76 CMXG personnel.

3.1.24 Training Sessions, as detailed in Section 8, shall be provided to include: on-site familiarization and training with the relevant personnel on all operations, maintenance sessions for mechanical maintenance and electrical familiarization, calibration sessions with PMEL personnel, and software/engineering sessions for an overview of maintenance, computer system, and software.

3.1.25 Prior to acceptance, RPMS and subcomponents shall be cleaned to adhere to the cleaning guidelines as defined in the applicable Commercial Data & Technical Order.

Cleanliness of the RPMS is important to satisfactory operation and to promoting a longer life for RPMS equipment and components.

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3.1.26 The calibration fluid flow path shall include appropriate filtration to capture particulate contamination which meets or exceeds allowances specified in Appendix G.

3.2 Construction: With exception to the specific components mentioned above, the RPMS modifications shall be constructed of parts that are new, without defects, and commercial-off-the-shelf (COTS). Quality of materials used in construction shall be equivalent to or superior to those used in construction of the existing RPMSs located in B3907. Metals shall be of corrosion resistant materials appropriate for use with MIL PRF 7024 Type II. The machine construction shall include all components, parts, and features necessary to meet the performance requirements specified herein. All parts subject to damage from environmental hazards shall be sealed or otherwise protected. The machine shall be capable of withstanding all forces encountered during operation of the machine at its maximum rating and capacity without distortion or failure. Welding, plugging, or filling with solder or paste shall not be employed as repair or reclamation measures for defective parts. All screws, pins, bolts and similar parts shall not be allowed to loosen themselves during normal operation of the RPMS. All parts subject to removal or adjustment, shall not be swaged, peened, staked, or otherwise permanently deformed. RPMS shall be built in compliance with Design Guideline 450 as shown in Appendix J. The final modernization design of the RPMS shall be neat, tidy, and conform to relevant industry standards.

3.3 Component Labeling: All RPMS components shall be labeled with an embossed metal tag denoting part number and listed in an Illustrated Parts Breakdown (IPB). All hoses shall also be labeled with an embossed metal tag and hose schedule included in the IPB that details required pressure rating of hose, hose size, length, fluid compatibility requirements, maximum temperature and nominal location. All electrical wiring shall have heat shrink labels (or equivalent) placed on either end of wire and labels and lettering shall suffer no degradation when subjected to any fluids associated with the RPMS.

3.4 Interchangeability: To provide for replacement of worn parts, all parts bearing the same part number shall be functionally interchangeable and dimensionally identical within the manufacturer’s tolerance limits. Replaced parts shall be the latest version available by the equipment supplier so that any replacement parts are available to the customer throughout the life of the equipment.

3.5 Maintainability: The machines shall be designed and constructed to permit effective maintenance. The machines shall be equipped with access covers (if applicable) to facilitate inspection, cleaning, repair and replacement of parts. Filtration or other physical design considerations shall be used to prevent debris that may be carried by return calibration fluid flow from damaging the pumps.

3.6 Lubrication: Means shall be provided to ensure adequate automatic lubrication for all moving parts. Recirculating systems shall include filters which are cleanable or replaceable.

Each lubricant reservoir shall have visible or mechanical means for determining fluid level.

All oil holes, grease fittings and filler caps shall be accessible. Parts consuming fluids shall be clearly identified as such along with the recommended periods of additions and the type of fluid that should be used. Contractor shall recommend a remedial maintenance schedule for servicing the lubrication system for the RPMS.

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3.7 Utilities and Maintenance Access: The Contractor shall provide maintenance access to the control panel, filters, pumps, and other parts requiring periodic maintenance or repair. All equipment access doors, control panels and process sensitive areas shall be lockable. Keying configurations and methods of locking shall be discussed in the design reviews. The Contractor shall label each breaker pulled from the main electrical panel. Electrical schematic(s) shall be attached inside of the control panel with all components labeled and identified. A listing of all components and their ratings shall be provided. Unions and isolation valves shall be placed inline before and after each pump to allow for better maintenance access to the equipment. Catwalks, ladders, platforms, and other access considerations shall be the responsibility of the Contractor. Ladders exceeding twelve (12) feet in height shall contain fall protection. Contractor shall denote on the RPMS main electrical device(s) the source panel name, location and circuit breaker number(s) used to feed the electrical device even if using existing connections.

