SOW.docx

Statement of Work (SOW) Environmental Lab - P1904 MILCON Building

Test System Equipment & Support Services

1.0 BACKGROUND AND SCOPE

1.1 BACKGROUND

Naval Air Warfare Center Weapons Division (NAWCWD) Life Cycle Environmental Engineering (LCEE) Branch provides environmental design and test requirements for weapon and target airframes, guidance, navigation, and control systems, and related equipment. Engineering, technical support, and facilities are utilized to perform environmental testing simulating the effects of climatic, induced thermal, dynamic, and loads environments in support of development, design, environmental qualification, airworthiness, product improvement, and failure investigations of Department of Defense (DOD) weapon and target systems across all services. The LCEE Branch also coordinates standardization efforts regarding national and international documents covering safety and suitability for service of weapon materiel and systems as affected by climatic, induced thermal, dynamic, and loads environments.

1.2 SCOPE

NAWCWD is purchasing new test system equipment for the new P1904 military construction (MILCON) building, along with design services to support the design/build phase of the P1904 MILCON building contract. The new equipment will be installed within the P1904 MILCON building tentatively scheduled for contract award in March 2021 with building completion in June 2023. In addition to providing the equipment and design services, the Contractor will provide Lead System Integration to ensure the equipment is properly integrated, installed, and commissioned within the P1904 MILCON building. The equipment will include a six degree-of-freedom (DoF) vibration test system, a shipboard shock and carrier takeoff and landing shock test system, a multi-DoF underwing vibration test system, a static load and low cycle fatigue test frame and associated equipment, a high impact drop shock test machine, an acoustic progressive wave tube test system, an aerodynamic radiant heat test system, a centralized hydraulic power supply and piping system, a centrifuge acceleration test system, a tensile/compression test machine, two general purpose vibration test systems, climatic, salt fog, and dust environmental test chambers, and shop equipment.

Because of the equipment complexity and criticality of building structural and functional interface, design services in support of the design/build phase of the P1904 MILCON building contract will include detailed equipment/building interface design/analyses and associated information and coordination with the building contractor.

2.0 APPLICABLE DOCUMENTS

2.1 MILITARY STANDARDS

2.2 INDUSTRY STANDARDS

3.0 REQUIREMENTS

The contractor shall supply equipment that meets the standards and/or characteristics described in the sections below. The contractor shall also provide design and lead system integration services, project management, delivery/storage, installation and training.

3.1 High Frequency Six DoF Vibration Test System Specifications The contractor shall provide High Frequency Six DoF Vibration Test System. This system subjects a test article to a realistic simulation of the field environment in which it will be handled, transported and operated. The system applies vibration loads to the test article in multiple degrees of freedom simultaneously, in all linear and rotational directions and with controllable coherence and amplitudes between axes. The system shall have the following characteristics:

· Twelve each shakers bearing upon a single table;

· Each shaker shall be coupled to the table through a preloaded hydrostatic combination planar and spherical bearing;

· Minimum of 3,500 lbf rms (pound-force root mean square) per axis;

· 1-inch peak-to-peak displacement;

· +/- 4 degree rotation around each axis;

· 2 kiloHertz (kHz) bandwidth defined as a flat random profile from 10 Hertz (Hz) through 2 kHz, with response remaining within +/- 3 decibel (dB) tolerance bands;

· 100-pounds (lbs) payload weight;

· 30-inch square specimen mounting surface;

· Automatic load biasing and table leveling;

· Integral air isolated reaction mass;

· Integrate with 460 Volts of Alternating Current (VAC)/60 Hertz (Hz)/3 phase supply voltage;

· Local and remote control of system subassemblies;

· 12 output multi-axis control system with sine, random, mixed mode and time replication software packages

3.2 Shipboard Shock and Carrier Take-off and Landing Test System The contractor shall provide Shipboard Shock and Carrier Take-off and Landing Test System. This system simulates the mechanical shock effects of near field underwater explosions on Subsidiary Components located on naval vessels. It also simulates the effects of acceleration and deceleration transients experienced by naval aircraft during Carrier launch and recovery operations. The system shall be configured with two major sub-assemblies, a dedicated vertical system and a dedicated horizontal system.

