Test Stand Data Acq System SOW_21Jan21.pdf

STATEMENT OF WORK

For

44X100 Test Stand

Data Acquisition System

Upgrade

Dated:

21 January 2021

Air Driven Accessories Tinker A.F.B., OK 73145

Prepared by:

76 CMXG/MXDEA

Section One

1. Scope

1.1. This Statement of Work (SOW) establishes the minimum requirements for the purchase, design requirements, delivery, installation, and verification of one (1) replacement Data Acquisition System for the existing Pneumatic Test Stand (Model 44X100) with equipment and accessories specified herein; and training on the maintenance, calibration, programming, and use of the replacement system. The Pneumatic Test Stand is currently used to functionally test B-1, B-2, B-52, C-5, C-130, KC-135, E-3, F-15, F-16, and F-22 high pressure air Control Valves as required per relevant Technical Order (T.O.)

instructions.

1.2 Background

1.2.1 The Data Acquisition System described in this document is intended for use in the Aerospace Repair Industry. The Data Acquisition System shall replace the existing data acquisition system utilized on the currently operational Pneumatic Test Stand. The current system is comprised of a computer with Windows XP operating system, obsolete data acquisition components, and proprietary programming. The Pneumatic Test Stand is operated in Building 200, Room 144 at Tinker Air Force Base (TAFB) OK 73145.

1.3 Item Description

1.3.1 76 CMXG request the purchase of the following item(s):

1.3.1.1 One (1) Replacement Data Acquisition System for the 44X100 Pneumatic Test Stand to include:

a. Initial Design Review

b. Final Design Review

c. Hardware Delivery

d. Installation

e. Acceptance Testing

f. Training

g. Documentation

h. The Contractor shall be responsible for insuring all services, parts and components provided under this contract are In Accordance With (IAW) the terms and conditions outlined in this Statement of Work (SOW).

1.4 Requirements

1.4.1 Period of Performance: The Contractor shall complete all work associated with this Statement of Work no later than twelve (12) months from contract award date.

1.4.2 The Data Acquisition System upgrade shall be new, unused and based on the design of the existing Pneumatic Test Stand.

1.4.3 All Data Acquisition System components shall be available as commercial off the shelf

(COTS) items.

1.4.4 The current manuals and software of the current data acquisition system and Pneumatic

Test Stand are proprietary to the Original Equipment Manufacturer and will not be available to use for this effort.

1.5 Prohibited Materials:

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

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

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

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

1.5.4.1 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.

1.6 Design and Construction

1.6.1 Data Acquisition System:

1.6.1.1 The Contractor shall provide one (1) new data acquisition system upgrade for the Pneumatic Test Stand.

1.6.1.2 The Contractor shall use a computer with data acquisition cards and/or a programmable logic controller (PLC) for the new data acquisition system.

1.6.1.3 The analog to digital converter shall be sixteen (16) bit or better.

1.6.1.4 The data acquired shall be for calculating air flows and displaying the Unit Under Test (UUT) test data on the LED touchscreens.

1.6.1.5 The data acquisition system shall be capable of displaying all transducer inputs on the LED touchscreens.

1.6.1.6 The data acquisition system shall have a minimum update response time of 100 millisecond.

1.6.1.7 The Contractor shall provide new DC power supplies required for the operation of the data acquisition system.

1.6.1.8 The data acquisition system shall directly connect to the existing transducers at a terminal location. No wire splices shall be allowed. No existing data acquisition system signal conditioners, filters, or circuit boards shall be utilized.

1.6.1.9 All computer components and computer data acquisition cards shall be mounted in a standard 19 inch rack mount enclosure with a minimum 4U height.

1.6.1.10 The Contractor shall provide one (1) each computer keyboard, one (1) each computer mouse, and one (1) each mouse pad.

1.6.1.11 The Contractor shall ensure adequate ventilation of all computer components and PLC equipment.

1.6.1.12 The data acquisition system shall be housed in the existing Pneumatic Test Stand without modification to any structural component or panel.

1.6.1.13 The data acquisition system shall interface with the existing pressure transducers, temperature sensors, and flow meters shown in Table 1.

