Statement of Work.pdf

STATEMENT OF WORK

FOR

ACTUATOR TEST STAND

Prepared by

ADAM MITCHELL

76 CMXG/MXDEC

6 January 2021

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Actuator Test Stand Statement of Work

6 January 2021

CONTENTS

Section/Para Page

1 Scope of Work 2 Applicable Documents and Definitions

2.1 Government Standards

2.2 Non-government Standards

2.3 Order of Precedence

3 Requirements

3.1 General

3.2 Construction

3.3 Utilities and Maintenance Access

3.4 Installation Plan

3.5 General Actuator Test Stand Configuration and Performance Requirements

3.6 Reliability Centered Maintenance (RCM)

3.7 Warranty

3.8 Personnel…

4 Quality Assurance Provisions

4.1 Responsibility for Inspections

4.2 Responsibility for Compliance

4.3 Environmental Conditions

4.4 Examination

4.5 Safety Analysis

4.6 Design Reviews

4.7 Test Readiness Review

4.8 Final Acceptance

4.9 Tests

4.10 Emergency POC

5 Technical Data

5.1. Manuals/Drawings

5.2. Work Plan Drawings

5.3. As-Built Drawings

5.4. Software Documentation

5.5. Commercial Manuals

5.6. Spare Parts & Consumables List

5.7. Site Preparation Data

5.8. Pre-Installation Plan

5.9. Installation Site Services

5.10. Factory Acceptance Test Report

5.11. Software Test Report

5.12. Correlation Test Report

5.13. Documentation

6 Training/Familiarization

Statement of Work

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6.1. Operator

6.2. Electrical/Mechanical

6.3. Calibration

6.4. Software Engineer

7 Special Provisions

7.1 Government Occupancy of Facilities & Responsibilities

7.2 Secure Area(s)

7.3 Working Hours

7.4 Safety, Foreign Object Debris (FOD), & Quality Control

7.5 Housekeeping

7.6 Tool Control and Accountability

7.7 Field Verify

8 Proposal by Contractor 9 Other Written Submittals 10 Government Furnished Property and Services

10.1. Government Furnished Property (GFP)

10.2. GFP Shipment to Contractor’s Facility

10.3. GFP Return Shipment to Government

10.4. Loss of Government Property

10.5. GFP Identification Labels

10.6. Plant Clearance (Disposition) Instructions

10.7. Standard Form 30, Contract Modification

10.8. Shared Property of the Government

10.9. Shared Storage Areas

10.10. Cease to Use and Return to Government

10.11. Government Furnished Services

10.12. Intangible Government Property

10.13. Government Furnished Drawings

APPENDICES

Appendix A: Design Guideline 450

Appendix B: Reserved

Appendix C: Safety Specifications

Appendix D: Glossary and Definitions

Appendix E: Environmental

Appendix F: Certification Test Plan Appendix G: Test Results Required-Minimum Appendix H: Drawings Rev D-Basis of Design and Component Locations Appendix I: UUT & Sub-component Test Specifications, Tooling, and Fixturing (Available Upon Request) Appendix J: Calibratable Items to be Utilized Appendix K: Reliability Centered Maintenance and Vibration Severity Chart Appendix L: Sample Operations and Maintenance Manual-Format Appendix M: Sample IPB, T.O. 33D4-6-670-4 Appendix N: 3C3970G05 Supplemental Drawings-Reference Only Appendix O: TDP Options Worksheet

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Attachment #1: Reserved Attachment #2: Government Furnished Property (GFP)

1. SCOPE OF WORK:

1.1 Scope: The following establishes the minimum requirement for the purchase, delivery and installation of one (1) Actuator Test Stand (TS) with equipment and accessories specified herein; and training on the maintenance, calibration, programming and use of said test stand. The test stand will be used to test F101, F108, F110-100, F110-129 and F118 Inlet Guide Vane Actuators (IGVA) and Variable Stator Vane Actuators (VSVA) as required and as per their relevant Technical Orders (T.O.’s). The overall project shall be considered a whole and complete procurement. That is, final acceptance requirements have been met and approved by the appropriate Government POCs and operational training has been conducted.

