Attachment_1_-_Statement_of_Work_-_X-ray_Systems_-_20_July_2015.docx

W58RGZ-15-R-0272

Attachment 1 STATEMENT of WORK

X-Ray System for Bldg 49

CIP FY15

Rotor Blade Facility X-Ray System As of 20 July 2015, REV E Prepared by William Avila

AMCC-PEC-C

Part 1 General Information

C.1. GENERAL: This project is to provide and install a Real Time Digital X-Ray Inspection System used to inspect rotor blades at the Corpus Christi Army Depot (CCAD) in Corpus Christi, TX. The contractor shall provide equipment, engineering, and installation services necessary to provide a complete and user ready system.

C.1.1 Description/Introduction: The Contractor shall provide all personnel, equipment, supplies, transportation, tools, materials, supervision, and other items and non-personal services necessary to furnish and install one Real Time Digital X-Ray Inspection System inside an exempt shielded vault and an external bridge crane with hoist lift system. This includes design, manufacture, assemble, construct, deliver, install, document, train personnel, and acceptance testing. The Contractor shall provide a fully functioning x-ray system in the Rotor Blade Facility (RBF) repair shop at CCAD, Corpus Christi, TX.

C.1.2 Background: CCAD is in the process of having the Rotor Blade repair Facility renovated. The Engine Non-Destructive Test Branch (NDT) is responsible for providing rotor blade x-ray inspection services at CCAD. In the past, workload was split between two existing x-ray systems located in the RBF (B49) and in Hangar 44; both being back-up systems to one another. Currently, rotor blade x-ray inspections are performed in Hangar 44 due to the on-going renovation. CCAD’s plan is to stand up a second x-ray system next to an existing system within the RBF to provide enough capacity to consolidate main and tail rotor blade x-ray inspections. In order to have the least impact on production, it is imperative that equipment installation be precisely planned. The contractor shall be responsible for fulfilling all the requirements as specified in this document, with the end goal of providing production ready equipment in the RBF building.

C.1.3 Objectives: The objective is to stand up a fully functioning new x-ray system in the RBF building to support rotor blade repair for CCAD.

C.1.4 Scope: Contractor shall provide all equipment and installation services necessary to provide a production ready x-ray system in the RBF building to support rotor blade repair for CCAD. The real time digital x-ray inspection system shall consist of an x-ray exempt shielded enclosure (vault), overhead gantry style system for synchronized movement of source and detector, source and generator set, detector, fixtures and stands for part holding and manipulation, workstation, control system and related software. System shall provide real-time x-ray digital image viewing and capability to capture, store image and data, and enhance images for analysis. System shall provide ability to develop inspection routines controlling part manipulation. The X-Ray System shall have an intuitive macro development of procedures for capturing images. Exempt shielded enclosure (vault) internal dimensions shall be 36’L x16’W x 10’H. The contractor shall provide a computer rack mount and a control system that shall be set up in control room. Contractor shall provide Heating, Ventilation, and Air Conditioning (HVAC) for the vault, lighting and electrical power connections for system, fire protection, compressed air connections, wiring, conduit, and piping to source utilities to make system complete. Contractor shall provide an electric ¼ ton hoist and over-running bridge crane with 25’ span for handling rotor blades.

C.1.5 Period of Performance: The period of performance shall be from contract award date thru delivery, installation and acceptance.

C.1.6 General Information

C.1.6.1 Quality Control: The Contractor shall develop and maintain an effective quality control program to ensure work is performed in accordance with this specification. The Contractor shall develop and implement procedures to identify, prevent, and ensure non-recurrence of defective work. The Contractor’s quality control program is the means by which he assures himself that his work complies with the requirement of the contract. A Quality Control Plan (QCP) shall be delivered to the Contracting Officer’s Representative (COR) within 30 days of contract award. (Microsoft (MS) Word Format or PDF) After review of the QCP the contractor will be notified of any proposed changes or acceptance of the plan by the COR. (CDRL A001)

C.1.6.2 Recognized Holidays: The Contractor shall not have access to CCAD or CCAD support on the following holidays:

C.1.6.3 Hours of Operation: The Contractor shall be responsible for conducting business, between the hours of 6:00 am and 2:30 pm Monday thru Friday except Federal holidays or when the Government facility is closed due to local or national emergencies, administrative closings, or similar Government directed facility closings. For other than firm fixed price contracts, the Contractor shall not be reimbursed when the Government facility is closed for the above reasons. The Contractor shall at all times maintain an adequate workforce for the uninterrupted performance of all items defined within this specification when the Government facility is not closed for the above reasons. When hiring personnel, the Contractor shall keep in mind that the stability and continuity of the workforce are essential. Any different hours or days are at the discretion and approval of the COR. This will be a firm fixed price contract so any overtime hours must be accounted for in the final quote.