Item Item Number

Identifier Number

Test Instrument

Manufacturer Order Code

Excitation or Input Voltage / Output Signal

1 E400A GP7 Pressure Transducer

Sensotec

FPG1DR2U5B6A

10.0 VDC

mv/v

2 E401A GP1 Pressure Transducer

Sensotec

FPG1CV2U5B6A

10.0 VDC

mv/v

3 E402A GP8 Pressure Transducer

Sensotec

FPG1CT2U5B6A

10.0 VDC

mv/v

4 E403A GP2 Pressure Transducer

Sensotec

FPG1CR2U5B6A

10.0 VDC

mv/v

5 E404A GP9 Pressure Transducer

Sensotec

FPG1CN2U5B6A

10.0 VDC

mv/v

6 E404B GP3 Pressure Transducer

Sensotec

FPG1CN2U5B6A

10.0 VDC

mv/v

7 E404C GP10 Pressure Transducer

Sensotec

FPG1CN2U5B6A

10.0 VDC

mv/v

8 E405A GP4 Pressure Transducer

Sensotec

FPG1BN2U5B6A

10.0 VDC

mv/v

9 E406A GD2 Pressure Transducer

Sensotec

FDW1CJ2U5B6A

10.0 VDC

mv/v

10 E407A GP11 Pressure Transducer

Sensotec

FPV1UG2U5B6A

10.0 VDC

mv/v

11 E407B GP5 Pressure Transducer

Sensotec

FPV1UG2U5B6A

10.0 VDC

mv/v

Identifier Number

Test Instrument

Manufacturer Order Code

Excitation or Input Voltage / Output Signal

12 E408A GD3 Pressure Transducer

Sensotec

FPW1WP2U5B6A

10.0 VDC

mv/v

13 E409A GD5 Pressure Transducer

Foxboro IDP10-

V22B11F-Z1-100-IN-

H20

9 – 30 VDC

1 – 5 VDC

14 E410A GD4 Pressure Transducer

Sensotec

FDW1UI2U5B6A

10.0 VDC

mv/v

15 E411A GP Pressure Transducer

Sensotec

FPA1CT2U5B6A

10.0 VDC

mv/v

16 E412A GP0 Pressure Transducer

Sensotec

AP122CT1A6A

10.0 VDC

mv/v

17 E413A GD1 Pressure Transducer

Foxboro IDP10-

V22B11F-Z1-200-IN-

H20

9 – 30 VDC

1 – 5 VDC

18 E4A T1 Thermocouple J-Type 19 E4B T2 Thermocouple J-Type 20 E420A T3 Thermocouple J-Type 21 E420B T4 Thermocouple J-Type 22 E420C T5 Thermocouple J-Type

23 E525A FM4 Flow Meter Teledyne HFM-

3000101020201-(100-

1000 SCCM) - AIR

11 – 36 VDC

0 – 5 VDC

24 E526A FM3 Flow Meter Teledyne HFM-

3000101020201-(10-

100 SCCM) - AIR

11 – 36 VDC

0 – 5 VDC

0 – 40 VDC

Power Supply Voltage

0 – 40 VDC

Current

0 – 300 VDC

Voltage

0 – 300 VDC

Current

Table 1.0 – Existing Instrumentation (Analog Inputs)

1.6.1.14 The data acquisition system shall be equipped with a minimum of thirty-two

(32) Analog Input (AI) channels. Twenty-eight (28) AI channels shall be for the existing instrumentation indicated in Table 1.0 and four (4) AI channels shall be spares.

1.6.1.15 The data acquisition system shall be equipped with a minimum of six (6) Analog Output (AO) channels. Four (4) shall be for the control of the instrumentation in Table 2.0 and two (2) shall be for spares.

Item Function

1 0 – 40 VDC Power Supply Output Voltage 2 0 – 40 VDC Power Supply Output Current 3 0 – 300 VDC Power Supply Output Voltage 4 0 – 300 VDC Power Supply Output Current

Table 2.0 – Control Chanels (Analog Outputs)

1.6.1.16 The data acquisition system shall interface with the existing safety hardware as shown in Table 3.0.

Item Function

1 Emergency Stops 2 Unit Under Test Switch 1 3 Unit Under Test Switch 2 4 Door Safety

Table 3.0 – Existing Safety Hardware (Digital Inputs)

1.6.1.17 The data acquisition system shall be equipped with a minimum of six (6) Digital Input (DI) channels. Four (4) DI channels shall be utilized for the hardware in Table 2.0 and two (2) DI channels shall be for spares.

1.6.1.18 The data acquisition system shall interface with the existing control hardware as shown in Table 4.0.

Function

1 E533C 100 / 5000 psig 2 E533D 10 / 600 psig 3 E533E 5 / 450 psig 4 E533F 0 / 150 psig 5 E533G 0 /100 psig 6 E533H 28 HG / 10 psig 7 E533I High Facility Pressure System 6500 psig 8 E533J Low Facility Pressure System 850 psig 9 0 – 40 VDC Power Supply On/Off 10 0 – 300 VDC Power Supply On/Off

Table 4.0 – Existing Control Hardware (Digital Outputs)

1.6.1.19 The data acquisition system shall be equipped with a minimum of twelve (12) Digital Output (DO) channels. Ten (10) DO channels shall be utilized for the hardware in Table 3.0 and two (2) DO channels shall be for spares.

1.7 System Accuracy

1.7.1 The Contractor shall ensure the Upgraded System Accuracy Relative to Input (RTI) for each transducer is a minimum of the values shown in Table 5.0 utilizing the Contractor provided components.

1.7.2 The Contractor shall provide calculations to verify the Upgraded System Accuracies. The

Contractor shall determine the Absolute Accuracy for each component. The Contractor shall determine the Upgraded System Accuracy RTI based on the square root of the sum of the squares of each component’s Absolute Accuracy divided by the input voltage based on the Contractor provided components.

1.7.3 The temperature shall be assumed to be 75 degrees Fahrenheit. No Temperature Drift adjustment is required.

1.7.4 The Contractor shall provide documentation in Word 2010 or Excel 2010 or higher detailing formulas, calculations, results, and comparison of System Accuracy results to Table 5.0.

Item Item Number Test Instrument System Accuracy RTI

1 E400A 0 – 5000 psig Pressure Transducer

1.50%

2 E401A 0 – 1000 psig Pressure Transducer

1.50%

3 E402A 0 – 750 psig Pressure Transducer

1.00%

4 E403A 0 – 500 psig Pressure Transducer

1.00%

5 E404A 0 – 250 psig Pressure Transducer

1.00%

6 E404B 0 – 250 psig Pressure Transducer

1.00%

7 E404C 0 – 250 psig Pressure Transducer

1.00%

8 E405A 0 – 50 psig Pressure Transducer

1.00%

9 E406A 0 – 150 psid Pressure Transducer

1.00%

10 E407A 0 – 30 inches HG Vacuum Pressure Transducer 1.00%

11 E407B 0 – 30 inches HG Vacuum Pressure Transducer 1.00%

12 E408A 0 – 200 inches H2O Pressure Transducer

1.00%

13 E409A 0 – 100 inches H2O Pressure Transducer 1.00%

14 E410A 0 – 50 inches HGD Pressure Transducer

1.00%

15 E411A 0 – 750 psia Pressure Transducer

1.00%

16 E412A 0 – 750 psia Pressure Transducer

1.00%

17 E413A 0 – 200 inches H2O Pressure Transducer 1.00%

18 E4A 32 F – 250 F J Type Thermocouple

2.00%

19 E4B 32 F – 250 F J Type Thermocouple

2.00%

20 E420A 32 F – 250 F J Type Thermocouple

2.00%

21 E420B 32 F – 250 F J Type Thermocouple

2.00%

22 E420C 32 F – 250 F J Type Thermocouple

2.00%

Item Item Number Test Instrument Manufacturer / Part Number 23 E525A Flow Meter 1.50% 24 E526A Flow Meter 1.50%

