Statement of Work_3D CT Scanner_Draft_5 August 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, assembling, and verification/calibration of a commercially available 3 Dimensional Computed Tomography Scanner (3D CT Scanner) for metal parts. The CT Scanner shall be utilized to inspect and measure surface and subsurface features of parts/assemblies without destroying the asset. The CT scanner shall accomplish the inspections via 3D CT & 2D X-ray scans in both micro and macro magnifications. The vendor 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/vendor technical personnel.

2.0. 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.

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 – Test procedures and instructions shall be provided for identification, location and repair of mechanical, electrical and electronic failures. 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 gage. Automatic processes of lubrication shall have a warning device to indicate when lube oil is low or system failure.

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. 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:

a. “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.”

b. “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.”

c. “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.

2.12. Scanning Capability:

a. The CT scanner will automatically capture, render, and provide basic analysis of standard 3D X-ray computed tomography data.

b. The CT scanner will automatically capture, render, and provide basic analysis of standard 2D X-ray computed tomography data.

c. The CT scanner shall be capable of conducting real-time analysis 2D X-ray computed tomography data:

I. Live image video capture

II. Still image capture III. Frame integration and averaging

d. The CT scanner shall be capable of conducting time and motion analysis 3D X-ray computed tomography data.

e. 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.

f. The vendor shall prove system capability prior to the awarding of the contract by successful non-destructive scanning of standard samples provided by the USAF requesting organization. Vendor will return the supplied standard sample along with scan results and system configuration for the scan (e.g.

voltage, number of frames, working distance, time of scan, etc.).

I. 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 A and B that will be provided to vendors bidding on solicitation.

II. 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.

g. The CT scanner will be able to scan and automatically stitch together 2D and 3D CT scans to provide a montage or #D model rendered view of parts larger than the detector window.

h. The CT Scanner shall be capable of performing 2D CT slice reconstructions.

i. The CT Scanner shall be capable of performing CT volume reconstruction for 3D inspections.

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

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

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

i. 225 kV micro focus range

a. <10 micron focal spot

b. Adjustable energy: 25kV – 225KV

c. Adjustable current: 0 mA – 3 mA

ii. 450 kV mini focus range (minimum)

0.4 and 1.0 mm focal spot per EN 12543

Adjustable energy: 10kV – 450KV

Adjustable current: 0 mA – 4.0 mA

iii. Automatic tube switching if multiple tubes are used

b. Detector

i. Type: Flat panel digital detector

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

iii. Maximum detector pixel size: 200 micron

iv. Minimum Resolution:16 bit

v. Minimum frame rate: 15 FPS @ full resolution

vi. Gadox scintillator screen

vii. Sensitivity: Ultra High

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

c. System Motion

i. System motion shall provide at least 3-axis of motion that allows:

The X-ray source and detector independently to travel between 8 and 59 inches away from the center vertical axis of the scan volume, at minimum.

The distance between the source and detector must have a range of 8-70 inches or greater.

An angular or rotational fourth degree of motion must provide 360 degrees of functional scanning of the scan volume.

d. Manipulator control

i. Automated control of all axis for CT imaging

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

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

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

e. Interior Lighting

f. X-ray tube control and monitoring

g. Complete control and monitoring of all manipulation axes

h. Capability to vary focal distance from 0 to 45 inches as measured from tube head

3.2 Radiation Source and Detector – The X-ray tube and detector should be adjustable to provide a larger working volume for large parts. System should be capable of supplying 220 KV and 450 KV X-ray source power.

3.3. Chamber Size - The CT Scanner must have a minimum of a 3X3X3 ft cube scan volume (9 cubic feet). The CT scanner must have a minimum of a 5X5X5 ft cube chamber size working volume, capable of rotating 360 degrees without manual manipulation nor repositioning of the sample.

3.4. Weight Capacity and Loading Capacity of Specimen Table - The sample table must be able bear 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 able to extend out of the chamber for part positioning and retract for scanning. The automated loading system will be integrated within CT scanner system, and fully supported by the vendor.

