Strand Burner Purchase Description - 20250310 Final.pdf

PURCHASE DESCRIPTION (PD)

STRAND BURNER

U.S AIR FORCE

309TH MMXG

10 March 2025 i

Table of Contents

1 SCOPE

2 REQUIREMENTS

2.1 5000 PSI Clover Leaf Triple Strand, Strand Burner System

2.2 Remote Valve Rack

2.3 Control Console

2.4 Data Acquisition System

2.5 Dynamic Circulator Temperature Control System

2.6 Standard Air Nitrogen Gas Booster and Storage System

2.7 Spare Test Cell Head

2.8 Test Body Jacket

3 INSTALLATION, SHIPPING, AND WARRANTY

3.1 Installation, Calibration, and Training

3.2 Crating and Shipment

3.3 Warranty

3.4 Inspection

3.5 Delivery and Shipping

3.6 Pressure Instability

3.7 Installation Requirements

3.8 Destination Acceptance Test

4 DOCUMENTATION AND MANUALS

4.1 Documentation

4.2 Manuals and Drawings

4.3 Certifications

5 DATA

5.1 Contract Data Requirement List (CDRL)

APPENDIX C – SAFETY……………………………………………………………...……. 8

1 SCOPE

The following establishes the minimum requirements for the purchase of a strand burn tester.

This document provides requirements of the equipment, installation requirements, warranty information, and shipping.

2 REQUIREMENTS

The strand burn tester shall be new (not a prototype) and one of the manufacturer’s standard current production models capable of operations in accordance with the requirements herein.

The machine shall be complete, so that when connected to the utilities identified herein, it can be used for any function for which it is designed and constructed.

2.1 5000 PSI Clover Leaf Triple Strand, Strand Burner System:

The strand burner system shall consist of multiple components required for the testing of linear burn rate of strand propellant:

a. Rated for 5000 psi at -65°F to +180°F.

b. Nitrogen gas pressurized to 5000 psi max.

c. Crawford style (MIL-STD-286) pulsed time break wire burn rate method.

d. Consist of a test head and body; test head and body constructed of SST-316.

e. Test body shall have a separate gas inlet and exhaust port.

f. A Nitrile O-ring seal shall be used between the test head and body.

g. Electrical feed-thrus shall be constructed of Hastelloy.

h. PT-100, Residence Time Distribution (RTD) is mounted through the center of the test head for accurate remote monitoring of internal temperature.

2.2 Remote Valve Rack:

Shall contain the pressure related components such as valves, surge tanks, regulating valves, and pressure transducers.

a. High pressure retaining metal parts shall be constructed of SST-316, except the surge tank, insulators, and seals.

b. 9/16” OD coned and threaded heavy wall tubing shall be constructed of SST-316, rated at 20,000 psi working pressure.

c. Surge tank shall be constructed of SA372 alloy steel, constructed per ASME Boiler and

Pressure Vessel Code, Section VIII, Division 1.

d. Transducers used for monitoring system pressures shall have an accuracy of ±0.01%

F.S.

e. Rack controlled by 24VDC from a control console.

f. Utilizes 100 psi filtered and dried shop air.

2.3 Control Console:

Shall contain all the controls and instrumentation for pressure control, monitoring, keyed safe and arm fired control, including, at a minimum:

a. The timing and fire control portion of the console shall consist of a keyed safe and arm switch, timer, and amp meter.

b. As many valves as possible shall be controlled from the remote console. Console mounted lights shall indicate open or close position of high-pressure valves. Contact switches shall be mounted on the valves.

c. All cables used for signal transmission shall be shielded and are up to 45’ to allow console to be mounted away from high pressure portion of system.

d. Supply rack with 24VDC for controls.

e. Differential pressure measurement.

