Attach_0001_PWS_X-ray_System_27May2016.docx

Performance Work Statement (PWS)

NEW XRAY SYSTEM B2728 CIP FY16

27 MAY 2016

Description of Requirement: Crane Army Ammunition Activity (CAAA), Crane, IN, has a requirement for a new high energy digital x-ray imaging system for the semi-automated inspection of munitions with the approximate dimensions of 36” high by 6” diameter with a weight of 100 Lbs. (45.45Kg). The x-ray imaging system shall meet all requirements in 21 CFR 1020.40, cabinet x-ray systems. A pre-proposal site visit is required so that the Contractor can see the area where the x-ray cabinet/conveyor system will be located and to determine necessary utility interfaces and identify any flooring considerations/issues.

1. SCOPE

The Contractor shall provide and install a high energy cabinet style digital x-ray imaging system with a conveyor system in an existing facility for Crane Army Ammunition Activity located on Naval Surface Warfare Center, Crane, Indiana. The x-ray system is necessary for radiographic inspection of M1122 projectiles, TNT or IMX-101 explosive loaded, nose end only. The requirements of the inspection require that the x-ray system be able to x-ray and automatically detect anomalies in 500 projectiles per day minimum. The system shall consist of a high frequency x-ray source capable of penetrating the explosive loaded projectile, a high resolution flat panel digital detector, a steel/lead/steel shielded enclosure with variable speed (indexing) transport conveyor (munition in vertical position), operator control console with computer workstation(s), image acquisition and processing software, and a high resolution digital display. The system shall provide 2-2T resolution when x-raying a M1122 projectile. The system shall be manufactured and tested at the Contractors facility; however, the system must be designed so that it can be disassembled in order to fit through a 7’ 8” x 7’ 10” (W x H) facility access door. The Contractor shall provide installation, radiation leak test certification after installation, and x-ray system operational training for seven (7) Nondestructive Tester (radiographic) personnel. The Contractor must provide a one year warranty and one year telephone and email support and preventative maintenance plan after the date of installation. The system must be installed and be operational by 31 December 2016. The system must be able to detect all of the x-ray defects listed in MIL-DTL-32374(AR) paragraph 3.6.

2. APPLICABLE DOCUMENTS

3. SPECIFIC SYSTEM PERFORMANCE REQUIREMENTS

The Contractor shall provide a high energy cabinet style digital x-ray imaging system with a conveyor system with all the hardware necessary to generate x-rays for industrial radiographic inspection. In addition to meeting these requirements, the system shall meet the specific requirements stated below. All components used in the construction of the system must be new, and the system shall be FDA compliant (21 CFR 1020.40).

3.1. X-RAY SYSTEM REQUIREMENTS.

· Energy Range 20kV-450kV

· Tube Type: metal ceramic

· Dual focal spot 0.4mm and 1.0mm

· Maximum Power: small focal spot >=650 Watts; large focal spot >=1400 Watts

· Constant potential high voltage -225, +225 high voltage generators

· Closed loop cooling with heat exchanger

· Coolant hose length suited for installation requirements

· X-ray Tube Collimator with placement for filters

· Control Unit and cable with lengths suited to the installation requirements

· High Voltage cables with lengths suited to the installation requirements

· Conveyor system capable of holding 24 projectiles (one pallet worth of M1122 projectiles)

· Legs/footings designed to distribute weight evenly on concrete floor surface

· Vibration/isolation mounts (if necessary) for forklift traffic

3.2 X-RAY IMAGING SYSTEM REQUIREMENTS.

· Software shall be DICONDE compliant

· Flat panel detector to be amorphous silicon based

· The detector shall be a premium grade panel

· The detector shall be designed for x-ray energies up to at least 450kV

· The panel shall have radiation sensitive shielded to minimize radiation damage

· Pixel size shall be 200 x 200 microns

· Pixel matrix 2048 x 2048

· Detector readout shall have a frame rate of a minimum of 7.5 fps with no binning and 15 fps for 2 x 2 binning