25 0 – 40 VDC Power Supply Voltage 1.50%

26 0 – 40 VDC Power Supply Current 1.50%

27 0 – 300 VDC Power Supply Voltage 1.50%

28 0 – 300 VDC Power Supply Current 1.50%

Table 5.0 – System Accuracy RTI Requirements

1.8 DC Power Supplies

1.8.1 The Contractor shall remove the two (2) existing DC power supplies.

1.8.2 The Contractor shall install one (1) each new Government furnished 0 – 40 VDC Power Supply. The power supply furnished will be an Ametek (Sorensen) Model Number DLM 40-15.

The power supply manual can be provided or can be found online at the manufactures’ website at https://www.powerandtest.com/- /media/ametekprogrammablepower/files/pdfs/dlm600/operationsmanualrevk.pdf?rev=158522922 4948.

1.8.3 The 0 – 40 VDC Power supply can work in conjunction with the current Pneumatic Test Stand wiring system rated for 6 amps and fused at 7 amps.

1.8.4 The Contractor shall install one (1) each new Government furnished 0 – 300 VDC Power Supply. The power supply furnished will be an Ametek (Sorensen) Model Number DLM 300-2.

The power supply manual can be provided or can be found online at the manufactures’ website at https://www.powerandtest.com/- /media/ametekprogrammablepower/files/pdfs/dlm600/operationsmanualrevk.pdf?rev=158522922 4948.

1.8.5 The 0 – 300 VDC Power supply can work in conjunction with the current Pneumatic Test Stand wiring system rated for 1 amp and fused at 2 amps.

1.8.6 The Contractor shall remove the existing voltage dividers and shunts.

1.8.7 The contractor shall remove existing wiring and install new wiring as required for installation and operation of the new DC Power Supplies.

1.8.8 The Contractor shall provide and install new hardware to enable DC voltage and current detection for display on the LED touchscreens.

1.8.9 The Contractor shall design, fabricate, and support plates required to mount the power supplies in the Pneumatic Test Stand. The mounting shall ensure adequate ventilation for the DC Power Supplies. The support plates shall be powder coated.

1.8.10 The existing data acquisition system incorporates two (2) DC Power Supplies, one (1) Multimeter, and one (1) Oscilloscope Data acquisition board. The Multimeter and Oscilloscope functions are no longer required.

1.9 LED Touch Screen Displays

1.9.1 The data acquisition system upgrade shall include three (3) new LED touch screen displays.

1.9.2 The new displays shall replace the current two displays.

1.9.3 Each LED display shall be touch screen, 19 inch minimum and capable of plus or minus https://www.powerandtest.com/-/media/ametekprogrammablepower/files/pdfs/dlm600/operationsmanualrevk.pdf?rev=1585229224948 https://www.powerandtest.com/-/media/ametekprogrammablepower/files/pdfs/dlm600/operationsmanualrevk.pdf?rev=1585229224948 https://www.powerandtest.com/-/media/ametekprogrammablepower/files/pdfs/dlm600/operationsmanualrevk.pdf?rev=1585229224948 https://www.powerandtest.com/-/media/ametekprogrammablepower/files/pdfs/dlm600/operationsmanualrevk.pdf?rev=1585229224948 https://www.powerandtest.com/-/media/ametekprogrammablepower/files/pdfs/dlm600/operationsmanualrevk.pdf?rev=1585229224948 https://www.powerandtest.com/-/media/ametekprogrammablepower/files/pdfs/dlm600/operationsmanualrevk.pdf?rev=1585229224948

85 degree wide side to side viewing angles with a minimum of 1280 x 1024 resolution.

The displays shall have at a minimum 1000:1 contrast ratio, a minimum of 250 nits brightness, and a minimum lifetime of 40,000 hours.

1.9.4 Each LED display shall be designed to mount in a standard 19 rack enclosure.

1.9.5 The Contractor shall provide one (1) new articulating arm. The articulating arm will house one (1) of the 19 inch rack mount LED touchscreens. The articulating arm shall be fabricated to accept standard 19 inch rack mount hardware. The articulating arm shall be equipped with a mechanism to allow easy vertical, horizontal, and monitor rotation adjustment by the test stand operator. The adjustable vertical travel shall be a minimum of 13 inches. The arm shall be located on the front side of the test stand and on the left side of the test stand safety enclosure as viewed by the operator. The Contractor shall design, provide, and install all hardware required to securely mount the articulating arm on the Pneumatic Test Stand.

1.9.6 The Contractor shall mount one (1) LED touchscreen in a 20.25 inch wide by 15.5 inch tall opening. The Contractor shall design, fabricate, and powder coat a mounting plate that shall accommodate the 19 inch rack mount LED display and mount to the Test Stand.

1.9.7 The two (2) LED touchscreens in Sections 2.3.3.5 and 2.3.3.6 shall display the same data screens at the same time.

1.9.8 The Contractor shall mount one (1) 19 inch rack mount LED display in the current display location. The Contractor shall design, fabricate, and install mounting plates that shall cover any openings on the front panel at the locations of the new LED displays. The plates shall be powder coated.