3.8 Utilities Interconnection: The RPMS is currently connected to all utilities necessary for operation. Any changes to the utilities required by the modernization shall be the responsibility of the Contractor. Any damages to the facility during the modernization of the pump stand shall be the responsibility of the Contractor to remedy. Contractor shall provide and run all conduit, conductors, and all other required electrical components from utility terminals to the stand in order to make the stand fully operational electrically. All interconnections shall maintain the hazardous classifications for both inside and outside the

RPMS.

3.9 Surge Protection: All equipment shall utilize surge protection provided by Contractor with Government approval.

3.10 Modernization Plan: Contractor shall submit a Modernization Plan to the Government POC for review and approval. Modernization Plan shall include:

3.10.1 Installation and design drawings for the RPMS modifications.

3.10.2 Design drawings denotes general locations of major components including, but not limited to pumps, motors, pressure transducers, tanks, conduit sizes, conductor types and sizes, seal off locations, RPMS electrical interconnect drawing and over-current protection devices and sizes.

3.10.3 All subcontractor and partnership information.

3.10.4 Modernization Plan shall be submitted to the Government POC a minimum of ten (10) working days prior to initial work on RPMS. Stand shall not be modified until written approval of plan has been received by Contractor from the Government POC. The government shall have 5 working days to review the Modernization Plan and initiate contact with Contractor to discuss/review/resolve any issues. Following resolution, Contractor shall have 5 working days to resubmit revised Modernization Plan to Government POC for review and approval.

3.11 RPMS Controlled Area: The surrounding test area B3907 room 115 is Class 1 Div. II and the pump module room, B3907 room 116, is Class I Div. I.

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3.12 PC and PLC Control System: Programmable Logic Controller (PLC) shall be Siemens S7-

300. Computer hardware should be such that there is minimal input/output latency and use SSDs in a RAID configuration.

3.12.1 PLC software shall be password protected at three separate levels as noted below:

3.12.1.1 Operator level: allows access for testing at test stations alone. Software changes and access to calibration data are NOT allowed at this level

3.12.1.2 PMEL Tech level: allows access to Operator level as well as Calibration level to permit RPMS calibration including entry of calibration data. Software changes are NOT allowed at this level

3.12.1.3 Administrative level: allows access to all previous levels as well as capability to modify any RPMS software as necessary. Any changes to software shall cause the associated Rev level of the software to change to the next logical level, i.e., Rev.

levels shall not be check sum based.

3.13 RPMS Preliminary/Final Calibration: Calibration process shall be delivered by Contractor for review at Intermediate Design Review. Review comments shall be delivered via the Government POC back to the Contractor within 10 working days. Contractor shall fully incorporate comments as necessary and resubmit revised procedure, prior to Critical Design Review, for review. Following modernization of RPMS at Tinker AFB, Contractor shall complete and prove out the entire approved calibration process prior to contacting PMEL personnel. The preliminary calibration process shall include a Calibration Summation spreadsheet completed by the Contractor detailing the following:

3.13.1 Each item calibrated and calibration results (Pass or Fail).

3.13.2 Initials of technician who performed item calibrated and date the calibration was completed.

3.13.3 As Left values for each item calibrated.

3.13.4 Any alignments or adjustments performed during calibration.

3.13.5 Final Calibration process shall be carried out as follows:

3.13.5.1 Review and perform entire calibration process step-by-step on the RPMS with PMEL personnel present

3.13.5.2 Modify calibration procedure and software as recommended and agreed to by PMEL personnel, as necessary

3.13.5.3 Once the calibration procedure is finalized, revised, and resubmitted by Contractor, PMEL shall formally calibrate the RPMS.