· Analog to digital conversion shall be 16 bit

· Panel scintillator shall be gadolinium oxysulfide (Gd2O2S) -DRZ Standard

3.3 COMPUTER SYSTEM REQUIREMENTS.

The hardware shall meet, at a minimum, the following requirements:

Wi-Fi®: The contractor shall not install any Wi-Fi® or other wireless communication hardware or modem on any components of the system. Hardware or software disabling of these types of devices is not acceptable. The contractor shall certify that no Wi-Fi®, 802.11 or other wireless communication hardware or modems are installed on any components of the RMIS system.

Processor: A dual processor motherboard with two quad-core (or better) class processors for all acquisition, viewing and reviewing computers such as an HP Z840 or equivalent.

Video: High-end NVIDIA® or AMD/ATI™-based graphics card(s), not built in to motherboard; sufficient to run a minimum of two 2560x1600 pixel or higher resolution monitors for viewing and reviewing computers.

Graphics Processing Unit (GPU) computer: Workstation(s) with image visualization must have a minimum of one NVIDIA® or equivalent GPU compute card installed, with a minimum 1.5 GB (gigabyte) on-board memory, which shall be used for accelerating computations therein for viewing and reviewing computers.

Each viewing & reviewing station shall contain a two megapixel, 21” minimum flat display with 10-bit display minimum, compliant with DICOM Part 14, containing a backlight brightness sensor and automatically adjust brightness. Brightness shall be 250 cd/m2 minimum and contrast shall be 250:1 minimum.

Each viewing & reviewing station shall also contain an additional 30-inch class monitor with the following characteristics:

A resolution of 2560x1600 pixels or better.

Minimum of 1000:1 true contrast ratio Minimum of 60 Hz vertical refresh rate at full resolution Brightness a minimum of 300 cd/m2 (candela per meter squared) Viewing & reviewing image display shall meet all requirements of ASTM E2698, section 7.5. System must be capable of displaying a full screen test pattern in accordance with SMPTE RP 133 (or equivalent) to allow performance of those tests.

Memory: The contractor shall provide a minimum of 128 32 GB per computer, with additional 128 32 GB capacity available without replacing installed memory.

Storage: The contractor shall provide a minimum of 3 TB (terabyte) of effective usable data storage space per workstation, in a minimum data protection standard of Redundant Array of Independent Disks 1 (RAID 1 - Mirroring) or better.

Login: A smart card reader shall be provided with each individual computer, with its interface drivers installed.

Human Interface: The contractor shall provide at a minimum a 101-key, enhanced keyboard and 3-button optical (e.g. laser) scroll mouse with every workstation.

Networking: Each machine shall have a minimum of one free Gigabit Ethernet port after installation. All Ethernet cabling shall be Category 6 (CAT-6) standard or higher performance.

Security: System shall include a Trusted Platform Module (TPM) version 1.2 or higher.

Software The contractor shall provide original installation media with license documentation for the computer operating system as well as every software installed application for each computer.

The contractor shall provide software back-up images of all boot drives as configured at the time of installation.

The contractor shall configure the software on the Viewing and reviewing computers so that the computers will be interchangeable.

The contractor shall provide Windows® 8 (64 bit) operating systems for the computers.

The contractor shall provide data acquisition software with the following salient features:

Software for acquisition of digital radiographic image data.

The software shall control all appropriate X-ray source parameters, manipulator positioning, and detector settings.

The Operator or Reviewer shall have the ability to save the raw, uncorrected images on a per-scan basis.