2.4 Data Acquisition System:

System shall be designed to allow the operator to acquire, monitor, and reduce the real time data generated by the sample firing. The data acquisition system shall produce raw data to be used to generate reports and graphs in spreadsheet and/or word processor format.

a. System shall be capable of measuring test cell pressure, test cell temperature, burn rate calculations, delta pressure and manually entered notes about each firing such as operator, date, sample number, etc.

b. Computer with Windows 11 Enterprise Operating System, Microsoft Office, Intel I5 CPU, 16 GB RAM, 500 GB Solid State Hard drive, TPM 2.0 security-enabled, and read-write optical drive. (Contractor should also consider adding UEFI/secure boot enabled with TPM 2.0).

1. The OS shall also include the following STIGs, at a minimum (available for download at public.cyber.mil):

i. .Net

ii. Edge

iii. Defender

iv. Firewall

c. 24” flat screen color monitor minimum.

d. All cables, IO boards, and interface boards.

e. Interface connection to the Contractor timing and fire control system.

f. Custom LabVIEW data acquisition software.

g. Laser printer and cable (with disabled or lacking Wi-Fi or Bluetooth capability).

2.5 Dynamic Circulator Temperature Control System:

a. Rapid heating and cooling rates for fast working temperature range of -92 to 250 °C.

b. Industrial color TFT touch screen interface.

c. Ability to connect to Test Cell to accurately read temperature.

d. RS232 port, stand-by input and Pt100 external temperature sensor port.

e. Hoses and thermal fluids shall be included.

f. Operator manual(s).

g. Certificate of Conformance factory performance test.

h. Additional high pressure stainless tubing and fittings for installation.

2.6 Standard Air Drive Nitrogen Gas Booster and Storage System:

a. Two stage nitrogen air driven gas booster.

b. Shop air filter, regulator, gage, and speed control valve.

c. Automatic start/stop – when nitrogen outlet pressure exceeds 5000 psi the unit will automatically stop and restart when the system drops around 10%.

d. Carbon steel frame.

e. Two 1.4 cu ft. high pressure storage bottles constructed of SA-379 series alloy steel.

f. Pressure gage, pressure relief valve, on/off valve per tank for maintenance, tubing, fitting, and all related hardware.

g. All high-pressure cone and threaded tubing, fitting, and valves shall be constructed of 316 stainless steels rated for 20,000 psi working pressure.

h. Contractor shall supply sufficient stainless-steel high-pressure tubing to connect the gas booster system to the valve rack.

i. Government shall run shop air and nitrogen supply lines for the gas booster.

j. The complete system shall be no larger than 40” W x 18” D x 84” H maximum.

2.7 Spare Test Cell Head:

Multiple test heads are recommended to expedite propellant testing.

a. Triple strand head assembly.

b. All metal parts exposed to combustion (except electrical feed-thrus) shall be constructed of type 316 stainless steel.

c. Electrical feed-thrus shall be constructed of Hastelloy.

d. 100-ohm RTD is mounted through the center of the head so internal test cell temperature can be accurately monitored.

2.8 Test Body Jacket:

a. Temperature range: -92 to 250 °C.

b. The jacket shall be constructed of 304 SST.

c. The jacket will be insulated and covered with a 316 SST outer shell.

d. Two (2) connection ports, size ½” NPT.

3 INSTALLATION, SHIPPING, AND WARRANTY

3.1 Installation, Calibration, and Training:

a. Minimum of two weeks for two people to supervise and assist with installation, working five standard eight-hour days per week.

b. Include calibration, testing, and training with the number of personnel trained limited by the time allowed.

3.2 Crating and Shipment:

a. Standard crating materials will be used.

b. Contractor will load goods at own facility docks.

3.3 Warranty:

a. The entire system shall be warrantied for 13 months from date of shipment.

b. Warranty shall be for items defective due to design or manufacture by Contractor.

System components supplied from a subcontractor without a warranty shall be furnished or repaired by Contractor without charge to the customer within the system warranty period.

3.4 Inspection:

a. Contractor shall inspect equipment prior to shipment, and the Government will “receive inspect” the equipment within one business day. The Government will advise Contractor immediately of any damages found during inspection.