C.1.6.4 Place of Performance: The work to be performed under this contract will be performed at CCAD, Bldg 49.

C.1.6.5 Type of Contract: The Government will award a firm fixed price contract.

C.1.6.6 Physical Security: The Contractor shall be responsible for safeguarding all Government equipment, information and property provided for Contractor use (See Para. C.3.3). Contractor shall adhere to all security requirements as outlined in Attachment 1, “Security Requirements for All Contracts Performed at Corpus Christi Army Depot”

C.1.6.7 Special Qualifications: The Contractor shall have at least 7 years of engineering and project management experience in installation of Real Time Digital X-Ray Inspection Systems used in the inspection of helicopter aviation/aerospace components. Offeror shall provide with proposal a list of company projects demonstrating related experience to include: project title, project dates, descriptive paragraph, point of contact reference, telephone number, and company address.

C.1.6.8 Post Award Conference/Periodic Progress Meetings: The Contractor agrees to attend any post award conference convened by the contracting activity or contract administration office in accordance with Federal Acquisition Regulation Subpart 42.5. The Contracting Officer, COR, and other Government personnel, as appropriate, may meet periodically with the Contractor to review the Contractor's performance. At these meetings the contracting officer will apprise the Contractor of how the Government views the Contractor's performance and the Contractor shall apprise the Government of problems, if any, being experienced. Appropriate action shall be taken to resolve outstanding issues. These meetings shall be at no additional cost to the Government.

C.1.6.9 Contracting Officer Representative (COR): The COR will be identified by separate letter. The COR monitors all technical aspects of the contract and assists in contract administration. The COR is authorized to perform the following functions: assure that the Contractor performs the technical requirements of the contract: perform inspections necessary in connection with contract performance: maintain written and oral communications with the Contractor concerning technical aspects of the contract: issue written interpretations of technical requirements, including Government drawings, designs, specifications: monitor Contractor's performance and notifies both the Contracting Officer and Contractor of any deficiencies; coordinate availability of Government furnished property, and provide site entry of Contractor personnel. A letter of designation issued to the COR, a copy of which is sent to the Contractor, states the responsibilities and limitations of the COR, especially with regard to changes in cost or price, estimates or changes in delivery dates. The COR is not authorized to change any of the terms and conditions of the resulting order.

C.1.6.10 Key Personnel:

C.1.6.10.1 Project Manager / Engineer: The lead project manager from the prime Contractor shall have at least 5 years of engineering and project management experience in installation of Real Time Digital X-Ray Inspection Systems used for the inspection of aviation/aerospace components. It is preferred that this individual has experience working in industrial Government facilities. Submit description of experience with proposal.

C.1.6.10.2 Engineers/Technicians: The contractor engineers/technicians shall have experience with engineering controls and industrial manufacturing related to x-ray inspection. Submit description of experience with proposal.

C.1.6.10.3 Trades Workers: The contractor trade workers shall be licensed for the tasks that they will be performing under this contract.

C.1.6.11 Identification of Contractor Employees: All Contractor personnel attending meetings, answering Government telephones, and working in other situations where their Contractor status is not obvious to third parties shall identify themselves as such to avoid creating an impression in the minds of members of the public that they are Government officials. They shall also ensure that all documents or reports produced by Contractors are suitably marked as Contractor products or that Contractor participation is appropriately disclosed. All Contractors shall be required to wear badges whenever visiting the Government facility. They shall give the COR a minimum of four days prior notice, so that Contractor can be placed in Government security system for access to the installation. Contractors that will be working for more than four weeks shall acquire a RapidGate ID.