1.2 Background: The test stands described in this document are intended for use in the Aerospace Repair Industry. The equipment shall be installed in Building 3907, North Test Cell, Tinker AFB, OK. This shop runs on a 24 hour basis Monday through Friday with possible overtime hours on the weekend. Test stands will be installed in a National Electric Code, Class I, Division II, Group D environment, as per NFPA 70, Article 500.

All installation work associated with this contract shall have no impact on production.

2. APPLICABLE DOCUMENTS AND DEFINITIONS:

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.”

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) http://www.osha.gov/

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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. UFC 3-600-01 – Fire Protection Engineering for Facilities

2.1.3.4. UFGS 07 84 00

2.1.3.5. UFGS 21 13 13

2.1.3.6. UFGS 21 13 22

2.1.3.7. UFGS 21 21 01

2.1.3.8. UFGS 21 21 02

2.1.3.9. UFGS 28 31 64

2.1.3.10. (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 11 – Standard for Low-, Medium-, and High-Expansion Foam, 2016 edition or most current

2.2.1.3. NFPA 12 – Standard on Carbon Dioxide Extinguishing Systems, 2018 edition or most current

2.2.1.4. NFPA 16 – Standard for the Installation of Foam-Water Sprinkler and Foam-Water Spray Systems, 2019 edition or most current

2.2.1.5. NFPA 70 – National Electrical Code, 2014 edition

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

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

2.2.1.8. (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

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) http://www.ihs.com/

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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.

3. REQUIREMENTS:

3.1. General: The Actuator TS equipment shall be new and unused (not a prototype).

Actuator TS particulars are noted below:

• Actuator TS construction and layout shall be of new design. However, the user interface and controls shall utilize the naming convention and/or Significant Identification Number (SIN) system of our existing Fuel Accessories Test Stands (FATS). The purpose of this being that the Unit Under Test (UUT) Technical Orders (T.O.) utilize specific SINs when providing instruction.

• Original FATS technical documentation are the property of the USAF and relevant sheets are attached in Appendix H. These technical documents shall provide a reference for design of a new Actuator TS. Any exceptions are noted below. Intent of Appendix H is as follows:

o Provide a baseline for required layout of stand consoles and panels (i.e., location of regulators, valves, bleed ports, connection ports and all other items denoted in Appendix H), drawers, doors and required coatings.

o Denote general location of major components including pumps, motors, pressure transducers, flowmeters and tanks.

o Provide a level of detail for required panel electrical connectors and their mating connectors for Unit Under Test (UUT) cables

• New Actuator TS shall be a completely standalone unit with all necessary fixturing, fully capable of successfully testing every UUT.

o Testing requirements for all UUT’s are detailed in the following Technical Order’s and are available to the contractor upon request:

*Note* Contractor shall verify latest Technical Order in use prior to software development.

F101 IGVA, 9H2-7-37-3

F110 Series IGVA, 9H2-7-42-3 F110 Series VSVA, 9H2-7-44-3 o No modification or tweaking by operator of any testing control loop shall be required regardless of UUT being tested mailto:central@iso.ch http://www.ihs.com/

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SOW-2020-Actuator Page 8 o Time to test a known good UUT by a certified Tinker mechanic shall not exceed the following:

F101 IGVA: 8 Hours F110 Series IGVA: 8 Hours F110 Series VSVA: 8 Hours

• Design shall include provisions for connecting test stand calibration fluid tank to existing Tinker central calibration fluid piping system, nominally 1” stainless steel piping. Test stand calibration fluid tank shall also include a sight glass.

• Design shall include provisions for a vent for connecting test stand calibration fluid tank to existing 1-1/2” calibration fluid tank vent piping system

• Inside of test stand and all components therein, shall be rated for a Class I, Division I, Group D environment, as per NFPA 70, Article 500

• If purge air cabinets are utilized, purge air requirements shall be limited to 200 scfm. Contractor shall be responsible for tapping into existing supply duct in the test bay as necessary for any required feed to purge air system/fan and shall include a manual volume damper for flow control.

• Purge air systems shall conform to National Fire Protection Agency (NFPA) 496 and International Society of Automation (ISA) 12.4 standards and be Underwriters Laboratory (UL) classified. Purge air system and enclosures shall be protected from over pressurization.

• Test stands shall be outfitted with a calibration fluid dump system in the event of excessive heat or fire within the test stand. Contractor shall be responsible for installation of all piping from test stand to floor drain. Test stand shall come with an option to allow manual operation of the dump system to drain calibration fluid tank when needed.