3.5 Delivery and Shipping:

a. Delivery of asset shall occur within one year after receipt of contract award. Delivery location: 7563 Wardleigh Road, Bldg. 847, Hill AFB, UT 84056, Attn: Buffi Tuttle 777-5200 or John Martinez 777-7420. Install location: 6357 Maple Lane, MSA II Bldg.

2021, Hill AFB, UT 84056, Attn: Buffi Tuttle 777-5200 or John Martinez 777-7420.

b. Shipment is FOB destination.

c. Shipping shall be the responsibility of the Contractor. The Government will coordinate and approve logistics with the Contractor prior to the shipment of the asset.

3.6 Pressure Instability:

a. Contractor shall be responsible for visual leaks on mechanical equipment.

b. Digital display leaks or variances that cannot be traced to bubble check leaks are acceptable, provided they are minor (not gross leaks).

3.7 Installation Requirements:

a. The Government shall ensure all installation requirements at the install site are completed prior to installation, (provided the Contractor has given a minimum of 60 days’ notice of said requirements), including:

1. Test Bay

i. Exhaust line size and locations.

ii. Nitrogen gas supply with regulator and feed line to valve rack or booster.

iii. Shop Air, 100 psi min <3 micron filter, oil/water removal filter, location.

iv. Fume ventilation hood over test cell.

2. Control Bay

i. 120 VAC/Single Phase, 60 Hz, 15-amp service.

3. Gas Booster

i. Shop air 90 PSI @ 50 SCFM, filtered, 1/2” diameter line to drive gas booster.

ii. Nitrogen gas supply, with regulator and feed line to booster.

b. The Government shall be responsible for unloading and locating equipment, pass through holes between bays, and drilling of holes in walls and floors to mount equipment, under the supervision of Contractor. Contractor shall supply anchoring hardware.

c. The Government will provide Contractor with plan and elevation views of the bays that will house the equipment and the approximate location of connections, such as electrical, water, exhaust, etc. Contractor shall use this to construct a layout drawing of the complete system for Government review.

d. Government shall provide a written statement that the utilities and facility are on-line and ready for installation of the system prior to Contractor scheduling the installation trip.

e. Government shall provide Contractor will holidays or expected plant closures upon contract award to ensure installation can be scheduled around those planned closures.

3.8 Destination Acceptance Test:

Final inspection, testing and acceptance shall occur at the Government Facility requiring the equipment. The buyer may select a part for testing to specification during installation.

Upon completion of installation, the Contractor shall perform a functional acceptance test demonstrating full performance per manufacturer’s specification(s) on the strand burner.

Prior to acceptance testing, the Contractor shall provide a written copy of the acceptance test procedures for government approval in accordance with CDRL A001 (DI-QCIC- 80553), Acceptance Test Plan. Upon approval of the acceptance test procedures, the Contractor shall schedule an acceptance test meeting with the PM and other Government technical representatives. All testing shall be completed until the strand burner passes all tests to the satisfaction of the Government team. Once the acceptance process is complete, the Contractor shall provide an acceptance test report for the strand burner in accordance with CDRL A002 (DI-QCIC-81891), Acceptance Test Report.

4 DOCUMENTATION AND MANUALS

4.1 Documentation:

All documentation, i.e. operation manuals, maintenance manuals, programming manuals, student training materials, drawings, vendor literature, laminated note cards, metal name and service plates, service bulletins, upgrade bulletins, and all associated charts/graphs, shall be written in the English language and grammatically correct.

4.2 Manuals and Drawings:

The Contractor shall furnish a minimum of one (1) hard copies of all technical manuals/drawings containing all information necessary for the programming, operation and maintenance (parts lists, electrical schematics, and any other applicable documents/diagrams) of the strand burner system in accordance with CDRL A003 (DI- TMSS-80527), Commercial Off-The-Shelf (COTS) Manuals & Associated Supplemental Data, at the time of delivery.

4.3 Certifications:

The Contractor shall provide certification that the strand burner system is designed to function a minimum of 20 years. All certifications shall be provided in accordance with CDRL A004 (DI-MISC-81356), Certificate of Compliance.