C.1.6.12 Warranty: The contractor shall warranty all equipment and installation services from defects for a minimum period of one year or equal to the manufacturer’s standard commercial warranty period, whichever is longer. The contractor shall submit warranty information with Operation & Maintenance Manual (O&M). (CDRLs A002, A006)

PART 2

DEFINITIONS & ACRONYMS

C.2. DEFINITIONS AND ACRONYMS:

C.2.1. DEFINITIONS

C.2.1.1. CONTRACTOR. A supplier or vendor having a contract to provide specific supplies or service to the Government. The term used in this contract refers to the prime.

C.2.1.2. CONTRACTING OFFICER. A person with authority to enter into, administer, and or terminate contracts, and make related determinations and findings on behalf of the Government. Note: The only individual who can legally bind the Government.

C.2.1.3. CONTRACTING OFFICER'S REPRESENTATIVE (COR). An employee of the U.S. Government appointed by the contracting officer to administer the contract. Such appointment shall be in writing and shall state the scope of authority and limitations. This individual has authority to provide technical direction to the Contractor as long as that direction is within the scope of the contract, does not constitute a change, and has no funding implications. This individual does NOT have authority to change the terms and conditions of the contract.

C.2.1.4. DELIVERABLE. Anything that can be physically delivered but may include non-physical things such as meeting minutes.

C.2.1.5. KEY PERSONNEL. Contractor personnel that are evaluated in a source selection process and that may be required to be used in the performance of a contract by the Key Personnel listed in the specification. When key personnel are used as an evaluation factor in best value procurement, an offer can be rejected if it does not have a firm commitment from the persons that are listed in the proposal.

C.2.1.6. PHYSICAL SECURITY. Actions that prevent the loss or damage of Government property.

C.2.1.7. QUALITY CONTROL. All necessary measures taken by the Contractor to assure that the quality of an end product or service shall meet contract requirements.

C.2.1.8. SUBCONTRACTOR. One that enters into a contract with a prime Contractor. The Government does not have privity of contract with the subcontractor.

C.2.1.9. WORK DAY. The number of hours per day the Contractor provides services in accordance with the contract.

C.2.1.10. WORK WEEK. Is defined as Monday through Friday, unless specified otherwise.

PART 3

GOVERNMENT FURNISHED PROPERTY, EQUIPMENT, AND SERVICES

C.3. GOVERNMENT FURNISHED ITEMS AND SERVICES:

C.3.1. Services: The Government will provide a lead project engineer who will be the COR and who will be the Contractor’s prime contact for the Government. The Government will provide the most recently available standard building and facility drawings for review.

C.3.2 Utilities: All utilities in the facility will be available for the Contractor’s use in performing the installation work outlined in this specification. The Contractor shall instruct employees in utilities conservation practices. The Contractor shall be responsible for operating under conditions that preclude the waste of utilities.

C.3.3 Equipment: Computer system hardware shall be provided by CCAD. The contractor shall provide CCAD IT Department with a detailed list of computer specifications to enable CCAD to purchase the appropriate hardware.

PART 4

CONTRACTOR FURNISHED ITEMS AND SERVICES

C.4. CONTRACTOR FURNISHED ITEMS AND RESPONSIBILITIES:

C.4.1 General: The Contractor shall furnish all supplies, equipment, facilities and services required to perform work.

C.4.2 Materials: The Contractor shall furnish all materials, supplies, and equipment necessary to meet the requirements under this specification.

C.4.3 Equipment: The Contractor shall provide all equipment needed to meet the requirements under this specification.

PART 5

SPECIFIC ITEMS

C.5. REQUIREMENTS:

C.5.1 SYSTEM DESCRIPTION

The contractor shall provide a real time digital x-ray inspection system consisting of at least, but not limited to, an x-ray exempt shielded enclosure (vault), overhead gantry style system for synchronized movement of source and detector, source and generator set, detector, fixture and stands for part holding and manipulation, computer rack mount and control system. System shall provide real-time x-ray digital image viewing and capability to capture, store image and data, and enhance images for analysis. System shall provide capability to develop inspection routines for controlling part manipulation. System shall be capable of intuitive macro development of procedures for taking images. Exempt shielded enclosure (vault) internal dimensions shall be 36’L x16’W x 10’H. Contractor shall provide a computer rack mount and a control system that shall be set up in the control room. Control room layout shall be configured to accommodate two workstations and control systems; one for the new control system, and the second an existing x-ray control system which will be relocated into same control room under separate contract. Contractor shall provide HVAC for the vault, lighting and electrical power connections for system, fire protection, compressed air connections, wiring, conduit, and piping to source utilities to make system complete. Contractor shall provide an electric ¼ ton hoist and over-running bridge crane with 25’ span for handling rotor blades.