1.10 USB Ports

1.10.1 The Contractor shall provide and install three (3) panel mounted USB ports located on the front panel of the Test Stand.

1.10.2 The Contractor shall provide and install three (3) panel mounted USB ports located on the left side of the Articulating Arm.

1.11 Software

1.11.1 The data acquisition system shall utilize commercial off the shelf (COTS) programming software. All software versions shall be the latest available. Both computer and or PLC shall have a hardware method to ensure a backup program can be copied and installed from a removable media source.

1.11.2 Computer based systems shall utilize Windows 10 Professional 64 Bit.

1.11.3 The computer and/or PLC shall be capable of three (3) levels for password protection. The minimum password protection levels required shall be for the operator, the calibration technician, and administrative (engineering).

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

1.11.3.2 Calibration Technician 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.

1.11.3.3 Administrative level: Allows access to all previous levels as well as capability to modify any test stand software as necessary. Any changes to software shall cause the associated revision level of the software to change to the next logical level, i.e., rev levels shall not be check sum based.

1.11.4 The programming shall allow for displaying the required end item test parameters.

1.11.5 The Contractor shall provide two (2) each copies of all programming source code on two

(2) DVD.

1.11.6 The Contractor shall provide one (1) each spare hard drive with a duplicate image of the computer hard drive.

1.11.7 The Contractor shall provide two (2) each backup copies of the PLC programming on a

DVD or required PLC Media.

1.11.8 The Contractor shall provide legal licensed copies of all software utilized in the data acquisition system.

1.11.9 The Contractor shall provide licenses for all software.

1.11.10 The Contractor shall provide the Government all software codes, password codes for accessing the system. The Codes shall be in a document in Word 2010 or higher on a DVD.

1.11.11 The Government shall have unlimited rights for all non-COTS software developed for this effort.

1.12 Test Screens

1.12.1 The data acquisition system shall be capable of displaying all pressure transducers, temperature sensors, flow meters, DC voltages, DC, currents, and Channel 1 and Channel 2 flow calculations required for UUT testing on the LED touchscreen displays.

1.12.2 The test screens shall provide for on screen control of the two (2) DC Power Supplies.

The control shall include on and off selection and the ability to enter set point values for the voltage and current for each power supply.

1.12.3 The test screens shall be configurable for a minimum of 100 different UUTs.

1.12.4 The test screen data display fields shall be a minimum of 0.75 inches high.

1.12.5 The test screens shall be capable of displaying a minimum ten (10) data fields and shall display no more than twenty (20) data fields.

1.12.6 Test variables shall be capable of being indicated in three ways: red if out of limits on the upper side of UUT Technical Data requirements, green if in limits of UUT Technical Data requirements, and yellow if out of limits on the lower side of UUT Technical Data requirements.

1.12.7 The test screens shall allow operator input of required flow orifice plate sizes for each of the two (2) orifice flow channels by utilizing the touch screen LED display.

1.12.8 The test screens shall be capable of indicating when each of the two (2) DC Power

Supplies are powered On and Off.

1.12.9 The display software shall be capable of test screen modifications including changes to test parameter limits and addition and deletion of transducer outputs limits without going into the main programming level.

1.12.10 The test screens shall be capable of inputting or selecting the required orifice channel and orifice size utilized for UUT testing.

1.12.11 The test screens shall be capable of indicating the selected orifice size for each of the two

(2) orifice flow channels.

1.12.12 The Government will approve all test screens prior to the installation of the data acquisition system.

1.13 Calibration Screens

1.13.1 The Contractor shall develop and program calibration screens which will be displayed on the LED displays.

1.13.2 The calibration screens shall be capable of recording as found, as left, and calibration summary data as a minimum and displaying the data on the LED display.

1.13.3 The calibration screens shall be capable of indicating the RAW values and the scaled values on the same screen.

1.13.4 The calibration screens shall have user input multi-point alignment tables for the required transducers.

1.13.5 The Contractor shall provide screen shots of the calibration screens at the Final Design

Review. The Government will approve the calibration screens within 10 calendar days after the Final Design Review.

1.14 Diagnostic Screens

1.14.1 The Contractor shall provide diagnostic screens that indicate First Out Alarms or Test Stand Shut-Down Alarms.

1.15 Flow Programming Calculations

1.15.1 The data acquisition system upgrade shall work with the current pressure transducers, temperature sensors, and orifice flow sections listed in Tables 1.0 and 6.0 to perform automatic flow calculations.

1.15.2 The flow calculations shall be based on American Gas Association (AGA) Report Number

3 Part 3 Orifice Metering of Natural Gas and other related Hydrocarbon Fluids – Concentric, Square-edged Orifice Meters, and Natural Gas Applications dated November 2013 or later.

1.15.3 The data acquisition flow programming shall be capable of updating and displaying the flow values for each of the two (20 orifice flow channels at a minimum update rate of 100 milliseconds.

1.15.4 The data acquisition programming shall provide for flow calculations based on the current test stand orifice flow sections, orifice sizes, pressure ranges, and flow ranges shown in Table 4.0.

1.15.5 The data acquisition programming shall allow for selection of the various orifice sizes indicated in Table 6.0 and automatically utilize the selected size for the flow calculations.

1.15.6 The flow calculation programming shall require correlation testing utilizing 12 data points for each of the current 1/2 inch flow channel utilizing six different orifice sizes and the 1 inch flow channel utilizing four different orifice sizes and the current as shown in Table 2.0.