5 DATA

5.1 Contract Data Requirement List (CDRL):

Contractor shall provide a minimum of two (2) copies of contract information data, one

(1) hard (paper) copy and one (1) electronic copy, in accordance with the corresponding requirement for each Data Item below:

CDRL Title Data Item

Description PD Paragraph

A001 Acceptance Test Plan DI-QCIC-80553 3.8 A002 Acceptance Test Report DI-QCIC-81891 3.8

A003 Commercial Off-The-Shelf (COTS) Manuals &

Associated Supplemental Data

DI-TMSS-80527 4.2

A004 Certificate of Compliance DI-MISC-81356 4.3

Appendix C - SAFETY

SAFETY, FIRE PROTECTION AND HEALTH

SPECIFICATION

INDUSTRIAL SAFETY REQUIREMENTS

OGDEN AIR LOGISTICS COMPLEX

UNITED STATES AIR FORCE

HILL AIR FORCE BASE, UTAH 84056

11 March 2025

Reviewed by:

Day, Brent W.

OO-ALC/SE

801-586-1472

Control Number: BD2503002

A. Safety Program Requirements

The contractor shall implement a safety program plan that ensures protection of Government personnel and property. The program shall consist of, as a minimum:

1. Mishap reporting, as defined in paragraph B1 below.

2. A Safety Plan that addresses, as a minimum, the subjects listed in Section II –Specific Requirements and shall be used during the performance of the work described in the contract.

The Safety Plan shall be approved by OO-ALC/SE (Safety Office) prior to commencement of any work described in this contract.

3. Routine and recurring surveillance to ensure the safety requirements of this contract are enforced.

4. Competent personnel to provide surveillance of the Safety Plan.

5. Identification of segregated work site locations for operations that cannot be co-mingled with general industrial operations and the process for ACO approval of operations and changes at these specific sites.

6. All contractor personnel shall be trained and qualified to perform their duties safely.

7. The contractor shall include a clause in all subcontracts requiring the subcontractors to comply with the safety provisions of this contract, as applicable.

B. Mishap Notification

1. The contractor shall notify OO-ALC/SE Workflow (OO-ALC.SE.Workflow@us.af.mil) or the Hill AFB Command Post (801-777-3007) after normal duty hours, and the designated Government Representative (GR), i.e., the ACO, PCO, or DCMA QAR (Quality Assurance Representative) within one (1) hour of all mishaps or incidents at or exceeding $2,000 (material + labor) in damage to DOD property entrusted by this contract, even if the government is wholly or partially reimbursed. This notification requirement shall also include physiological mishaps/incidents. A written or email copy of ALL the mishap/incident notification shall be sent within three calendar days to the GR, who will forward it to OO-ALC/SE. For information not available at the time of initial notification, the contractor shall provide the remaining information no later than 20 calendar days after the mishap, unless extended by the ACO.

Mishap notifications shall contain, as a minimum, the following information:

(a) Contract, Contract Number, Name and Title of Person(s) Reporting

(b) Date, Time, and exact location of accident/incident

(c) Brief Narrative of accident/incident (Events leading to accident/incident)

(d) Cause of accident/incident, if known

(e) Estimated cost of accident/incident (material and labor to repair/replace)

(f) Nomenclature of equipment and personnel involved in accident/incident

(g) Corrective actions (taken or proposed)

(h) Other pertinent information

2. The contractor shall cooperate with all government mishap investigations. Additionally, if requested by government personnel or designated government representative (GR), i.e., the ACO, PCO, or DCMA QAR (Quality Assurance Representative), the contractor shall immediately secure the mishap scene/damaged property and impound pertinent maintenance and training records, until released by safety investigators.

3. The contractor shall provide copies of contractor data related to mishaps, such as contractor analyses, test reports, summaries of investigations, etc. as necessary to support the government investigation.

4. The contractor shall support and comply with the safety investigation and reporting requirements of DAFI 91-204, Chapters 1 – 5.