3.2.1 Vertical Shipboard Shock and Carrier Take-off And Landing Test System

· Single vertically oriented actuator;

· Provide excitation over a 500 Hz bandwidth;

· 10 ½ inch of peak-to-peak displacement;

· 45,000 lbf peak;

· 11 ½ feet per second (138 inches per second) velocity transient capability;

· 36 inch square specimen mounting area;

· Local and remote control of all subassemblies;

· Actuator and table mounted upon an air isolated reaction mass of no less than 20,000 lbs and an isolation frequency less than 3 Hz;

· Up to 1,200 lbs test specimen weight;

· Single axis test controller with sine, random, mixed mode, shock, shock response spectrum (SRS) and time waveform replication software

3.2.2 Horizontal Shipboard Shock and Carrier Take-off and Landing Test System The contractor shall provide Horizontal Shipboard Shock and Carrier Take-off and Landing Test System with the following characteristics:

· Single horizontally oriented actuator with linear hydrostatic slip table permanently installed;

· Slip table to have a minimum of 0.46 x 106 in-lbs of both pitch and roll moment;

· Provide excitation over a 500 Hz bandwidth;

· 10 ½ inches of peak-to-peak displacement;

· 45,000 lbf peak;

· 11 ½ feet per second (138 inches per second) velocity transient capability;

· 36 inch square specimen mounting area;

· Local and remote control of all subassemblies;

· Actuator and table mounted upon an air isolated reaction mass of no less than 20,000 lbs and an isolation frequency less than 3 Hz;

· Up to 1,200 lbs test specimen weight;

· Single axis test controller with sine, random, mixed mode, shock, SRS and time waveform replication software

3.3 Multi-Degree-Of-Freedom (MDoF) Underwing Test System

The contract shall provide Multi-Degree-Of-Freedom (MDoF) Underwing Test System. The MDoF Underwing Test system excites suspended stores while maintaining 5 degrees of freedom control. The degrees of freedom control are Vertical and Lateral translation, Pitch, Roll and Yaw. The system shall be configured to provide the following characteristics:

· Total force in the vertical axis – 140,000 lbf peak, 45,000 lbf rms;

· Total force in the horizontal axis – 70,000 lbf peak, 23,000 lbf rms;

· Displacement in each axis – 3.5 inches peak-to-peak;

· Velocity – 60 inches per second;

· Bandwidth of excitation – up to 500 Hz;

· Maximum dimension of payload – 12 feet long, 36” in diameter;

· Maximum weight of payload – 2,000 lbs;

· Vertical actuators mounted onto air isolated cantilevered mass;

· Horizontal actuators mounted onto reaction mass configured to isolate energy transmission;

· Test Specimen load/unload system;

· Static Load Test fixture designed to apply constant static load upon suspended store throughout vibration excitation;

· 4 each shakers, 13,500 lbf rms with isolated trunnions. Include needed stinger to attach each shaker to suspended store and provisions to allow stinger/store interface to traverse the displacement in each degree of freedom generated by out of phase actuation;

· 10 output test controller with sine, random, mixed mode, shock and time waveform replication software;

· Design calculations for reaction mass structure

3.4 Static Test Frame and Test Components

The contract shall provide Static Test Frame and Test Components. This system is used to input static and low cyclic rate loading to failure on various test objects. The system shall be modular to permit the user to reconfigure as necessary to accommodate a variety of test objects. The system shall have the following characteristics:

· T-slot bed plate embedded into laboratory floor, approximately 15 feet by 15 feet;

· 16 each heavy duty I-beams designed to be anchored to the bed plate in the vertical orientation at user selectable location;

· I-beams to be configured to permit flexibility in mounting both actuators and test object anchoring systems;

· Required linear actuators:

· 8 each 27 kip, +/- 5” stroke, 10 gallons per minute (gpm) valve, hose set with Quick Disconnects (QDs), Linear Variable Differential Transformer (LVDT) and base swivel;

· 8 each 20 kip, +/- 5” stroke, 10 gpm valve, hose set with QDs, LVDT and base swivel;

· 4 each 12 kip, +/- 5” stroke, 10 gpm valve, hose set with QDs, LVDT and base swivel;

· 2 each 50 kip, +/- 5” stroke, 10 gpm valve, hose set with QDs, LVDT and base swivel;

· 3 each Preload Fixture, 30,000 lbs capacity;

· 2 each Preload Fixture, 50,000 lbs capacity;

· 1 each Storage Rack for actuators;

· Required rotary actuators:

· 2 each 30,000 in-lbs, +/- 50 degrees, 10 gpm valve, hose set with QDs, Rotary Variable Differential Transformer (RVDT);

· Hydraulic rams:

· 6 each Dual action 20,000 lbs

· Hydraulic Ram pumps:

· 6 each manual;

· 3 each electric

· Instrumentation:

· 8 each Load Cell, 10,000 lbf;

· 8 each Load Cell, 20,000 lbf;

· 8 each Load Cell, 5,000 lbf;

· 4 each Load Cell, 50,000 lbf;

· 1 each Load Cell, 200,000 lbf;

· 3 each Dual Pressure Transducer Valve Mounting Manifold;

· 2 each Hydraulic Flow Meter, 20 gpm;

· 3 each Torsional Load Cell 30,000 in-lbs

· Hydraulic Supply and Manifold:

· Hydraulic Power Supply, 40 gpm at 3,000 pounds per square inch (psi), quiet version;

· 8 each Hydraulic Conditioning Manifold with QDs

· All equipment compatible with existing MTS FlexTest controller

3.5 Drop Shock Machine

The contract shall provide Drop shock Machine. This system is used to produce varying duration, very high shock pulses into payloads up to 100 lbs. The system shall have the following characteristics:

· 125 lbs payload;

· 24-inch square table payload mounting surface;

· Maximum acceleration of 10,000 x g with tolerance of +/- 10%;

· Minimum pulse duration with 125 lbs payload must be 0.5 milliseconds (msec) ½ sine

3.6 Progressive Wave Tube

The contract shall provide Progressive Wave Tube. This system is used to reproduce the acoustic sound pressure level environments. The system shall have the following characteristics:

· Interior payload mounting dimensions of 4 feet x 4 feet by 12 feet long;

· Means to suspend payload from upper surface, maximum payload weigh 2,000 lbs;

· Operates using Nitrogen gas;

· Test duration of at least 30 minutes;

· Able to accommodate future capabilities by adding up to two additional acoustic noise sources;

· Design calculations to manage exterior noise levels in surrounding facility areas;

· Able to generate the following acoustic profiles to levels up to 170 dB overall sound pressure level

3.7 Radiant Heat System

The contract shall provide Radiant Heat System. This system simulates the surface heating weapon systems are exposed to during flight. The system shall have the following characteristics:

· Able to generate surface temperatures up to 2,500 degree F;

· Able to be configured to efficiently handle test objects from small panels (12 inches square) up to large weapon systems 4 feet in diameter and 16 feet long

3.8 Central Hydraulic Power Supply (HPS) and Piping System

The contract shall provide Central Hydraulic Power Supply (HPS) and Piping System. This system provides the needed hydraulic flow required to operate all hydraulic test systems. The piping system conducts the flow to and from the hydraulic power supply to the various locations where the test systems are located. The contractor shall design and fabricate a hydraulic power supply using good industrial design practices and the system shall have the following characteristics:

· Adequate pressure to produce the force required at the various test systems, with pressure drop due to long piping runs taken into account;

· Oil temperature in the reservoir shall be maintained to ensure the viscosity of the hydraulic fluid is within design tolerances;

· Flow demand will vary from zero to maximum flow during test system operation. Cooling system shall maintain desired reservoir temperature under all flow demand conditions. The HPS is required to maintain full pressure at zero flow conditions for indefinite periods of time;