C.5.2 STATE OF THE ART PRODUCTION MODEL

The real time digital x-ray inspection system and hoist/bridge crane system shall be new and use the latest proven state of the art design and technology. It shall be based upon a current production model which utilizes proven design concepts and equipment which have performed satisfactorily under operating conditions by either Government or industry performing rotor blade x-ray inspection. Products such as prototypes, pre-production models or experimental units are not permissible. It shall not be permissible to use reclaimed parts as is, or rebuilt from scrap or other used equipment. System shall comply with U.S. Army Technical Manual (TM) 1-1500-335-23 Nondestructive Inspection Methods, Basic Theory; and TM 1-1500-366-23 Nondestructive Inspection General Procedure and Process Control. Contractor shall follow requirements as specified in the following: Army Society for Testing Materials (ASTM)-E-1742 / E-1742M-11 – Standard Practice for Radiographic Examination.

C.5.3 EQUIPMENT SPECIFICATIONS/REQUIREMENTS

C.5.3.1. EXEMPT SHIELDED ENCLOSURE

The exempt shielded enclosure (vault) shall be of a modular design to handle helicopter rotor blades and operate with a 160kV x-ray source. The internal dimensions of the enclosure shall be 36’L x 16’W x 10’H and house the gantry system. Enclosure shall fit in an envelope of dimensions 37’8”x16’10”x 12’ (Door frame may extend another 6”). Enclosure shall have a pair of motorized trench-style opposed sliding doors that create an opening 8’ wide x 9’ high for component entry/exit. Motorized doors shall be placed in the 16’ wide end of the enclosure. A personnel door shall be provided in the enclosure leading to the control room on the opposite end of the enclosure from the motorized doors. Contractor shall install trench for sliding doors. All doors shall be interlocked with system operation. Two digital viewing cameras shall be provided by the contractor inside the vault at opposite corners to monitor gantry and detector system operation. Camera signal and control shall be interconnected and viewable on control system at workstation. An additional monitor for continuous camera image viewing shall be provided by the contractor. Contractor shall provide lighting, electrical receptacles, switches, exterior x-ray in use warning beacon visual and audio, interlocked doors, and HVAC system with temperature and humidity control.

C.5.3.2. X-RAY SOURCE

The x-ray source shall be a 160 kV cone-beam design with focal spot size of 0.8mm. It shall be self-shielded to prevent any radiation leakage. Include x-ray collimator to project beam onto a digital panel and reduce scatter. Source shall have state of the art controls and safety features. Generator shall be capable of adjusting voltage and amperage range to improve image quality.

C.5.3.3. DETECTOR

A real-time high resolution flat panel detector shall be provided by contractor. Detector shall have an active area of 16”x16”. Panel is to be capable of acquiring images at up to 30 fps or better for real-time imaging. Panel shall have a 200um pixel pitch, and a 2048x2048 pixel matrix. Selectable gain setting and 3.5 Hz frame rate. Dynamic range shall be greater than 75 dB. Non-uniformity response less than +/-2% (10% to 90% FSR).

C.5.3.4. DETECTOR SHUTTER ASSEMBLY

The contractor shall provide shutter designed for high resolution flat panel detector for masking of parts in the field of view for superior image quality.

C.5.3.5. GANTRY MANIPULATOR FOR SOURCE AND DETECTOR

The contractor shall provide design and supply of a gantry-style manipulator with solid base frame of two opposed towers. Gantry shall enable synchronized motion of the source and detector and allow for greater than 6’ of vertical movement for optimal component coverage and pivot right and left. Manipulator travel rate must be adjustable. The contractor shall provide local gantry control inside vault in addition to at the workstation system control.

C.5.3.6. PART FIXTURE

Part fixtures and stands shall be provided by contractor and designed for motorized manipulation of the various rotor blade type parts (five main rotor and two tail rotor) to allow various orientations for inspection. Rotation about the long axis and up and down through 360 degrees is required. Manipulation shall be controlled from the control room via computer software. Software shall allow development of inspection routines controlling the manipulation of the part in conjunction with x-ray inspection operation.