• All pressure sensing devices must be located within the shortest distance possible from the fuel control.

• No “T” fitting shall be allowed in any of the main flow lines. The contractor shall specify their approach to fulfilling this requirement.

• No sharp 90 degree bends or elbows are allowed in the main flow lines. The contractor shall specify their approach to fulfilling this requirement.

• Area where stands are to be installed is rated Class I, Division II, floor to ceiling

• All Actuator TS components shall be available as commercial off the shelf (COTS) items.

• All items requiring calibration shall be currently listed in Air Force Metrology and

Calibration Program (AFMETCAL) (Air Force TO 33k-1-100-2) as approved devices.

• New equipment shall be enclosed and enclosure shall include access to all repairable components and doors large enough to repair & replace without major disassemble.

• Any connection adaptors and/or cables shall be provided by Contractor.

• Test Stand Shall Include o Fork lift pockets o Internal drip pans with drain and holding tank (75 Gal min) accessible externally for regular empting.

o Stainless steel sink and work space

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SOW-2020-Actuator Page 9 o Door switches with lighting o Plexiglas (or equivalent) protective removable barrier for sink

• Software assurance shall be designed into the software and shown as part of the Software Acceptance Test Procedure.

• The Data Acquisition (DAQ) system shall utilize LabVIEW to develop a test program to communicate with a PLC controller selected by contractor and approved by Government Technical POC.

• No proprietary software or technical data is allowed. 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 along with the COTS licenses at the end of the contract.

• Interior of the Actuator TS and footprint of the Actuator TS from floor to ceiling shall be Class I, Division I rated as per NFPA 70, Article 500. Areas exterior to this region shall be Class I, Division II rated as per NFPA 70, Article 500. This project shall in no way compromise these existing ratings.

• One, Class I, Division II LED retractable lights shall be provided, incorporated into the TS, and be capable of extending eight (8) feet from console face.

• Shop air on retractable reel shall be provided with sufficient length to comfortably reach any point on UUT

• Test variables shall be indicated one of three ways: red if out-of-limits (OOL)-high, green if in limits and yellow or white if OOL-low

• Test stands shall be outfitted with plexiglass UUT cover that can be easily retracted laterally to allow full access to UUT

• Stands shall be modular in design and shall be able to fit through an exterior rollup door with maximum dimension of 119” X 119”

• Delivery date for new Actuator TS shall be no later than eighteen (18) months after date of contract.

• Stand shall be provided with at least two (2) separate exhausts, detailed as follows:

o One sink exhaust, sized for 40 SCFM at 0.5 in. water vacuum o Minimum of one (1) interior exhausts properly separated for exhausting floor-level fumes, each sized for 100 SCFM at 0.5 in. water vacuum o Each exhaust shall be outfitted with volume damper; damper shall close automatically in the event of fire suppression gas discharge but also maintains a manual ability to open/close o Contractor shall be responsible for tying into nearest existing exhaust duct.

• Required calibration features for test stands are detailed below:

o Real-time feedback on HMI of item being calibrated o A minimum of 20 data points available for each item requiring calibration o As Found and As Left data broadcast to HMI during calibration with an option to save data to hard drive during calibration process o Raw signal and final units shown on HMI for items requiring calibration o Five (5) alignment points minimum for items requiring calibration

• Stands shall have a software Administrative Level ON/OFF option to allow UUT test results/reports to be automatically uploaded to the existing LAN system only when turned ON.

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3.1.1. 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).

3.1.2. Measuring/Indicating Devices: All measuring and indicating devices, such as dial indicators, pressure gages, 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.

3.1.3. 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 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.

3.1.4. 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 mark on the plates.

3.1.5. Noise Levels: The noise level emitted by the equipment under load 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 of the equipment associated with the Actuator TS unit as measured on the “A” weighted scale of a standard Type II sound level meter.

3.1.6. Chemicals: The Contractor shall furnish to the Government POC a list of all chemicals used in conjunction with installation and maintenance of the equipment, and their Material Safety Data Sheets (MSDS) 90 days prior to delivery of equipment. If time frame specified does not match with expected delivery schedule then the Contractor shall propose an alternate schedule that makes delivery of chemical information to the Government prior to installation with a minimum of 4 weeks for review of the data and comments by all interested Government parties.