3.13.5.4 Contractor shall have appropriate personnel present during the entire Final Calibration process.

3.13.5.5 Limitations on the calibration are not acceptable and any limitations noted by PMEL shall be fully resolved by Contractor.

3.14 RPMS and As-Built Drawing Review:

Prior to government calibration, contractor shall provide the latest data package to the government.

The government shall verify the accuracy of all As-Built drawings, to include but not limited to

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SOW-H2WC10 Remote Pump Module Page 16 all drawings associated with the project. Document shall include a detailed list of As-Builts including drawing name, date, and rev level of each drawing.

Contractor shall also hire an independent Consultant to verify the accuracy of all As-Built drawings, COM data and all other submitted documentation required as a part of this contract.

Following review, Consultant shall list all deficiencies noted and submit list to Contractor for correction. All deficiencies shall be corrected by Contractor prior to final documentation submittals unless otherwise approved by 76 CMXG/ENC Engineering. Once finalized, Consultant shall submit a signed and dated document noting that As-Built drawings, COM data and all other submitted documentation are 100 percent accurate. Please note that Level 3 drawings as per MIL- STD-31000B are required.

3.15 Software: The Contractor shall procure or develop software to allow control of the RPMS functions and include a test mode for authorized users to use for troubleshooting purposes.

The software shall perform data acquisition, conversion, limit, and alarm checking, data logging, real time calculations, control loop updates, initiate data saves and computations.

3.16 Executive Software: Contractor shall transfer all executive software that is currently installed on HMI laptop and re-install on new the new panel mount touch screen HMI. The Executive Software shall run on the latest Air Force approved Windows OS platform.

Occasionally, a Windows OS may freeze or lock up when a software program performs an illegal operation, or it may include an Interrupt Request line (IRQ) conflict, incompatible device driver, virus, etc. To prevent such problems, all software updates to OS, device drivers, or anti-virus software or the addition of hardware shall be performed by an authorized software maintainer. A password protected Administrative level shall be used to limit user access to executive software including drives, read/write access, and OS privileges in order to prevent transfer of viruses or unwanted data. However, if it is suspected that a host computer is infected with a computer virus, a qualified user shall be able to initiate a system scan. In the event of Windows OS lock ups, a manual E-stop switch shall allow the operator to bring the RPMS and the test stations to a safe condition.

3.17 PC and Software Security: The contractor shall take the following necessary steps to ensure Government data is safeguarded and secure.

3.17.1 The contractor shall protect Government data by implementing safeguards addressing, at a minimum, the 15 listed areas, which corresponds with the following NIST security controls: AC-6, AC-3, AC-20, CA-3, SC-7, AC-22, IA-2, IA-8, MP-6, PE-3, SI-2, and

SI-3.

3.17.2 The contractor shall ensure that details about the safeguards for protecting critical program information are not disclosed or published without written consent of the Contracting Officer.

3.17.3 The contractor shall allow the Government access to facilities and resources necessary to execute an inspection program to verify that Government data is secured.

3.17.4 The contractor shall Safeguard all DoD covered defense information in accordance with DFARS Clauses 252.204-7008, “Compliance with Safeguarding Covered Defense Information Controls” (AUG 2015) and 252.204-7012, “Covered Defense Information and Cyber Incident Reporting” (SEP 2015) on all information systems that are owned, 29 April 2022

SOW-H2WC10 Remote Pump Module Page 17 or operated by or for, a contractor and that processes, stores, or transmits covered defense information (SSE Guidebook V1.1, p. 41).

3.17.5 The contractor shall report cyber incidents in accordance with DFARS Clauses 252.204- 7008, “Compliance with Safeguarding Covered Defense Information Controls” (AUG 2015) and 252.204-7012, “Covered Defense Information and Cyber Incident Reporting” (SEP 2015) (SSE Guidebook V1.1, p. 59).