· Oil cleanliness standard to be maintained in reservoir equal to or less than (International Organization for Standardization) ISO 16/14/11;

· Return line back pressure shall be considered in the design to minimize potential for high speed cavitation;

· The system shall be fitted with the appropriate sensors, switches, and interlocks to provide warning and abort operation if set points are exceeded;

· Good industrial practices shall be used in the design and fabrication of the reservoir to ensure oil has sufficient dwell time to de-aerate;

· The hydraulic pipe used in the distribution system shall be fabricated from material specifically developed for tight tolerance hydraulic operated mechanical systems. Also, upon completion, the entire piping system shall be certified as clean prior to system start up. The diameter and layout of the piping system shall minimize the pressure drop from the HPS to the furthest distant test system. Any hoses used for interconnecting the test systems and the piping system shall be properly sized for the maximum flow rate, have the appropriate safety factor and use leak-tight end fittings. The Government shall verify all hoses are clean prior to system start up. A number of access points to the piping distribution system shall be provided, with the appropriate isolation valves, check valves and other devices needed to facilitate safe connection/disconnection of test equipment.

3.9 Centrifuge

The contract shall provide centrifuge that is used for testing component level equipment. It shall have the following characteristics:

· Maximum payload dimension, 24-inch cube minimum;

· Maximum payload weight, 200 lbs per arm;

· Acceleration range, 0 to 200 x g at 44 inch radius;

· Maximum G lbs, 20,000;

· Rate range, 0 to 400 revolutions per minute (rpm);

· Slip rings numbering at least 100;

· Complete operator interface controls;

· Operate on 230 VAC/60 Hz/3 phase with a 70 amp service

3.10 Material Test System

The contract shall provide Material Test System. This system tests the compression and tensile strength of material and other equipment. The system shall have the following characteristics:

· Load capacity of at least 10,000 lbf, +/- 0.5% from 1% to 100% full scale;

· Encoder resolution, 0.0004 inches;

· Actuator Stroke, 8 inches;

· Materials and Product Testing software control

3.11 24-Inch Slip Table Vibration Test System The contractor shall provide 24-inch Slip Table Vibration Test System. The system shall have the following characteristics:

· 25,000 lbf rms with +/- 3 inch displacement;

· 5 Hz to 2 kHz operating bandwidth;

· Shaker system fitted with a 24 inch square horizontal slip table

· Slip table to incorporate low pressure (600 psi) linear hydrostatic bearings;

· System to have a 24 inch diameter head expander;

· System to be mounted upon an air isolated reaction mass with the ability of the shaker to be oriented either vertically or horizontally;

· All amplifier, cooling systems, and remote control panels necessary for operation to be included

3.12 36-Inch Slip Table Vibration Test System The contractor shall provide 36-inch Slip Table Vibration Test System. The system shall have the following characteristics:

3.13 Environmental Chambers

The contractor shall provide environmental chambers. The system shall have the following characteristics:

3.13.1 Dust Chamber

· Interior dimensions, 36 inch x 36 inch x 36 inch;

· Electrical power requirement, 115 VAC/60 Hz/1 phase 15 amp circuit

3.13.2 Temperature/Altitude/Humidity Walk-in Chamber

· Interior dimensions, 7 feet wide x 14 feet long x 8 feet high;

· Temperature range, - 100 degree F to 350 degree F;

· Humidity range, 20% to 95% relative humidity (RH);

· Temperature/Humidity control, +/- 1.1 degree C, +/- 5% RH;

· Altitude range, ambient site pressure to 100,000 feet;

· Chamber fitted with man access door and large product loading door;

· Control and data collection system

3.13.3 Temperature/Altitude/Humidity Chamber

· Interior dimensions, 48 inches x 48 inches x 48 inches;

· Temperature range, -100 degree F to 350 degree F;

· Humidity range, 20% to 95% RH;

· Temperature/Humidity control, +/- 1.1 degree C +/- 5% RH;