Channel Channel

Bore Size Orifice

Size Data

Points Pressure Range

Flow Range

(inches (inches) (psia) (ppm)

FM1 0.560 0.033 10 15 to 515 0.003 to 0.059 FM1 0.560 0.053 10 15 to 515 0.009 to 0.158 FM1 0.560 0.087 10 15 to 515 0.023 to 0.410 FM1 0.560 0.138 10 15 to 515 0.060 to 1.061 FM1 0.560 0.211 10 15 to 515 0.150 to 2.637 FM1 0.560 0.322 10 15 to 515 0.420 to 7.383 FM2 1.065 0.207 10 15 to 515 0.130 to 2.344 FM2 1.065 0.321 10 15 to 515 0.330 to 5.859 FM2 1.065 0.500 10 15 to 515 0.900 to 15.821

FM2 1.065 0.717 10 15 to 515 2.400 to 42.188 Table 6.0 – Orifice Flow Calculation Verifications

1.16 Standard Products/Service Availability

1.16.1 Materials and equipment furnished by the Contractor shall be new and standard products of a manufacturer regularly engaged in the manufacture of such products. The standard products shall have been in satisfactory commercial and/or industrial use for two (2) years prior to proposal and still be in production at the time of award of this contract.

1.17 Emergency Stops

1.17.1 The Contractor shall provide interfaces for the existing test stand emergency stop buttons.

1.17.2 The emergency stop buttons shall remove all air and power from the end item testing area identical to the current system.

1.18 Protection Circuits

1.18.1 The data acquisition system upgrade shall provide all protection circuits and safety shutoffs that the current system performs. The circuits shall automatically reset upon determination of safe or in limits conditions identical to the current system.

1.19 Facility Utilities/Connections

1.19.1 The data acquisition system upgrade shall utilize the existing Pneumatic Test Stand internal electrical power availability. No modifications to the existing Pneumatic Test electrical system shall be performed.

1.20 Electrical

1.20.1 The label or listing of the Underwriters Laboratories, Inc. (UL), shall be accepted as evidence that the materials or equipment conform to the applicable standards of that agency. In lieu of this label or listing, a statement from a nationally recognized, adequately equipped testing agency indicating that the items have been tested IAW required procedures and that the materials and equipment comply with all contract requirements will be accepted. -

1.20.2 For other than equipment and materials specified to conform to UL publications, a manufacturer's statement indicating complete compliance with the applicable Federal Specification, or standard of the American Society for Testing and Materials, National Electrical Manufacturers Association (NEMA), or other commercial standard, is acceptable.

The data acquisition system shall utilize multiple colored wires for the different types of wiring circuits for all new required wiring.

1.20.3 The data acquisition upgrade system wiring shall be labeled on both ends of all wires/cables with plastic sleeves or similar material describing wire list reference.

1.20.4 The Contractor shall ensure all new wire, components, equipment, and installation are in compliance with the latest versions of the NEC, NEMA standards and National Fire Protection Agency (NFPA) 70, NFPA 70E, and NFPA 79.

1.20.5 The Contractor shall not use splice connections for connection to existing terminals or hardware.

All wiring shall be continuous from end to end.

1.21 Pneumatic Test Stand Components

1.21.1 The contractor shall not relocate or modify any existing test stand components including but not limited to tubing, fittings, hoses, valves, pressure transducers, temperature sensors, flow meters, power supplies, or orifice plate flow section assemblies.

The contractor shall not relocate or modify any existing test stand electrical hardware that is not associated with the data acquisition system upgrade.

1.22 Labeling/Identification

1.22.1 The Contractor shall provide new labeling of all new components of the data acquisition system upgrade.

1.23 Installation

1.23.1 The Contractor shall begin installation of the data acquisition system upgrade only after approval of the Final Review.

1.23.2 The installation shall comply with the latest edition of the NEC and NFPA codes.

1.23.3 The Contractor shall provide a schedule which shall include as minimum the following phases; design, material procurement, pre-fabrication, installation, operational check out, calibration, and acceptance testing. The initial build schedule shall be provided at the Initial Design Review.

1.23.4 The Contractor shall provide the data acquisition system upgrade installation start date sixty (60) calendar days in advance (in writing) to the Government POC.

1.23.5 The Contractor shall remove all equipment, hardware, and electrical wiring and conduit replaced by the new data acquisition system.

1.23.6 The Contractor shall remove the existing data Acquisition system, two (2) DC power supplies, multimeter, circuit boards, and hardware not required by the new data acquisition system.

1.23.7 The Contractor shall remove the existing integrated Multimeter.

1.23.8 The Contractor shall remove all unused wiring back to the nearest terminal block or termination. All unused wire shall be terminated at terminal block. No wire nuts shall be used to terminate a wire.

1.23.9 All removed hardware shall remain the property of the Government.

2. Design Reviews and Evaluation

2.1 Initial Design Review

2.1.1 The Contractor shall provide a Preliminary Design Review. The review shall be completed at the zero to five percent (0-5%) design stage.

2.1.2 The Contractor shall conduct the meeting at Tinker Air Force Base (TAFB) or by telephone. The date and time will be coordinated by the Government POC.

2.1.3 The Contractor shall submit two (2) paper copy packages and one (1) electronic copy of the data package on DVD. The package shall include the engineering data, specifications, certificates, reports, and final products including catalog excerpts and salient characteristics to the Government POC. The submittal shall be sent via FedEx or UPS to the Government POC NLT seven (7) calendar days prior to meeting. The Contractor shall not use USPS to send the documentation.

2.1.4 The Contractor shall be responsible for taking minutes during the on-site meeting and shall provide one (1) electronic copy on Word 2010 or higher via email to the Government POC NLT seven (7) calendar days after the meeting date.

2.2 Final Design Review

2.2.1 The Contractor shall provide a Final Design Review. The design review shall be completed approximately 95 percent (95% into the design stage.

2.2.2 The Contractor shall conduct the meeting at Tinker Air Force Base (TAFB).

The date and time will be coordinated by the Government POC.