3.8. 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):

Hardware:

a. High End Workstation Computer System that meets the recommended requirements to run the CT Scanner software

b. High End Workstation Computer System that processes and models CT Scanner data output and runs all applications detailed in the Software section Standard reconstruction benchmark time of a 2000-voxel resolution cube in 140 seconds or better Minimum one (1) Workstation-grade quad-core CPU or better 64-bit Windows operating system Minimum one (1) Discrete GPU with 8 GB VRAM or better and ports to support multiple monitors via HDMI type connectors Minimum 64 GB ECC RAM 8 TB min of storage Blu-Ray compatible internal optical drive

c. Two (2) 27” minimum, LCD/LED Monitors with cable

d. Wireless Keyboard

e. Wireless Mouse

f. CT Scanner Controller Suite

Software:

a. Windows 10-based Operating System

b. Microsoft Office Suite

c. Solidworks

d. Solidworks import/export compatibility

e. Digital 2D Radiography Features

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

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

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

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

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

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

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

h. Spatial calibration and measurements in all axes

i. Pseudo colorizing and thresholding of density varyations.

j. Latest version of Design X by Geomagic or equivalent

k. Latest version of Control X by Geomagic or equivalent

l. Geomagic export compatibility

m. Video rendering of 3D scan

n. Recording of projections

o. Image processing tools and projection filtering to allow cropping of multiple planes/angles (slicing)

p. Video rendering of time and motion analysis of 3D scans

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

r. Beam hardening and ring artifact reduction.

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

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

u. Metrology analysis tools to include output files for engineering analysis tools such as AutoCaD, Solid works. Surface extraction to CAD formats such as STL, DXF.

v. ANSYS Software

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.

4.2. Rack and Storage Systems – A rack and storage system shall be provided to house all items or accessories not in use. This rack should be able to accommodate all additional accessories provided with the CT Scanner. Individual maximum shelf load capacities must be provided.

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 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. 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. The contractor will provide the necessary equipment for surge protection, outage soft landings, and power cleaning for all electrical components provided. The contractor will provide full documentation of the electrical requirements and any power conditioning requirements before contract approval. All electrical equipment design and documentation is subject to final approval by the Government.

7.0. Contract Monitor Provisions

7.1. Responsibility for Inspection – Unless otherwise directed by the contracting officer, the contractor is responsible for performance of all inspection requirements herein. Except as otherwise directed by the contracting officer, the contractor may use their own or any other facilities suitable for the performance of inspection requirements specified herein, unless overruled by the Government. The Government reserves the right to perform any of the inspections set forth in the specification when such inspections are deemed necessary to ensure supplies and services conform to prescribed requirements.

7.2. 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 8.3. and the tests in 8.4. 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. The warranty period commencement/initiation is contingent upon full installed system acceptance.

7.3. 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 vendor and customer.

7.4. Tests – In addition to the specific testing requirements of 3.2.d, the vendor 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.

7.5 Certifications – Vendor shall be ISO 9001 certified.

8.0. Warranty – All components of this purchase will come with a 1-year warranty over hardware, software, and computer operating system. This warranty will not be required on standard wear and tear on items deemed consumables. The warranty period will begin once installation, inspection, all testing and government acceptance has been approved by the contract monitor and representatives of the government. See 7.2.

8.1 Service Contract – The supplier will show documentation that they can provide a complete service contract for the CT Scanner system and estimated annual cost (or ROM).

9.0. Training – The contractor will provide basic training for a minimum of (32 hours) on all equipment and software use within 2 business days after installation for at least two people. Additional applications training (40 hours) for two people will be provided by the vendor after a period of familiarization on the instrument.

9.1 Training Services – The contractor will provide documentation showing regular availability of additional, comprehensive professional training services applicable to the provided machine for future opportunities.

10.0. System/Software Support – Vendor will supply all software updates and/or patches free of charge for 1 year after acceptance via DVD/Blue Ray disks. This software support will include 1 year of 24 hours/7 days a week of telephone or online support associated with all functions of the operation of the 3D CT Scanner. Vendor support will include stateside support and response for remedial equipment and software maintenance calls withing 48 hours of notification to the OEM.

11.0. Shipping – The contractor shall include all costs associated with shipping or transport of all items associated with this purchase description to the final destination of Tinker AFB, OK. Upon delivery, Tinker AFB personnel will assist with offloading the crated equipment to a staging area until representatives of the contractor can be on site for uncrating and final installation. Any special accommodations will be noted by the vendor prior to receipt of equipment. Delivery and installation of the CT Scanner System shall not exceed 9 months from the awarding of the contract unless negotiated and agreed upon by the vendor and contracting officer if changes from the original contract are deemed necessary.

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 vendor and contracting officer if changes from the original contract are deemed necessary.