· Altitude range, ambient site pressure to 100,000 feet;

· Control and data acquisition system

3.13.4 Temperature/Humidity Chamber (2 each)

· Interior dimensions, 48 inches x 48 inches x 48 inches;

· Temperature range, -100 degree F to 350 degree F;

· Humidity range, 20% to 95% RH;

· Temperature/Humidity control, +/- 1.1 degree F +/- 5% RH;

· Rain Test Capability Option in accordance with MIL-STD-810, Method 506.6, Procedures II and III (One chamber only);

· Solar Radiation (Sunshine) Test Option Capability in accordance with MIL-STD-810, Method 505.7, Procedure II (One chamber only);

· Control and data acquisition system

3.13.5 Automated Thermal Shock System

· Payload dimensions, 25 inches x 25 inches x 25 inches;

· Payload weight, 120 lbs;

· Temperature range, hot zone, 140 degree F to 390 degree F;

· Temperature range, cold zone, -100 degree F to 350 degree F;

· Control and data acquisition system

3.13.6 Temperature Chamber with Blower

· Interior dimensions, 24 inches x 26 inches x 28 inches;

· Temperature range, -90 degree F to 350 degree F;

· Temperature control, +/- 0.5 degree F;

· Remote conditioning blower, 500 cubic feet per minute (cfm);

· Control and data acquisition system

3.13.7 Salt Fog Chamber (2 each)

· Interior dimensions, 96 inches x 48 inches x 36 inches;

· Able to meet wide range of accelerated corrosion tests such as American Society for Testing and Materials (ASTM) G85;

· Control and data logging system

3.14 Miscellaneous Shop Equipment

The contractor shall provide miscellaneous shop equipment that includes a belt sander, drill press, and lathe.

3.14.1 Belt Sander

· 4-inch x 36-inch belt;

· Vertical/Horizontal operation;

· Adjustable work table

3.14.2 Drill Press

· Variable speed;

· T-slot bed and base;

· ½ inch chuck;

· Keyless chuck;

· 3/8 inch to 1 inch chuck;

· Arbor adaptors

3.14.3 Lathe

· 13 inch x 40 inch geared head;

· 6 inch D1-4 3 jaw chuck;

· 6 inch D1-4 4 jaw chuck;

· Backing plate

3.15 LEAD SYSTEM INTEGRATOR & DESIGN SUPPORT SERVICES

The contractor shall serve as the lead system integrator in support of the design/build phase of the facility-building contract collaborating with the building contractor to ensure the following:

· Adequate electrical power, with appropriately sized circuit breakers located convenient to the test equipment being powered in both the laboratory and machinery space;

· Adequate cooling water to satisfy equipment requirements;

· Adequate pneumatic supply to satisfy equipment requirements;

· Design and performance specifications of any in-ground reaction mass(s) that may be needed. Special attention to be paid to energy transmission mitigation into surrounding sub-soil;

· Access to simplify load/unload test equipment;

· Maintenance access to all equipment in both laboratory space and machinery room;

· Rejected heat load into laboratory space and machinery room to optimize heating, ventilation and air conditioning requirements

3.16 PROJECT MANAGEMENT

The contractor shall provide general project management support for the project. Functions include managing and administrating the contracted effort. The Project Manager serves as the primary interface and point of contact with Government project authorities on technical and project issues. Specific activities include a kick off meeting held at NAWCWD, China Lake, CA, between the contractor and government stakeholders within two months of receipt of contract award, monthly telecom meetings held throughout the duration of the design and fabrication process, and an on-site equipment pre-installation meeting at NAWCWD, China Lake, CA (CDRL A001).

3.17 DELIVERY/STORAGE

The contractor shall deliver all equipment to the site of the P1904 MILCON building located on main base NAWCWD, China Lake, CA. The contractor shall receive authorization from the Government technical point of contact prior to shipment and/or delivery of any equipment. If the Government is not ready to receive delivery of the equipment, it will be necessary for the contractor to store/warehouse the equipment until instructed by the Government to deliver. Equipment storage/warehouse needs may be necessary for up to 12 months. All tasks associated with the shipment, delivery, and storage/warehouse is the responsibility of the contractor.