2.2.2.1 The Contractor shall submit two (2) paper copy packages and one (1) electronic copy of the data package on DVD including engineering data, specifications, certificates, reports, and final products including catalog excerpts and salient characteristics to the Government POC. The submittal shall be sent via FedEx or UPS to the Government POC NLT seven (7) calendar days prior to meeting. The Contractor shall not use USPS to send the documentation.

2.2.3 The Contractor shall provide one (1) electronic copy on Word 2010 or higher via email to the Government POC NLT seven (7) calendar days after the meeting date.

2.2.4 The Final Design shall be approved by the Government POC in writing prior to purchase of any materials or fabrication.

2.3 Calibration

2.3.1 The Contractor shall provide the required training of calibration support technicians per Section 7. The Government will calibrate the test stand after Contractor provided training is completed. The Contractor shall assist Government calibration personnel during initial calibration of the test stand.

2.3.2 The Contractor shall not perform acceptance testing IAW the approved Acceptance

Test Procedure until after calibration is executed by Government Calibration personnel.

2.4 Acceptance Testing

2.4.1 The Government tester shall execute Acceptance Testing for each end item asset listed in Table 1.

2.4.2 The Government tester shall perform Acceptance Testing on the Pneumatic Test Stand after operational checkout and calibration is complete.

2.4.3 Acceptance Testing shall include on-site tests of each of the three (3) end items on the current configured Pneumatic Test Stand. The Acceptance Testing will be performed at Tinker AFB at the Pneumatic Test Stand. Each end item will be tested three (3) times. The Contractor shall witness the testing of the three (3) end items on the existing test stand at Tinker to verify the test results. A Government Technical representative will be present during the testing. The on-site tests of the end items shall serve as the correlation reference by which the upgrades to the test stand will be verified. The Government will package and store the three (3) end items after testing on the existing test stand. The Contractor shall be responsible for correction of any deficiencies in the test stand upgrade design to ensure successful testing of each of the three (3) end items. In the event, that the test results cannot be correlated, additional test runs of the end items shall be conducted by Contractor to determine the root cause.

The Contractor shall provide an Acceptance Test Report upon successful testing of the end items on the Pneumatic Test Stand.

2.4.4 The required hours for performance testing each end item for one complete test are provided in Table 5.0.

Item

Description Control Number Technical

Order Test Type Standard Test

Time

Valve 15464A

15E2-2-65-3

3 run correlation 1.05 hrs. per test

Valve 36389A 9P10-4-30-3 3 run correlation 1.10 hrs. per test

Valve 33488A 9H8-4-222-3 3 run correlation 1.47 hrs. per test

Table 5.0 – End Items for Acceptance Testing

2.4.5 The required hours for performance testing each end item for one complete test are provided in Table 5.0.

2.4.6 The Contractor shall provide an Acceptance Test Report after successful Acceptance Testing is complete. The Contractor shall provide one (1) paper copy and one (1) electronic copy in Word 2010 or higher on a DVD of the Acceptance Testing Report to the Government NLT seven (7) calendar days after the successful date of testing. The Government will have three (3) calendar days after receipt of the Acceptance Test Report to review and provide comments to the Contractor.

2.4.7 Technical Data

2.5 Technical Data

2.5.1 Manuals, Instructions, and Procedures

2.5.2 The Contractor shall develop and provide manuals for the data acquisition system.

The manuals shall be in Microsoft Word Version 2010 or higher. The manuals shall have separate sections which include Operation instructions, Maintenance instructions, Calibration instructions, Programming instructions, Detailed Drawings, Schematics and Illustrated Parts Breakdown. The Contractor shall provide a total of two (2) hard copies and two (2) electronic copies NLT seven (7) calendar days after the completion of the final acceptance of the data acquisition system to the Government POC. The Contractor shall provide the COTS operation, maintenance, calibration and programming manuals from the component manufacturer for the equipment and software provided.

2.5.3 The manuals shall only be required for the data acquisition system and integration into the existing Pneumatic Test Stand.

2.6 As-Built Drawings

2.6.1 The Contractor shall produce “as-builts” of the final configuration for the physical and software architecture of the system. The final configuration “as-builts” shall be representative of the actual installation at completion of project.

2.6.2 The drawings shall only be required for the data acquisition system and integration into the existing Pneumatic Test Stand. The Government shall have unlimited rights for all technical data developed for this effort.

2.7 Operation Instructions

2.7.1 The Contractor shall provide a complete set of instructions on the operation of the individual controls for each equipment item on the test stand in Microsoft Word Version 2010 or higher. The instructions shall include operation of the touch screen and controls.

2.7.2 The operation manual shall only be required for the data acquisition system and integration into the existing Pneumatic Test Stand.

2.8 Maintenance Instructions

2.8.1 The Contractor shall provide a complete list of materials and description where applicable, including manufacturer and model number, for all components used in the data acquisition system. The list shall also include a vendor source for all materials and parts.

2.8.2 The Contractor shall provide detailed drawings for all materials and equipment specified in the list. The drawings shall consist of a complete list of equipment and materials, including manufacturer's descriptive and technical data, catalog cuts and any special installation instructions which may be required. Drawings shall show applicable schematic diagrams and equipment layout. The Government shall have unlimited rights for all technical data developed for this effort.

2.8.3 The maintenance instruction and drawings shall only be required for the data acquisition system and integration into the existing Pneumatic Test Stand

2.9 Programming Instructions

2.9.1 The Contractor shall provide commercial and integration manuals for all software delivered as part of the data acquisition system.

2.10 Calibration Instructions

2.10.1 The Contractor shall provide a step-by-step instruction manual including required metrology equipment for the complete calibration of the data acquisition system in Microsoft Word Version 2010 or higher. The instruction manual shall provide all calibration procedures and unique support equipment required for calibration of the replaced components. The components shall include all pressure transducers, temperature sensors, and flow meters.