The data acquisition software shall store the data images in a well-defined, non-filtered, full dynamic range, documented, non-compressed, non-proprietary format conforming to ASTM E2699-11 Standard Practice for (DICONDE) for Digital Radiographic (DR) Test Methods to the following minimal compliance:

Digital images shall be stored in the DICONDE format with the following metadata fields as specified by the user at a minimum:

•Component ID (0010, 0020) •Component Name (0010, 0010) •Study Description (0008, 1030) •Study Date (0008, 0020) •Series Description (0008, 103E) •Examining Company’s Name (0008, 0090)

The system shall save the following DICONDE metadata fields automatically:

•Manufacturer (0008, 0070) •Manufacturer’s Model Number (0008, 1090) •Device Serial Number (0018, 1000) •Modality (0008, 0060) •Imager Pixel Spacing (0018, 1164) •Software Version(s) (0018, 1020)

Original (raw) image without any image enhancements shall be retained. The original data shall be capable of being re-processed and re-displayed using the same or other process algorithm without having to take another radiographic exposure.

System shall allow the user Operator or Reviewer to select images for viewing from a list. The list shall show the following fields at a minimum and shall allow the user to sort the list by any of these fields. User shall also be able to filter the list to only show specific values for any of these fields.

•Component ID •Component Name •Inspection Date •Examining Company’s Name

3.4 CONVEYANCE SYSTEM REQUIREMENTS.

Conveyor System. The electrically powered conveyor system shall move the M1122 projectiles in the vertical/upright position loaded in contractor provided conveyor racks from a conveyor loading station to the x-ray cabinet, through the x-ray inspection operation, and moving the x-rayed projectiles to a conveyor offloading station and to a rack return conveyor/ball bearing table. Conveyor belts, if used, shall be conductive. The conveyor shall be comprised of separate sections, which may be controlled either independently or together. The contractor may also elect a closed loop conveyor system. (The preferred method of conveyance will be determined at the pre-proposal site visit based on building layout). At a minimum, the conveyor shall have one section from the projectile loading station to the x-ray cabinet, one section inside the x-ray cabinet, and one section from the x-ray cabinet to the unloading station. A fixture rack return ball bearing top table and a conveyor shall be provided that will return the unloaded fixture racks to the loading station to repeat the process. It shall be equipped with sensors allow bridging of sections automatically as product transfers. The conveyor operation shall be integrated for continuous, safe, and successful operation with the existing x-ray inspection system. The conveyor operation shall be electrically-powered and have a stand-alone or remote control console, which will independently function manually with the operating tools to provide full conveyor control. The conveyor will be capable of coming to a full stop, reversing its motion, and re-starting motion depending on the discretion of the inspector/operator.

Safety features must be provided at the projectile loading and unloading stations that provide a visible warning that the conveyor is ready to move and prevent advancement until both the load and unload operators press and release a control. Ideally, the same people will load and unload the projectiles. Emergency stops are to be provided at all locations deemed necessary for safe operation; at a minimum include the control room, the conveyance area inside the annex, and at the primary building where conveyance adjoins.

A minimum of two (2) ball-bearing tables will be provided with dimensions of 4 foot x 15 foot and 4 foot x 18 foot (minimum). The conveyor and ball bearing table system shall be of sufficient construction strength, design, and durability to be rated two (2) times as strong as the minimum weight, gage, or load rate required to ensure total system reliability and reduce premature deterioration from wear and fatigue.

In order to allow access to the flat panel detector, the conveyor shall be hinged or otherwise modified to allow a section to be moved in order to allow access to the imaging panel and panel manipulator inside the x-ray cabinet. The conveyance system shall be designed for maximum throughput, durability, and stability. It shall be designed to not allow munitions that are to be radiographically inspected to tip, fall, or otherwise drop from the respective surfaces to the floor.

The conveyor system shall have color cameras to cover the full length of the conveyor and inspection operation and provide color monitors (10 inch screen minimum) in the x-ray control area for continuous monitoring. Cameras inside the x-ray area shall be commercially available cameras.

The provided cabinet shall have two (2) openings for conveyor access that measure approximately 50 inches tall and 33 inches wide, aligned with one another and on opposing walls. The distance from the centerline of the conveyor openings and the primary or x-ray target wall is approximately 50 inches. The digital flat panel detector and its shielded holding fixture/manipulator will be located in this area of the cabinet, between the conveyor and the primary or target wall. The base of the conveyor openings is approximately 31 inches from the floor.