3.18 INSTALLATION

The contractor shall install all equipment procured under the contract. Installation activities will include:

1) Supervise the uncrating and placement of each set of equipment;

2) Anchor the equipment to the facility floor or reaction mass, as necessary;

3) Interconnect system components as required;

4) Perform agreed upon commissioning and validation tests Note: all lifting and rigging, including the supply of needed equipment, shall be performed by NAWCWD personnel. Connection of electrical power, cooling water and other building utilities shall be performed by NAWCWD personnel.

3.19 TRAINING

The contractor shall provide a one-time training on the operation and periodic maintenance of each set of equipment after installation. The training shall be conducted on site at the P1904 MILCON building, NAWCWD, China Lake, CA. Training will include:

1) Familiarization with the general layout of the equipment;

2) Detailed instruction on any control systems provided with the equipment;

3) Detailed instruction on how to safely initiate, perform and terminate a test;

4) Detailed instruction on maintenance tasks required on a periodic basis to maintain equipment in operational readiness The contractor shall provide Operational and Maintenance Manual for each equipment set (CDRL A002).

3.20 CDRLs (Contractor Data Requirements Lists)

Specific items of meeting minutes and operation/maintenance instructions shall be provided in accordance with the applicable CDRLs.

Table 1. CDRL List

4.0 PLACE OF PERFORMANCE

The contractor shall perform the work at their own facility and at NAWCWD, China Lake, CA. Approximately 22% of this work will be performed at NAWCWD, China Lake, CA and 78% conducted at the Contractor’s place of business.

5.0 SECURITY

5.1 Unclassified Contract

In the case of an unclassified contract, that requires no access to Classified Military Information (CMI), but that does require access to Controlled Unclassified Information (CUI), NAWCWD Restricted Areas, and/or Government Information Technology (IT) systems, contractors are required to comply with non-NISP (National Industrial Security Program) processing requirements before local access to CUI, Restricted Areas, and IT can be granted. This process shall be coordinated by the Contracting Officer’s Representative or Technical Point of Contact through the NAWCWD Industrial Security office.

5.2 IT Security: Access to CUI, FOUO, and/or Government IT Systems Information Security. Direct Support contractor personnel working under the purview of a DoN Commanding Officer/Commander shall comply with the local security provisions and the requirements of SECNAV M-5510.36 (series). The contractor shall implement and maintain security procedures and controls to prevent unauthorized disclosure of controlled unclassified information and to control distribution of controlled unclassified information in accordance with DoD 5220.22-M, National Industrial Security Program Operating Manual (NISPOM), and SECNAV M-5510.36.

For Official Use Only information generated and/or provided under this contract shall be marked and safeguarded as specified in DoDM 5200.01, Information Security Program Manual (Volume 4) available at http://www.dtic.mil/whs/directives/corres/pdf/520001_vol4.pdf . Contractor shall not store or transmit CUI on personal information technology systems or via personal e-mail. Unclassified e-mail containing any DoD CUI shall be encrypted. Prior to sending CUI to any non-Navy Marine Corps Internet (NMCI) addressees, the sender must first positively verify all recipients are authorized access to CUI and have need-to-know. Non-NMCI recipients must have a DoD compliant Private Key Infrastructure (PKI) certificate that enables electronic transmission via unclassified networks while protecting the CUI with a digital signature and encryption.

5.3 Public Disclosure of Information

Public Release. Disclosure of information is covered by DFARS 252.204-7000 Disclosure of Information, incorporated in Section I of the contract. Concerning subsection (a)(2), “information otherwise in the public domain” is information officially released into the public domain, e.g. via Distribution Statement A, and does not include information in the public domain that has not been officially released. For disclosure of unclassified information that has not been officially released, the contractor must seek specific approval from the Contracting Officer, with approval from the NAWCWD Public Affairs Office (PAO).

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