2.10.2 The Calibration instructions shall be submitted to the Government POC as part of the Final Design Review. The Government will have fourteen (14) calendar days after the meeting to complete the review and provide comments. If revised Calibration Instructions are required, the Contractor shall have fourteen (14) calendar days to submit the revised Calibration Instructions to the Government POC. The Government will complete the review of the revised Calibration Instructions and provide comments to the Government POC.

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

2.10.3.1 Review and perform entire calibration process step-by-step on the Pneumatic with installed data acquisition system upgrade with PMEL personnel present.

2.10.3.2 Modify calibration procedure as recommended and agreed to by

PMEL personnel, as necessary.

2.10.3.3 Modify calibration software as recommended and agreed to by PMEL personnel.

2.10.3.4 Once the calibration procedure is finalized, revised and resubmitted by

Contractor, PMEL will formally calibrate the Pneumatic Test Stand utilizing the data acquisition system upgrade. The Contractor shall have appropriate personnel present during the entire Final Calibration process.

2.11 Documentation

2.11.1 All documentation provided by the Contractor shall have the following disclosure notice statement on the cover page:

2.11.1.1 “DISCLOSURE NOTICE: This information is furnished upon the condition that it will not be released to another nation without the specific authority of the Department of the Air Force of the United States, that it will be used for military purposes only, that individual or corporate rights originating in the information, whether patented or not, will be respected, that the recipient will report promptly to the United States, any known or suspected compromise, and that the information will be provided substantially the same degree of security afforded it by the Department of Defense of the United States. Also, regardless of any other markings on the document, it will not be downgraded or declassified without written approval of the originating United States agency.”

2.11.2 All documentation provided by the Contractor shall have the following distribution statement on the cover page:

2.11.2.1 “DISTRIBUTION STATEMENT D: Distribution authorized to Department of Defense and U.S. DoD contractors only, Critical Technology 1 November 2002.”

2.11.3 All documentation provided by the Contractor shall have the following warning statement on the cover page:

2.11.3.1 “WARNING: This document contains technical data whose export is restricted by the Arms Export Control Act (Title 22, U.S.C. 2751 et seq.) or the Export Administration Act of 1979, as amended, Title 50, U.S.C., App. 2401, et seq. Violation of these export-control laws is subject to severe criminal penalties. Dissemination of this document is controlled under DoD Directive 5230.25.”

2.11.4 All documentation provided by the Contractor shall have the following handling and destruction notice statement on the cover page:

2.11.4.1 “HANDLING AND DESTRUCTION NOTICE: Destroy by any method that will prevent disclosure of contents or reconstruction of the document.”

2.11.5 All designs, drawings, specifications, notes and other works developed or modified in the performance of this contract shall become the sole property of the Government and may be used on any other design or fabrication without additional compensation to the Contractor

3. Training and Familiarization

3.1 The Contractor shall provide a training session for calibration support technicians.

Training for the calibration support technicians will be for three (3) technicians. The training time will be four (4) hours at the upgraded Test Stand in Room 142, Building 200 Tinker AFB, OK.

3.2 The Contractor shall provide a training session for test operators. Training for the test operators will be for two (2) operators. The training time will be two (2) hours.

3.3 The Contractor shall provide a training session for maintenance technicians. Training for the maintenance technicians will be for four (4) technicians. The training time will be two (2) hours.

4. Warranty

4.1 The Contractor shall warranty all equipment and workmanship free of defects for a period of no less than 365 calendar days, beginning the date the test stand is fully installed, operational, and accepted by the Government.

5. Contractor Qualifications

5.1 The Contractor shall have been actively and successfully designing and building process and/or test equipment for a minimum of five (5) years. The Contractor shall provide a list of past work which includes as a minimum: the name of the test equipment, general description of test equipment, date of sale, name of company/POC the equipment was sold to, and the name of the Contract project manager.

5.2 The Contractor shall have on-staff at least one (1) each registered professional engineer. The engineer’s resume and professional engineer certification shall be submitted with the Contractor’s bid proposal.

5.3 The Contractor shall have on-staff certified integrators with a minimum of five (5) years of experience integrating systems using Wonderware, LabView, or equivalent software.

The integrator shall have factory certification which shall be verified by submitting the factory listing of authorized/certified dealers with the Contractor’s bid proposal.

5.4 The Contractor shall have a minimum of five (5) years of experience integrating control systems using National Instruments, Siemens, Allen Bradley, or equivalent software. The integrator shall have factory certification which shall be verified by submitting the factory listing of authorized/certified dealers with the Contractor’s bid proposal.

6. Contractor Personnel

6.1 The Contractor shall provide the name of the Project Manager and any alternate(s) who shall act for the Contractor when the Project Manager is absent and they shall be designated in writing. The Contractor shall provide telephone numbers and email addresses of the Project Manager and alternate(s) where these persons may be contacted at any time. The Project Manager or alternate shall have full authority to act for the Contractor on all matters relating to operation of this contract at TAFB. The Contractor shall provide a Project Manager and alternate(s) who can read, write, speak, and understand English fluently.

6.2 The Contractor and all their employees shall be required to identify themselves as

Contractor personnel by introducing themselves or being introduced as Contractor personnel and displaying distinguishing badges or other visible identification.

7. Applicable Documents and Definitions

7.1 The contractor is required, at a minimum, 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.”

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

7.2.1 U.S. Department of Labor

7.2.1.1 29 CFR 1910 – General Industry, OSHA Safety and Health Standards (29 CFR 1910), 2010 or most recent edition (available at http://www.osha.gov/).

http://www.osha.gov/

Application for copies should be addressed to the U.S. Department of Labor, 200 Constitution Ave, Washington, D.C. 20210)

7.2.2 Environmental Protection

7.2.2.1 40 CFR 82 – Protection of Stratospheric Ozone, 2010 or most recent edition.