If necessary, the delivery of the equipment shall be delayed to allow for the chemical review and comment period. Additional delivery delays may be required if the Government requests alternative chemicals. The Contractor shall submit this proposed schedule at time of contract award for Government approval. The Contractor shall furnish all chemicals required for the installation and start-up of the Actuator TS (Exception: Government will supply necessary calibration fluid for Actuator TS following installation at Tinker AFB. All other fluids required prior to test stand acceptance shall be provided by Contractor and properly disposed of by Contractor following acceptance). The government reserves the right to reject

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SOW-2020-Actuator Page 11 use of any chemicals and request alternative(s) be proposed for completion of the installation. Proper use, storage and removal of any chemical required during commissioning of test stand shall be coordinated with the Tinker Unit Environmental Coordinator (UEC). UEC info will be made available to Contractor by Government POC, as needed.

3.1.7. Prohibited Materials:

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

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

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

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

3.1.7.5. Ozone Depleting Chemicals (ODC) Restrictions: Class I ozone depleting substances in accordance with 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.

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

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

3.1.10. 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 and suffer no degradation when subjected to it.

3.1.11. 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.

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Nomenclature of the Machine Manufacturer’s Name and Address Manufacturer’s Model Number Manufacturer’s Serial Number Date of Manufacture Contract Number Services Requirements – All service requirements to be included.

3.2. Construction: The Actuator TS shall be constructed of parts that are new, without defects, commercial-off-the-shelf (COTS), and free of repairs. Quality of materials used in construction shall be equivalent to or superior to those used in construction of existing test stands located in B3902. Metals shall be of corrosion resistant materials unless suitably protected to resist corrosion. 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 be installed with means of preventing loss of tightness. All parts subject to removal or adjustment, shall not be swaged, peened, staked or otherwise permanently deformed. Actuator TS shall be built in compliance with 76CMXG Design Guideline as shown in Appendix A.

3.2.1. 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 paste shall not be used on casting and forgings for reclaiming any parts of the machine. Such processes may only be used for enhancing surface finish and appearance.

3.2.2. 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.

3.2.3. 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.

3.2.4. 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

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SOW-2020-Actuator Page 13 and horsepower throughout the speed ranges without failure for the expected service life of the machine.

3.2.5. Painting: See Appendix H drawings for painting/coatings required. Yellow or orange safety color-coding shall be used for designated physical hazards.

3.2.6. 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.

3.2.7. 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. Records, including detailed parts drawings, shall be maintained by the equipment supplier by part number throughout the life of the equipment in order than any replacement part can be supplied to the customer.

3.2.8. 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.

3.2.9. Lubrication: Means shall be provided to insure 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.

3.3. 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 test stand main electrical device(s) the source panel name, location and circuit breaker number(s) used to feed the electrical device.

3.3.1. Utilities Interconnection: The Government will provide the required utilities, with the exception of the electrical, to within twenty-five (25) feet of test stand location.

Contractor shall make final terminations of utilities to test stand. Contractor shall provide and run all conduit, conductors, and all other required electrical components from this connection point to the stand in order to make the stand fully

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SOW-2020-Actuator Page 14 operational electrically. All interconnections shall maintain the hazardous classifications for both inside and outside the test stand.

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

3.4. Installation Plan: Contractor shall submit an Installation Plan to the Government POC for review and approval. Installation Plan shall include:

• Drawing denoting test stand locations onto existing floor plan

• Drawing denoting conduit sizes, conductor types and sizes, seal off locations, test stand electrical interconnect drawing and over-current protection devices and sizes.

• All subcontractor and partnership information

Installation Plan shall be submitted to the Government POC a minimum of sixty calendar (60) days prior to delivery of test stand. Stands shall not be delivered until written approval of plan has been received by Contractor from the Government POC.

The government shall have 14 calendar days to review the Installation Plan and initiate contact with Contractor to discuss/review/resolve any issues. Following resolution, Contractor shall have 7 calendar days to resubmit revised Installation Plan to Government POC for review and approval.