3.17.6 The contractor shall ensure cloud computing services adhere to the requirements in DFARS Clauses 252.239-7009, “Representation of Use of Cloud Computing” (SEP 2015) and 252.239-7010, “Cloud Computing Services” (AUG 2015) (SSE Guidebook V1.1, p. 46).

3.17.7 The contractor shall insure that system administrators have access to perform mandatory patch management and security scans in order to comply with current AFSC System Maintenance Plan and Information System Configuration Management.

4. Acceptance Tests

4.1 Acceptance Testing with Baseline Data: Baseline data is condition monitoring information that is representative of equipment in a new and / or properly operating condition. The baseline data is the foundation of the predictive trending analysis required to forecast equipment condition. Baselining, including Equipment Health Checkout, is detailed in Appendix B and shall be completed by personnel from 76 MXSG/MXDEQ. This effort shall be performed following Final Calibration of the RPMS and prior to commencement of Correlation Testing and shall be attended by a Contractor’s technical representative.

4.2 Vibration Baseline Testing: Contractor shall complete a vibration baseline for each motor, motor/drive and pump/motor combination. All data shall be taken in accordance with ISO10816-3 and acceptable vibration levels are as per the “New machine condition” range detailed in the ISO 10816-3 Vibration Severity Chart (see Appendix B). This data shall form the vibration baseline for each motor and pump/motor combination, provided all data is in Good Condition or better, as per ISO10816-3. Vibrations that are unacceptable as per the ISO 10816-3 Vibration Severity Chart, New Machine Condition shall be remediated prior to install. Vibration data shall be submitted to Government POC for review prior to modification of RPMS.

4.2.1 Following Final Calibration of the RPMS at Tinker AFB and prior to Correlation Testing, all motor and pump/motor vibrations shall be re-checked by 76 MXSG/MXDEQ personnel. Any vibration reading that has increased by twenty-five

(25) percent or more from factory readings or falls outside of New Machine Condition, as per ISO 10816-3 Vibration Severity Chart shall be remediated by Contractor, at no cost to the government. Following successful remediation, a final vibration report noting all components/combinations tested, Root Mean Squared (RMS) and “Derived Peak” vibration data in inches per second (in/sec) as read at Tinker by Contractor and by 76 MXSG/MXDEQ shall be completed by Contractor and submitted to the Government POC for review. Report shall also include class of motor, motor/drive and pump/motor combination tested and zonal results, all as per ISO10816-3.

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4.3 Monthly Status Report: A one-time Integrated Master Schedule (IMS) shall be provided to the Government POC ten (10) working days following contract award for approval.

Afterwards, the contractor shall provide a monthly status report to the Government POC as an update on the current status of the project in relation to the IMS, the current and subsequent month’s priorities, along with any concerns or constraints.

4.4 Test Plan: The test plan shall address all testing requirements specified in Appendix F and in section 4. Contractor shall clearly identify: tests to be performed, test points, evaluation criteria, and a testing schedule to assure complete compliance with this SOW.

4.5 Training Plan: The training plan shall address all training requirements specified in section

8. The Contractor shall clearly identify content and scheduling of the training in such a manner as to assure complete compliance with this SOW. All training shall occur during normal operation times and be scheduled at least 10 working days in advanced of the scheduled training. Instruction shall be conducted after successful operational testing and approved implementation audit. Trainers shall use a sign-in sheet to record personnel attending the training sessions. The Government shall supply the sign-in sheet(s).

4.6 Warranty: The Contractor shall warranty all equipment and workmanship free of defects for a period of no less than 730 calendar days. The Contractor shall be notified of defects by the Government in writing. The Contractor shall respond to all reported problems within twenty-four (24) hours or less. Defects shall be remedied at no cost to the Government within 14 calendar days. Contractor shall be responsible for correcting any found defect or inconsistency with this SOW to the Government’s satisfaction. If the defect or inconsistency persists beyond the 730 calendar day period or the standard warranty period, whichever is longer, the Contractor shall still be responsible for corrective action until the issue is rectified. All equipment shall be subject to usage 24 hours a day, 7 days a week. Warranty shall start after all training, implementation audit(s), testing, deliverables, and final approval(s) are completed and the Government POC has issued their final acceptance of the

RPMS.