C.5.3.7. HARDWARE/SOFTWARE

The contractor shall provide all hardware and software necessary to operate system, imaging and analysis, and integration between detector and software. The contractor shall provide ability to develop inspection routines controlling part manipulation. Auto seamless blade contour following is required. System shall provide ability for intuitive macro development of procedures for taking x-ray image shots. Software shall not be dependent upon proprietary hardware. Software shall be compatible with existing system. Software shall be Windows 7 based with multi image display and report customization capability. Three levels of security (password protected) shall be provided within the software: 1) Administrator – Full access to programming functions, user accounts, etc.; 2) Operator – Full access to system functions with exception of configuration settings and menu setups; 3) Technician – Ability to view images with basic processing functions. System shall allow for expansion.

HARDWARE: IT and Industrial System Requirements

Physical Environment Specifications:

Any computer system provided shall be able to operate in the environment it will be placed in. Temperature, humidity, and the use of harsh chemicals or liquids in the designated installation area shall dictate the use of an appropriate NEMA rated enclosure for the equipment and/or certification of the equipment itself. It shall also dictate the use of rugged peripheral equipment as necessary.

COMPUTER HARDWARE SPECIFICATIONS:

All computer systems shall be provided by CCAD if possible. If there are technical reasons why the vendor must provide the computer system it shall be coordinated with the CCAD IT Division. The Contractor shall provide CCAD IT with a detailed list of computer specifications to enable CCAD to purchase the appropriate hardware.

If CCAD does not provide the computer systems, they must meet the following minimum requirements:

All new Industrial Computer Systems at the Corpus Christi Army Depot shall meet the following minimum requirements: an Intel Core i5-2400 (3.10 Ghz) or AMD+ FX-6120 Six Core (3.5 Ghz) processor, 4 GB of RAM, Windows Aero-capable graphics card w/256 minimum memory, 500 GB (single partition) SATA 6.0 GB/s or Serial ATA w/8 MB drive cache, and DVD-RW/CD-RW.

The peripheral equipment will be capable of generating data output onto the dedicated computer system through either a standard serial cable connection (USB/RS-232) or an Ethernet connection. The applicable interconnection cables shall be furnished. If an Ethernet connection is used to interconnect the dedicated PC to peripheral equipment, an extra Network Interface Card shall be supplied with an extra RJ-45 port to allow an ANSI Standard 802.3, 100 Base-T, or an IEEE 802.3ah 1000Base-T card Ethernet connection supporting the full Transmission Control Protocol/Internet Protocol (TCP/IP) stack implemented by firmware.

OPERATING SYSTEM SPECIFICATIONS:

System OS must be Microsoft Windows 7, Windows Server 2008R2, or RedHat Linux version 5 or higher. If for technical reasons these choices cannot be the OS, specific technical details must be provided in writing as to why they cannot be used. Any OS supplied with the system must contain all the latest necessary service packs, updates, patches, and hot fixes.

Programmable Logic Controllers (PLC)

If a PLC is to be installed in the system it shall be manufactured by Allen Bradley and must provide an Ethernet Connection to allow for connection to the Industrial Network if required/desired. If an Ethernet connection is used to interconnect the PLC to peripheral equipment an additional Ethernet Port must be provided.

SYSTEM SOFTWARE SPECIFICATIONS:

Supplied software must be capable of operating in a multi-user environment. The user accounts can be local or domain-level accounts depending on the networking and system environment requirements (see the following section). Users shall only be authorized minimum security rights to operate the application software and shall not have access to system/software configuration items (ie. Control panel, software/hardware installation). Under no circumstances will the intended end users of the system log in using the administrator or root account for routine operation of the equipment. The use of this account will be restricted only for administrative activities that are carried out by Government CCAD Information Technology personnel.

SYSTEM ENVIRONMENT SPECIFICATIONS:

If it is determined that the system will be required to interact with other CCAD network resources available through the Windows network, then the system is required to operate using domain-level user accounts through Active Directory.

If applications such as Norton Anti-Virus, Microsoft Systems Management Server, or any other application will interfere with the operation of the system, then a written statement must be provided explaining the technical restrictions.