3.5. General Actuator TS Configuration and Performance Requirements: The Actuator TS shall generally be configured, calibrated and tested as noted below:

3.5.1. General Configuration. Actuator TS construction and layout shall be no more than 100 ft2.

Data acquisition chassis, controllers and cards shall have at least one (1) secondary, independent manufacturer as identified by Contractor that provides a COTS functional replacement.

3.5.2. Actuator TS Interior-Electrical Items: All electrical/electronic components and connections located within Actuator TS footprint, floor to ceiling shall be Class I Division I Group D rated as defined in NFPA 70 Article 500. All components located inside the stand envelope and not Class I, Division I Group D rated shall be located in purge air enclosures. Purge air enclosures may be accessible from test stand interior provided point of access is reasonable from a maintenance perspective. All purge air enclosures shall be configured in accordance with all specifications listed and referenced in this SOW.

3.5.3. Actuator TS Exterior-Electrical Items: All electrical/electronic components outside the area detailed in immediately preceding paragraph shall be a minimum of Class I Division II Group D rated as defined by NFPA 70 Article 500 and shall be mounted in an enclosure(s). Enclosure(s) interior shall only be accessible from outside the Actuator TS envelope.

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While the intent is to maintain the integrity of a Class I Division II environment for all exterior electrical items, the very nature of electrical connections resident on the UUT’s prevents strict adherence with this rating. Refer to para. 3.1 above and Panel H schematic in Appendix H, Rev D or drawing package in Appendix N for additional cable connection information.

3.5.4. Professional Computer (PC) and Programmable Logic Controller (PLC) Control System: Control system as originally designed is obsolete and no longer available.

Consequently, Actuator TS shall be controlled using a PC/PLC configuration as noted below:

• PLC shall be Siemens S7-1500 Series and controlled using LabVIEW, no substitutes accepted

• Latest Air Force approved Windows Enterprise version

• CPU: Quad Core i7 (minimum)

• Redundant Array of Independent Disks (RAID) array based with a minimum of 1TB Solid State Drive SSD’s

• 8GB Synchronous Dynamic Random - Access Memory (SDRAM)

(minimum)

• 17” color flat screen (touch screen) HMI (minimum) with adjustable

StrongArm (or equivalent) mount to test stand

• Detachable, standard 101 key computer keyboard and mouse, Class I, Division II, Group D rated

• Built-in DVD-ROM/CD-RW and USB mass storage device ports

• No custom proprietary software shall be used

• LAN connection capability to existing LAN system allowing full interface with and backup capability of Actuator TS PC and PLC

• System shall be configured to allow flowmeter calibration data to be uploaded to test stand thru USB port or similar (subject to Tinker approval).

Manual loading (keying in) of flowmeter calibration data shall not be required.

• Hardware shall be chosen, where feasible, that has error handling capabilities

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

• Operator level: allows access for testing of UUT’s alone. Software changes and access to calibration data are NOT allowed at this level

• PMEL Tech level: allows access to Operator level as well as Calibration level to permit test stand calibration including entry of calibration data.

Software changes are NOT allowed at this level

• Administrative level: allows access to all previous levels as well as capability to modify any test stand software as necessary. Any changes to

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SOW-2020-Actuator Page 16 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.

3.5.5. Actuator TS Component Labeling: All test stand components shall be labeled with an embossed metal tag denoting part number as per the 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 Actuator TS.

3.5.6. Actuator TS Anchoring: If Actuator TS are required to be anchored to the slab, anchors shall be no longer than three and three-quarter inches (3.75”) in length. All holes required to be drilled into the slab shall be no more than four inches (4”) deep.

Any damage to the existing vapor barrier due to holes deeper than those allowed shall be fully repaired by the Contractor. Repair method and final repair shall be reviewed and approved by Tinker AFB Civil Engineering.

3.5.7. Actuator TS Preliminary/Final Calibration: Calibration process shall be delivered by Contractor for review at Intermediate Design Review. Review comments will be delivered via the GOVERNMENT POC back to Contractor within 14 calendar days. Contractor shall fully incorporate comments as necessary and resubmit revised procedure prior to Critical Design Review for review.