(Application for copies should be addressed to the U.S. Department of Labor, 200 Constitution Ave, Washington, D.C. 20210)

7.2.2.2 Tinker Air Force Base (TAFB) Supplement to Air Force Instruction (AFI) 32-

7086, “Hazardous Materials Management”, Tinker AFB procedures per Tinker Air Force Base Instruction (TAFBI) 32-7004, “Hazardous Waste Management”, and Complex procedures per

Oklahoma City Air Logistics Complex (OC-ALC) Sup to AFI 32- 7086, “Hazardous Material Management” and OC-ALCI 32-101 “Air Quality

7.3 Non-Government Standards

The following documents form a part of this document to the extent stipulated herein.

7.3.1 National Fire Protection Association (NFPA)

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

7.3.1.2 NFPA 70 – National Electrical Code, 2014 edition

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

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

8. Special Provisions

8.1 Safety, Foreign Object Debris (FOD), Dropped Object Prevention (DOP) & Quality Control

8.1.1 Safety and Quality Control

8.1.1.1 Contractor is responsible for ensuring and enforcing industry safety practices, and quality control of the job site.

8.1.1.2 Contractor shall comply with all safety practices posted in the assigned work area and Personal Protection Equipment (PPE) requirements. PPE shall include, but is not limited to, safety glasses and hearing protection.

8.1.1.3 Contractor and his/her representatives shall have appropriate environmental and safety training required by the state and federal government according to Resource Conservation Recovery Act

(RCRA).

8.1.1.4 The Contractor is advised that electric service is in the work area. Fall protection, PPE, and any other safety related material needed shall be provided by the Contractor for contract employees. All safety signage in the work area and OSHA regulations shall be strictly followed by the Contractor. The Contractor’s onsite supervision shall be responsible for ensuring personnel related to this project observe and follow the safety guidelines and properly wear the correct PPE. Hard hats shall be required in the facility periodically due to the ongoing construction, as well as hearing and eye protection and safety glasses.

8.2 FOD and DOP

8.2.1 All Contractor personnel and their subcontractors working on this project are required to comply with AFMCI 21-122.

8.2.2 Contractor shall be responsible for ensuring and enforcing compliance with

FOD requirements of the job site.

8.2.3 All Contractor personnel and their subcontractors working on this project are required by AFMCI 21-122 to receive FOD/DOP Awareness and Prevention Training.

8.2.4 The work to be performed in this area will require Contractor to work in or travel through areas near equipment producing flight capable parts for use on military aircraft, engines, munitions, missiles, support equipment, and/or Aerospace Ground Equipment (AGE).

8.2.5 Trainers and/or the Contractor personnel may be operating vehicles and equipment in maintenance areas.

8.2.6 FOD/DOP Awareness and Prevention Training is available on the Tinker Intranet, https://org.eis.afmc.af.mil/sites/76MXW/QA/76%20MXW%20FOD%20Program/F orms/AllItems.aspx. This training is also available via CD-ROM upon request by the Contractor for an alternate form of training.

8.3 Housekeeping

8.3.1 Contractor shall keep the work areas clean and neat in accordance with Industry Standards, Occupational, Safety and Health Administration (OSHA), fire and https://org.eis.afmc.af.mil/sites/76MXW/QA/76%20MXW%20FOD%20Progr safety standards and this SOW. Cleanup at the end of each day is required. All tools shall be properly stored in a lockable tool box and trash removed. All hardware shall be properly stored in ziplock bags and the work area in orderly condition, no exceptions.

8.3.2 Packing material, material remnants, rubbish and debris shall be removed from

Government property daily, unless otherwise directed, to avoid accumulation at the work site. Materials that cannot be removed DAILY (NO EXCEPTIONS) shall be stored in areas specified by the government project engineer.

8.4 Tool Control and Accountability

8.4.1 While performing contract services in or around Maintenance Production Shops including Ramp areas, Contractor shall comply with AFMCI 21-107, Tool Control and Accountability Program and Tinker Instruction 21-112, Tool Management.

8.4.2 Tool Listing: Contractor shall identify and list each tool separately on a “tool listing” kept inside each container or bag.

8.4.3 Securing Tools: Contractor personnel shall ensure all tools are secured when not in use.

8.4.4 Unattended Tools: Contractor personnel shall ensure no tools are left unattended at any time.

8.4.5 Beginning Inventory: Contractor personnel shall inventory the container or bag of tools at the beginning of the day.

8.4.6 Ending Inventory: Contractor personnel shall inventory the container or bag of tools at the end of each day.

8.4.7 Missing Tools: Contractor personnel shall immediately notify the GOVERNMENT POC of any tools that are missing.

9. Government Furnished Property and Services

9.1 Government Furnished Property

9.1.1 Government Furnished Property (GFP) is listed in Appendix B. The GFP is located at Tinker AFB and can be accessed by the Contractor. The GFP shall remain on Tinker AFB at all times during the execution of the contract.

9.1.2 Shared Property of the Government is not applicable to the performance of this contract.

9.2 Government Furnished Services

9.2.1 Government Furnished Services (GFS) are applicable during the performance of this contract. The Government will furnish the following services at TAFB, OK:

9.2.1.1 Security Forces: The Government will provide general on-base security forces' service. The security forces’ telephone numbers are 911 for emergencies, 405- 734-2000 for crime in progress, and 405-734-3737 for non-emergency calls.

The off-base 911 center receives 911 cell phone calls. Cell phone callers need to advise the 911 off-base center they are on TAFB in order to be connected with the on-base 911 center.

9.2.1.2 Fire & Emergency Services: The Government will provide general on base fire…