The contractor will provide a control console that will provide the x-ray inspection personnel a manual means of opening and closing the conveyor doors to provide access to the cabinet during the radiographic exposure, and work in conjunction with the cabinet radiation safety interlocks. The console must have a light to visually indicate and verify the conveyor doors in the completely open and completely closed position from the remote x-ray control area.

Conveyor Performance Requirements. The conveyor system shall provide for x-ray of the M1122 in the vertical/upright orientation.

The conveyor system shall be built for mass production and high speed volumes with a minimum throughput rate of one (1) projectile per 50 seconds for M1122 projectile inspection. Production rate is 500 rounds per 10 hour shift for M1122 projectiles.

Intended use of the system is 15 years. A spare parts list for high wear, low life expectancy items is required upon delivery of the system.

3.5 CABLE LENGTHS.

Cable lengths for all applicable equipment are to be determined by the contractor. All applicable and connecting service and operational cables from the inspection viewing/control room to the 450kV cabinet/enclosure and the equipment therein shall be mounted or laid in an adjoining contractor provided and installed overhead cable tray. Contractor is to ensure all required cables are of adequate continuous length with no splices or breaks allowed with the correct cable end terminations provided.

4. SYSTEM INTERFACES

The Contractor shall ensure that the x-ray system works with the physical and electrical interfaces of the existing facility. The Contractor shall identify any interface issues/needs during the pre-proposal site visit and in the quote/proposal. Government will prepare utility interfaces once the interface needs are identified by the Contractor prior to installation of the system. The Contractor shall also identify the approximate weight and footprint of the cabinet system in the quote/proposal so the Government can ensure the proper floor strength for the system. If the floor needs to be strengthened, the Government will prepare the floor.

5. INSTALLATION

The Contractor shall install, leak test, and calibrate the cabinet x-ray and conveyor system. Furthermore, the contractor will run the x-ray system using 24 inert M1122 projectiles for initial performance qualification in the CAAA facility to ensure the system performs correctly prior to running any energetic loaded projectiles on the system (see paragraph 12.3, 12.4.2). A Leak Test Report is required to be turned into the Technical POC and the RSO. A calibration report is required to be turned into the Technical POC and the RSO. A Performance Qualification Report is required to be turned in to the Technical POC and the RSO prior to running any energetic loaded projectiles on the system. The Contractor must apply for an ARP permit (30 days prior to coming on site) to generate x-rays using the x-ray equipment on CAAA installation per DA PAM 385-24, paragraph 2-7.d.

6. TRAINING

The Contractor shall provide operational training for a minimum of seven (7) radiographers in the operation and software of the high energy cabinet style digital x-ray imaging system with a conveyor system on-site at Crane Army Ammunition Activity, Crane IN after installation.

7. WARRANTY

The Contractor shall provide a standard comprehensive 1-year on-site warranty. One year should start on the last day of system training, and shall include all labor, parts and travel expenses.

8. DATA REQUIREMENTS AND DELIVERABLES

Successful Installation of X-ray System/conveyor at CAAA (Contractor)

10 January 2016 12.3, 12.4.2

System installation shall be performed at the following location:

9. STATUS REPORTS

The Contractor shall submit monthly status reports to the Government’s Technical Point of Contact (TPOC) and Contract Specialist identified in the contract. The first status report shall be due on or before the tenth (10th) day after the first complete month following award of the contract. The Contractor shall submit subsequent status reports on or before the tenth (10th) calendar day of each subsequent month for the duration of the contract. The status reports may be emailed.