Following installation of Actuator TS at Tinker AFB, Contractor shall complete and prove out the entire approved calibration process prior to contacting PMEL personnel. Final calibration procedures must be exact. Any errors in the calibration procedures shall be corrected prior to PMEL Calibration. Preliminary calibration process shall include a spreadsheet summation completed by Contractor detailing the following:

• Each item calibrated and calibration results (Pass or Fail)

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

• As Left values for each item calibrated

• Any alignments or adjustments performed during calibration

• Technical documentation revision history in the event of documentation changes

Final Calibration process shall be carried out as follows (please note that additional calibration procedure changes may be discovered during Final Calibration, see below):

• Review and perform entire calibration process step-by-step on the Actuator TS with PMEL personnel present

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

• Modify test stand calibration software as recommended and agreed to by PMEL personnel

• Once the calibration procedure is finalized, revised and resubmitted by Contractor, PMEL will formally calibrate the Actuator TS. Contractor shall have appropriate personnel present during the entire Final Calibration process. Limitations on the calibration are not acceptable and any limitations noted by PMEL shall be fully resolved by Contractor.

3.5.8 Actuator TS IVV and As-Built Drawing Review: Prior to government calibration, contractor shall provide the latest data dackage to the government. The government will verify the accuracy of all As-Built drawings, to include but not limited to Illustrated Parts Breakdown (IPB) and all drawings associated with the project.

Following review, the Government shall list all deficiencies noted and submit list to Contractor for correction. All deficiencies shall be corrected by Contractor prior to final As-Built drawing submittals. Once finalized, the Government shall submit a signed and dated document noting that As-Built drawings are 100 percent accurate.

Document shall include a detailed list of As-Builts including:

• Drawing name, date and rev level of each drawing associated with the Actuator TS.

• IPB.

3.5.9 Actuator TS UUT Fixturing: Contractor shall provide all fixtures one (1) set per test stand, necessary for mounting and testing each UUT onto Actuator Test Stand.

Legacy fixtures do not need to be reproduced. Fixtures may be incorporated into new test stand design. However, if legacy fixtures are utilized, fixtures may be reverse engineered and fabricated or authentic from Original Equipment Manufacturer (OEM). If fixtures are reverse engineered, manufacture drawings shall be included for all tools and fixtures that are reverse engineered and fabricated. Manufacture drawings shall be such that local manufacture of any item can be achieved without further engineering. Requirements for fixtures can be found in Appendix I.

3.5.10 Software: The Contractor shall develop a Test Executive as well as individual UUT Computer Software Configuration Items (CSCI’s) so that they can have separate configuration management at the completion of the contract. The software shall be developed utilizing an object oriented design such that there is an Executive piece that calls independent pieces for each UUT.

3.5.10.1 Self-Test: The Contractor shall develop self-test software to identify faulty equipment in the test stand and be used for troubleshooting of the stand.

3.5.10.2 Executive Software: Contractor shall develop executive software that is common to all UUT types tested.

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3.5.10.3 Unit Under Test (UUT) Software: Contractor shall develop menu screens that shall be used for unit under test (UUT) test screens. The Test Points (TPs) shall be formatted in accordance with the target test equipment style requirements. The main menu shall list each individual TP. Naming convention shall reflect the primary attribute (for example, variable, procedures, object, function, and class names) that they represent. Reserved words of each language shall be identified in the target test equipment style guide. Hardware and Operator Error handling shall be integrated into the software.

Test results shall be permanently stored electronically in Actuator TS PC and available for easy retrieval by Operator in PDF format. Test results may not be allowed to be electronically changed in any way and may only be allowed to be removed from the PC at the Administrative level. Test results in PDF format shall also be capable of being printed out in hard copy for every UUT and every required test point (see Appendix G for minimum content required). All tests are to be programmed and carried out in accordance with UUT Technical Orders (T.O.’s) including applicable AF Form 202’s.

3.5.11 Electrical System: The machine shall be designed to operate from a single 460 volt (± 3%). 3 phase, 60-hertz (HZ) (± 1 hertz) power source. All electrical equipment shall comply with NFPA 79, NFPA 70 and NFPA 70E standards.

3.5.12 Extended Spares Kit: Contractor shall supply a full set of spare flowmeters as used in the Actuator TS.

3.6 Reliability Centered Maintenance (RCM)

3.6.1 RCM 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 K and will be completed by personnel from 76 MSXG/MXDEQ. This effort shall be performed following Final Calibration of Actuator TS and prior to commencement of Correlation Testing and shall be attended by a Contractor’s

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SOW-2020-Actuator Page 19 technical representative. Additional information requested in Appendix K shall be provided to the GOVERNMENT POC for distribution.