1. Software:

a. All licensing for any computer or PLC and other control units/systems software product required to run, troubleshoot or amend will be surrendered to IT branch chiefs as appropriate for their respective responsibilities; and will become Government property upon Government acceptance of system.

b. All software products will employ a minimum of 3 Security/Permission levels of access.

- Administrative - full control at root level, which shall be restricted to CCAD IT personnel and vender representatives for amendments as required.

- Programmer/Maintenance - minimally required control to perform maintenance and alter programming as required -Operator - minimally required control to perform routine operations of software. In no instance shall this level be able to alter the programming or delete/alter executable files.

All data files containing any or all information relevant to permissions shall be hidden from view and inaccessible to less than administrative level access.

2. Documentation:

a. Vender/Contractor shall provide a minimum of two sets of network design drawings to the branch chiefs of Industrial Automation and Operations including complete data flow diagrams, sufficient for system familiarity and troubleshooting.

b. Vender/Contractor shall provide to Industrial Automation branch chief a minimum of two electronic copies of all PLCs and other control units/systems programs (including description files of the ladder logic) and a minimum of 2 each of any specific cabling required to connect to the PLCs or other control units/systems. The PLCs nor other control units/systems will not be password protected nor any other form of lockout measures shall be implemented by other than CCAD employees.

c. Vender/Contractor will provide electrical wiring diagrams, for all PLCs and control systems/units utilized to Industrial Automation branch chief.

3. Training:

a. Vender/Contractor shall hold hands-on operator's familiarization/ training with all operators, including question answer sessions to ensure all operational aspects and queries have a resolution.

b. Vender/Contractor shall train/assist local IT/Operations personal in setting up appropriate user permission levels and provide IT personal with full administrative permission users for maintenance and amendments as necessary.

c. Vender/Contractor will go over ladder logic or other instruction set to sufficiently familiarize Industrial Automation representatives with the logic of all PLCs and other control units/systems.

DOCUMENTATION REQUIREMENTS:

A complete set of instruction manuals shall be provided that contain all the information necessary to operate, maintain, and reinstall all software and hardware in the system. Step by Step instructions shall be provided to facilitate rebuilding the system in the event of a fatal system crash.

Prior to acceptance, if the software has been customized for CCAD's use or is other than Commercial Off The Shelf, the contractor shall provide copies of all source code, firmware and software used in the system, as well as one set of backup and configuration software for the data acquisition, PLC, and system control / communication computer(s). All programs shall have been tested, delivered, and fully operational.

If any special programming software or programming software interface devices (such as hardware "keys", dongles or "PIC" modules) were required to access software, these programs and devices shall be included along with necessary registration information. If custom application software was written and provided, a copy of the required compiler (with license) shall be provided as well. At acceptance, all these items shall become property of the government. Any software/hardware purchased for this project shall be registered to Commander, Corpus Christi Army Depot, Corpus Christi, Texas 78419.

ARMY GOLD MASTER (AGM):

The AGM is a collection of security settings for Microsoft Operating systems that must be applied to all Army computer systems. The AGM will be supplied to the vendor by the Corpus Christi Army Depot, the vendor is responsible for installation of the AGM and to ensure their software runs correctly with the AGM installed.

CERTIFICATE OF NETWORTHINESS:

Networthiness certification ensures Automated Information Systems (AIS) utilizing the Army Network are developed in compliance with the Clinger Cohen Act and are secure, supportable, sustainable, and compatible with the Army Enterprise Infrastructure (AEI) (as defined in AR 25-IA). Each new AIS capability and all capability modifications/upgrades must be assessed to verify/validate its Networthiness (network security, network impact, compatibility with the infrastructure, infrastructure requirements, spectrum support, security policy compliance, JTA-A standards compliance, communications and information manpower, training, logistics support, schedule, and funding). The vendor contractor shall work with CCAD IT Department personnel to ensure the proper paperwork is completed to request a Certificate of Networthiness.

ALTERNATE SPECIFICATONS:

Proposals or specifications that deviate from those described herein shall be pre-coordinated for specific approval or rejection by the Government CCAD Information Technology representatives prior to shipment, installation, and acceptance of the equipment.