10. MANUALS, ELECTRICAL CIRCUIT DIAGRAMS, AND SUPPLEMENTAL DATA

The Contractor shall provide at minimum two sets of Operator and Maintenance Manuals, schematics and supplemental data to the Government upon successful installation. The information can be supplied in paper or electronic format (electronically on DVD’s is preferred). The Government will require sufficient rights to the data to enable it to duplicate and transmit the schematics and supplemental data for the purposes of obtaining safety approval for this system. Distribution of these documents will include other government personnel including the Army’s Radiological Safety Officer (RSO). The Contractor shall include in the Supplemental data a specific diagram of the radiation safety interlocks with a description of their function. The Contractor shall provide a description of how to properly test the interlocks in the Operation and Maintenance manual(s).

11. Electromagnetic Environmental Effects Report The Contractor shall provide a Hazards of Electromagnetic Environmental Effects Report to the Government at the time of delivery. This report shall detail applicable hazards of electromagnetic effects to personnel and ordnance items when the system is operating and idle. The report shall also identify and chart electromagnetic radiation specific to this model from radio frequencies through “hard” x-rays in both energies and while idle. There will be no RF nor X-rays when the system is in idle mode. Wavelengths studied shall be 103m through 10-11m. Report shall be approved by the Contractor’s cognizant radiation expert (Radiation Hazard Officer or certified Professional Engineer). The report shall give an analysis of what electromagnetic effects the equipment is producing, paying particular attention to effects on humans and ordnance.

12. QUALITY ASURANCE SURVEILANCE PLAN (QASP) AND MONITORING OF WORK DELIVERABLES

12.1 Prior to x-raying any items on the system onsite at CAAA, the Contractor shall perform a cabinet radiation leak test on the machine to ensure the safety of all personnel who operate the x-ray machine. The Contractor shall leak test the cabinet within 5 days of complete and successful installation of the machine. The leak test must pass the requirements in 21 CFR 1020.40 for cabinet x-ray systems. A Leak Test Report is required to be turned into the Technical POC and the RSO.

12.2 All work under this contract shall be monitored by the CAAA Technical Contact and or CAAA NDT-RT personnel and the Radiation Safety Officer (RSO) listed in section 19 below, who will act as the primary technical representatives for the government.

12.3 Final inspection and acceptance of installed system shall be performed at the place of installation by the CAAA Technical POC. Contractor shall x-ray 24 inert loaded M1122 projectiles for Performance Qualification. After successful performance qualification, the CAAA NDT–RT personnel will x-ray several energetic loaded M1122 projectiles on the machine to ensure the machine is acquiring clear sharp images of energetic area and meeting 2-2T resolution prior to acceptance of the x-ray machine. The Contractor shall submit a Performance Qualification Report to the Technical POC and RSO. The CAAA NDT-RT personnel & the CAAA Technical POC will communicate this information/acceptance to the COR via email for WAWF invoice acceptance.

12.4 COR Acceptance criteria are as follows:

12.4.1 Contractor provides all data requirements and deliverables listed in paragraph 8 table above.

12.4.2 Successful completion of Performance Qualification consisting of CAAA NDT-RT personnel successfully loading the conveyor with 24 inert loaded M1122 projectiles, contractor successfully x-raying the projectiles with no system issues, achieving 2-2T resolution in a clear/sharp image. (CAAA can ship adequate quantities of inert loaded M1122 projectiles to the Contractor at their factory in order for the Contractor to test the x-ray cabinet system at their facility prior to delivery to CAAA). Successful completion of CAAA NDT-RT personnel x-raying energetic loaded projectiles.

12.5 Nonconforming Work:

12.5.1 Cabinet found to be leaking radiation above and beyond the 21 CFR 1020.40 requirements after installation shall be fixed by the Contractor prior to acceptance.

12.5.2 System found to fail the performance qualification following the installation shall be evaluated by the Contractor and fixed by the Contractor prior to Government acceptance.

13. NOTICE REGARDING LATE DELIVERY

The Contractor shall notify the Contracting Officer (listed in section19 below), as soon as it becomes apparent to the contractor, that the scheduled date(s) of performance will be late. The Contractor shall include in the notification the rationale for a later date of performance and the new expected date of performance.