4.6.1 Any spills caused by an equipment defect shall be cleaned up within two (2) hours at no cost to the Government. Contractor shall be responsible for damages caused by the defect and for any damages to the facility during the modernization period. All materials and labor for corrective action, modifications, and defects shall be supplied by the Contractor, including a tracking number and carrier name e-mailed to the Government POC. The period of performance for this contract shall include a minimum of two (2) year warranty. The warranty shall not be considered null and void if governmental personnel are required to perform emergency shutdown or repairs to the equipment due to a defect that present a clear and present danger, such as could cause grave damage to the environment (i.e. toxic release of chemicals), present a health hazard to personnel working in and around the equipment, or presents a safety hazard to the building, personnel within the building or other equipment surrounding the Contractor’s equipment.

4.6.2 Contractor shall provide a method for reporting problems encountered with RPMS following modification and throughout the warranty period. Upon receipt of problem report, Contractor shall analyze and respond with their planned corrective action and recommendations to the Oklahoma City Air Logistics Center (OC-ALC). Problem

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SOW-H2WC10 Remote Pump Module Page 19 reports shall be classified as by the OC-ALC as urgent or routine. Initial response time for urgent problem reports shall be forty eight (48) clock hours or less. Initial response time for routine problem reports shall be seven (7) calendar days. Contractor shall provide contact information (phone, e-mail address at a minimum) for a primary and back-up POC for reporting problems.

5. QUALITY ASSURANCE PROVISIONS

5.1 Responsibility for Inspections: The Contractor shall be responsible for the performance of all inspection requirements as specified herein. The Government reserves the right to perform any inspections set forth in the specification where such inspections are deemed necessary to ensure the machine, supplies and services conform to the prescribed specifications. The Contractor shall provide all tooling, fixtures, measurement indicating devices, material, and programs required for compliance, accuracy, alignment, and machining inspection.

5.2 Responsibility for Compliance: All deliverables shall completely meet the requirements of Section 3. The inspections set forth in this specification shall become a part of the Contractor’s overall inspection system or quality program. The absence of any inspection requirements in the specification shall not relieve the Contractor of the responsibility of ensuring that all products or supplies submitted to the Government for acceptance comply with all requirements of the contract. Sampling inspection, as part of manufacturing operations, is an acceptable practice to ascertain conformance to requirements, however, this does not authorize submissions of defective material, either indicated or actual, nor does it commit the Government to accept defective material.

5.3 Examination: The RPMS shall be visually examined to determine compliance with all requirements within section 3.

6. Design Reviews

6.1 Preliminary Design Review: The Contractor shall provide a Preliminary Design Review (PDR). The design review shall be completed at the five to ten percent (5-10%) RPMS design stage, no later than 30 calendar days after contract award. The Contractor shall be required to conduct a meeting at the OC-ALC for the Preliminary Design Review. The Government POC shall coordinate and attend the on-site meeting with the Government Technical Point of Contact (POC) and the Contractor. The Contractor shall submit two (2) complete hard copy data packages and one (1) electronic data package. These packages shall include the engineering data, specifications, certificates, and reports and final products including catalog excerpts and salient characteristics. The submittal shall be sent to the Government POC no later than (NLT) fourteen (14) calendar days prior to the on-site meeting. The Government POC shall provide the two (2) complete hard copy data packages and one (1) electronic data package to the Government Technical POC within two (2) working days of receipt of the packages from the Contractor in order to allow time for the Government Technical POC to review prior to the on-site meeting. The Contractor shall be responsible for taking minutes during the on-site meeting and shall provide one (1) electronic

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SOW-H2WC10 Remote Pump Module Page 20 copy, via email or CD-ROM, to the Government POC NLT seven (7) calendar days after the meeting date.

6.1.1 Personnel from Tinker Bio-environmental, Fire Department, Safety, Quality,…