CABINET REQUIREMENTS:

Cabinets containing "Industrial computer systems" shall meet with the following specifications; they will be required to maintain an average maximum internal operating temperature of < 95 degrees Fahrenheit with a sustained average external temperature of up to 115 degrees Fahrenheit. Additionally the humidity is also of concern; so the cabinets shall also provide for a maximum internal average humidity of 80% when the external average humidity is 98%

INDUSTRIAL EQUIPMENT W/O IMBEDDED COMPUTERS:

The control system shall include a live RJ-45 port to allow for an ANSI Standard 802.3, 100 Base-T, Ethernet connection supporting the full TCP/IP stack implemented by firmware. Also the system shall have an Electronics Industry Association RS232C standard serial port for backup and restore purposes.

C.5.3.8. IMAGE ENHANCEMENT

System shall provide state-of-the-art capability of digital image x-ray enhancement technology. As a minimum image enhancement technology shall manipulate contrast and brightness for optimizing clarity and definition of defects. It shall be capable of enhancement of low contrast structures across gradients due to different thickness of material to show discontinuities.

C.5.3.9. IMAGE HANDLING

System shall have ability for communication and procedures for handling, storing, printing, and transmitting information in nondestructive imaging through file format definition and network protocol. Digital image must be able to pass phantom style process control. System must have capability for Image Quality Indicators (IQI).

C.5.3.10. LIGHTING

Lighting and switches shall be provided within the exempt shielded enclosure to provide even distribution and minimize shadows. An X-Ray ON warning beacon shall be provided at all entrances to exempt shielded enclosure.

C.5.3.11. SYSTEM ELECTRICAL

The contractor shall provide all electrical wiring, conduit, panel, circuit breakers, disconnect switches necessary to provide a complete turn-key x-ray system. Include lighting, electrical receptacles, switches, exterior x-ray in use warning beacon, interlocked doors, and HVAC system.

C.5.3.12. HVAC

The contractor shall provide a complete independent HVAC split system for the exempt shielded enclosure to meet room requirements of the x-ray system and rotor blade components. HVAC system shall provide temperature and humidity control to maintain computers and electronics environment within the shielded enclosure. HVAC system shall maintain relative humidity under 50%. Temperature shall be maintained at 70+/-2 degrees F. System shall be designed to minimize current draw and have an efficient Seasonal Energy Efficiency Ratio (SEER) rating of 13 or greater. All wiring, disconnect switch, controls, piping, pads/stands, ducting, filters and components necessary to make a complete operational HVAC system shall be provided by Contractor. Condensate shall be piped to the nearest available drain line as approved by COR. Contractor shall follow requirements as specified in the following: American Conference of Governmental Industrial Hygienists (ACGIH) Industrial Ventilation: A Manual of Recommended Practice for Design; American Society of Heating, Refrigerating and Air-Conditioning Engineers (ASHRAE) Handbooks – Fundamentals (2013), and HVAC Applications (2011); and Unified Facilities Criteria (UFC 3-410-04N, 10/25/04).

C.5.3.13. PREVENTATIVE MAINTENANCE AND SUPPORT AGREEMENT

Contractor shall provide system preventative maintenance and system support once the system is initially installed for one (1) year after x-ray system acceptance. Contractor shall provide a minimum one technician of a level that is fully qualified to support the entire x-ray system to visit CCAD 3 times a year for (3) days each visit. Dates shall be coordinated with COR.

C.5.3.14. CONTROL SYSTEM

Contractor shall provide and install a computer rack mount and system controls in a control room that will house two x-ray control systems. One control system is for this new x-ray system and the other is for an existing control system which will be relocated to same control room in a separate contract.

C.5.3.15. HOIST AND BRIDGE CRANE

The contractor shall provide and install a ¼ ton electric over-running bridge crane with hoist and pendant control for handling rotor blades just outside the vault main sliding doors. Bridge crane shall have a 25’ span and operate on an existing rail system.

C.5.3.16. UTILITY

While there are various types of electrical utilities available at CCAD, 480 volt/60 Hz/3 phase power shall be used. Contractor shall provide transformers for other voltages required. The following utility services will be provided for connection approximately 50 feet: 480V/3Ph electricity, water, compressed air, and drain line. The Contractor shall provide all electrical wiring, disconnects, components, piping, valves, and equipment necessary to make the system operational with required utilities.