C. General Safety Requirements:

If the safety plan is modified, the contractor shall submit the proposed modification, in writing, to the Contract Administration Office safety representative.

The contractor is solely responsible for compliance with all federal, state and local laws, the Occupational, Safety and Health Act (OSHA) (Public Law 91-596) and the resulting standards, OSHA Standards 29 CFR 1910 and 1926, as applicable, Air Force Occupational Safety and Health Standards (AFOSH STD), to include DAFMAN 91-203, Air Force Occupational Safety, Fire, and Health Standards, DAFI 91-204, Safety Investigations and Reports, Contract Safety, and the protection of their employees. Additionally, the contractor is responsible for the safety and health of all subcontractor employees.

The contractor shall ensure assigned personnel are adequately trained and qualified for the task being performed. Brief all personnel on the hazards involved with operations and applicable precautions to be taken. Should unidentified hazards arise, cease operations until actions are taken to eliminate or mitigate hazards to safe levels.

Compliance with OSHA and other applicable laws and regulations for the protection of contractor employees is exclusively the obligation of the contractor. Note: AFOSH STDs are annotated because many of the Air Force Standards exceed the OSHA standard criteria. If a conflict is noted, the most stringent requirement takes precedence. The government shall assume no liability or responsibility for the contractor's compliance or non-compliance with such requirements.

The contractor shall furnish to each of his/her employees a place of employment, which is free from recognized hazards. The contractor shall brief his/her employees on the safety requirements of this contract and on hazards associated with prescribed tasks. The contractor is responsible for compliance with OSHA Public Law and the resultant standards identified within. In addition, the contractor is required to flow down the safety requirements/specification to all subcontractors. This applies to Federal Acquisition Regulation (FAR) 12 commercial acquisitions as well. This contract shall in no way require persons to work in surroundings or under working conditions which are unsafe or dangerous to their health. The contractor must coordinate and perform work so as not to impact the safety of government employees or cause damage to government property. This requires providing personnel with protective equipment and associated safety equipment as may be necessary. The contractor must also protect personnel from hazards generated by the work.

If the contractor employs BILINGUAL speaking employees, they must post bilingual signs and have written procedures for specific tasks in applicable languages.

SECTION II – SPECIFIC REQUIREMENTS

The contractor’s prepared Safety Plan shall:

Provide contact information for on-site personnel.

Include a work hazard analysis of the worksite and operations to be performed to include baseline hazard identification and required control measures.

Identify employee safety and health training requirements and the documentation process.

The contractor shall ensure that each element identified below is adequately addressed in detail in the safety and health plan:

PEDESTRIAN CROSSWALKS: All contractor personnel are required to use the closest crosswalk, or traffic-controlled intersection when crossing the road. Pedestrians must look both ways to ensure the coast is clear before stepping out into the crosswalk. Pedestrians DO NOT have the right of way unless they are already in the crosswalk. Contractor vehicle operators have the same responsibilities as pedestrians, to share the road and mutually observe and yield to pedestrians.

MOTOR VEHICLES: Contractor shall comply with the standards in: DoD Directive 5525.4, Enforcement of State Traffic Laws on DoD Installations", Nov 2, 1981, Para 3-4;

DODI 6055.4, DoD Traffic Safety Program, 20 Jul 99; AFI 91-207, USAF Traffic Safety Program, 22 May 07; Each applies to all persons at any time on an Air Force Installation and includes all leased, owned, or privatized property including housing areas. In addition:

AFI 13-213, Airfield Management, 29 Jan 08, Paragraphs 1.3.6 and 4.4.2.1 applies to all contractors, sub-contractors, vendors, commercial delivery companies, and all other private business vehicles who operate anywhere on Hill Air Force Base, including the airfield (to include the industrial areas and any buildings or hangars located upon the airfield) in support of their mission.

HOUSEKEEPING: Housekeeping shall be conducted according to the requirements in OSHA Standard 29 CFR 1910.141. CLEAN AS YOU GO will be enforced.