3.6.2 Vibration Baseline Testing

Following factory alignment by the Contractor, Contractor shall complete a vibration baseline at the factory for each motor, motor/drive and pump/motor combination. All data shall be taken in accordance with ISO 10816-3 and acceptable vibration levels are as per the “New machine condition” range detailed in the ISO 10816-3 Vibration Severity Chart (see Appendix K). This data will form the vibration baseline for each motor and pump/motor combination, provided all data is in Good Condition or better, as per ISO 10816-3. Vibrations that are not unacceptable as per the ISO 10816-3 Vibration Severity Chart, New Machine Condition shall be remediated at the factory prior to shipment. Vibration data shall be submitted to Government POC for review prior to shipment of stand.

Following Final Calibration of installed Actuator TS at Tinker AFB and prior to Correlation Testing, all motor and pump/motor vibrations will 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 (ips) as read at both the factory by Contractor and at Tinker 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.

3.7. Warranty: The Contractor shall warranty all equipment and workmanship free of defects for a period of no less than 365 calendar days. The Contractor will be notified of defects by the Government in writing. The Contractor shall respond to all reported problems within 24 hours. Defects shall be remedied at no cost to the Government within 10 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 365 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 will 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 Actuator TS.

Any spills caused by an equipment defect shall be cleaned up within 2 clock hours at no cost to the Government. Contractor shall be responsible for damages caused by the defect. 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

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SOW-2020-Actuator Page 20 minimum of one (1) 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.

Contractor shall provide a method for reporting problems encountered with Actuator TS following installation 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 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.

3.8 Personnel: The contractor shall have the following minimum personnel on staff:

• At least one mechanical engineer with minimum of ten (10) years of experience in test stand construction and configuration.

• At least one technician with at least ten (10) years of experience with LabVIEW and PLC systems.

• At least one National Instruments Certified LabVIEW Architect.

• At least one technician with at least ten (10) years of experience in the design, fabrication and installation of aircraft component testing equipment.

4. QUALITY ASSURANCE PROVISIONS

4.7. Responsibility for Inspections: The Contractor shall be responsible for the performance of all inspection requirements (examinations and tests) as specified herein. The Contractor may use his own or any other facilities suitable for the performance of the inspection requirements specified herein, unless disapproved by the Government. 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, fixturing, measurement indicating devices, material and programs required for compliance, accuracy, alignment and machining acceptance tests.

4.8. Responsibility for Compliance: All items shall meet the requirements of Section 3 of the SOW. 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, 6 January 2021

SOW-2020-Actuator Page 21 either indicated or actual, nor does it commit the Government to accept defective material.

4.9. Environmental Conditions: All tests shall be performed in an indoor facility with ambient conditions of 41° F to 104° F and 20% to 95% relative humidity.

4.10. Examination: The Actuator TS shall be visually examined to determine compliance with all requirements within section 3 of the SOW.

4.11. Safety Analysis: The Contractor shall provide a Cause and Effect Matrix (Alarms and Shutdowns) and a Test Stand Safety Analysis. The Contractor shall provide one (1) each hard copy and one (1) each electronic copy of the Cause and Effect Matrix and Test Stand Safety Analysis. The electronic copy via email or CD-ROM shall be in Acrobat Adobe version 9 or higher. The Cause and Effect Matrix and the Test Stand Safety Analysis shall be provided to the COR as part of the Critical Design Review.

4.12. Design Reviews

4.12.1. Preliminary Design Review: The Contractor shall provide a Preliminary Design Review. The design review shall be completed at the five to ten percent (5-10%) test stand design stage. The Contractor shall be required to conduct a meeting for the Preliminary Design Review. The GOVERNMENT POC will coordinate and attend the on-site meeting with the GOVERNMENT POC identified 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, software and hardware specifications, certificates, and reports and final products including catalog excerpts and salient characteristics. See Section 5 for Technical Data requirements. 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 will provide the two

(2) complete hard copy data packages and one (1) electronic data package to the GOVERNMENT POC identified Technical POC within two (2) calendar days of receipt of the packages from the Contractor in order to allow time for the GOVERNMENT POC Identified Technical POC to review prior to the on-site meeting.