14. FACILTY ACCESS

Access shall be limited to the hours of 6:30 a.m. to 4:30 p.m. EST Monday-Friday (excluding federal holidays).

15. PERSONNEL

The Contractor is responsible for providing personnel with the necessary level of expertise to support the activities and requirements of this SOW. The Contractor shall provide a single point of contact, within 5 days of contract award that shall serve as the project manager for the life of the contract. Single point of contact information should be forwarded to the Contracting Officer and CAAA Technical POC listed in paragraph 19. The Contractor is required to follow all OSHA regulations and the EM 385-1-1, Safety and Health Requirements Manual.

16. CONTRACTOR MANPOWER REPORTING (CMR)

The Contractor shall report ALL contractor labor hours (including subcontractor labor hours) required for performance of services provided under this contract via a secure data collection site. The Contractor is required to completely fill in all required data fields using the following web address: http://www.ecmra.mil/ Reporting inputs will be for the labor executed during the period of performance during each Government fiscal year (FY), which runs October 1 through September 30. While inputs may be reported any time during the FY, all data shall be reported no later than October 31 of each calendar year, beginning with 2016. Contractors may direct questions to the help desk at: http://www.ecmra.mil/

17. INVOICE SUBMISSION

All invoices must be processed through Wide Area Work Flow (WAWF). The Contract Officer Representative (COR) is responsible for accepting the invoice(s) in WAWF upon receiving all acceptance criteria from The Contractor and the CAAA Technical POC.

18. Antiterrorism/Operations Security Review. The Contractor personnel performing the services must complete Antiterrorism Level I training (general) prior to performing any work. The Contractor personnel shall access and read the general protection policy and procedures for Antiterrorism. The Contractor does not require a common access card (CAC) and will only need a visitor’s gate pass to access the installation through the Crane Visitor’s Center. The Contractor must also complete iWATCH training prior to performing any work.

18.1 AT Level I training: The Contractor personnel shall submit certificate of completion for each employee that requires access to the installation prior to performing any work. Please submit the certificate to the COR listed in paragraph YY within 10 days of contract award. AT level I training is available at the following website: http://jko.jten.mil

18.2 Access and general protection/security policy and procedures. This standard language is for contractor employees with an area of performance within an Army-controlled installation, facility, or area. Contractor and all associated subcontractor employees shall provide all information required for background checks to meet installation access requirements to be accomplished by the installation Provost Marshal Office, Director of Emergency Services, or Security Office. Contractor workforce must comply with all personal identity verification requirements (CFR clause 52.204-9, Personal Identity Verification of Contract Personnel) as directed by DOD, HQDA and/or local policy. In addition to the changes otherwise authorized by the changes clause of this contract, should the Force Protection Condition (FPCON) at any individual facility or installation change, the Government may require changes in contractor security matters or processes.

18.3 For contractors that do not require CAC, but require access to a DOD facility or installation. Contractor and all associated subcontractor employees shall comply with adjudication standards and procedures using the National Crime Information Center Interstate Identification Index (NCIC-III) and Terrorist Screening Database (Army Directive 2014-05/AR 190-13); applicable installation, facility and area commander installation and facility access and local security policies and procedures (provided by Government representative); or, at OCONUS locations, in accordance with status-of-forces agreements and other theater regulations.

18.4 iWATCH training. The contractor and associated subcontractors shall brief all employees on the local iWATCH program (training standards provided by the requiring activity ATO, aaron.w.siek.civ@mail.mil). This locally developed training will be used to inform employees of the types of behavior to watch for and instruct employees to report suspicious activity to the COR. This training shall be completed within ten (10) days of contract award. Once completed, please notify the COR listed in paragraph 19.

19. POINTS OF CONTACT

812-854-4069 Patricia.s.staggs.civ@mail.mil

812-854-5472 Pamela.r.morrison5.civ@mail.mil

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SOW NEW XRAY CIP FY16 rev05272016_rev2_final