C.5.3.17. SAFETY

The system shall monitor all of its process parameters and safety interlocks in order to immediately implement appropriate actions to ensure the safety of the personnel, equipment, facility, and blades located within the x-ray system. X-ray system shall shut-off when the safety interlocks are activated. Both audible and visual cues will be used to notify users of a safety related event in addition to storing the relevant event data into a log. Contractor shall follow requirements as specified in the following: American National Standards Institute/Health Physics Society (ANSI/HPS) N43.3-2008 General Radiation Safety – Installations Using Non-medical X-ray And Sealed Gamma-ray Sources, Energies Up to 10 Me.

C.5.3.18. FIRE PROTECTION

The contractor shall provide and design for extension and installation of fire suppression sprinklers in vault. Contractor shall follow requirements as specified in National Fire Protection Association (NFPA) 101 – Life Safety Code.

5.4. GENERAL REQUIREMENTS

C.5.4.1 NOISE

Operations of system shall not subject personnel or operators to dB noise levels that exceed Occupational Safety and Health Administration (OSHA) Section 1910.95 standards, Occupational Noise Exposure. Permissible noise exposure shall be based on OSHA time weighted average of over an eight (8) hour testing sound level of 80 dB. The test shall be run using OSHA approved equipment and procedures. When the test is run, all equipment must be operating.

C.5.4.2 SURFACE FINISH

External surfaces shall be smooth and all edges shall be rounded or beveled. Other outside surfaces or unpainted parts shall be suitably finished to prevent corrosion.

All surfaces of castings, forgings, molded parts, stampings and welded parts shall be cleaned and free from sand, dirt, fins, spurs, scale, flux, and other harmful or extraneous materials.

C.5.4.3 PAINTING

The system shall be painted with two (2) coats of enamel or lacquer or other suitable coating to prevent corrosion. Shop surfaces and equipment marred during installation of the new equipment shall be repainted.

If dissimilar metals are used in intimate contact, suitable protection against galvanic corrosion shall be applied, such as proper electrical insulation of the joints or by excluding electrolyte if this is feasible.

C.5.4.4 CABLING, WIRING, AND CONNECTORS

The contractor shall provide system cabling and wiring in compliance with the requirements of the National Electric Code (NEC) for interconnecting electrical cable, for attachment of wires and leads, and shall include all cabling, wiring, functional boxes, and connectors necessary to interconnect internal components in their operating position.

Cabling shall also be provided by contractor between components and entry panels, including connectors. Sufficient cable length and test cables and extender cords shall be provided for any mounted equipment to permit operation and maintenance. Each electrical cable harness shall contain a minimum of 10% additional cabling to allow for future cable breakages.

C.5.4.5 CIRCUIT BREAKERS AND FUSES

Except as otherwise specified herein, selection and application of circuit breakers and fuses shall conform to the NEC. Fuses shall not be used to provide over current protection in multiphase powered equipment. If fuses are used in single phase power applications, then blown fuse indicators shall be provided by contractor.

C.5.4.6 MAIN DISCONNECT SWITCH

A manually operated fusible disconnect switch of adequate size to carry the maximum electrical load of the equipment shall be provided by the contractor for connection to the specified electrical supply service. This switch shall be readily accessible to the operator and constructed so that personnel required to perform any type of maintenance can physically lock this disconnect into the "OFF" position.

C.5.4.7 ELECTRICAL INSTALLATION

The Contractor shall furnish all labor and material required for complete installation of all electrical equipment supplied. Installation shall include all power, control and interconnect wiring installed in conduit. Installation shall conform to all local codes and NFPA-70. All electrical wiring shall be designed and installed per the current requirement of Joint Industrial Council (JIC) Electrical Standards.

An across-the-line fused disconnect switch shall be included with the equipment supplied. The disconnect switch lever shall be located on the face of the control cabinet (readily available to the operator and clearly identified). All electrical circuits shall be fused as required to protect the different components of the system. "Allen Bradley", "Square D", or equal, relays, starters, switches and disconnects shall be provided by contractor.

Input voltage shall be a single source of 480 volts, 60 Hertz, 3 phase, 3 wire with ground. Contractor shall provide step down transformer(s) for other required voltages.

All control wiring shall be 120 volt, 60 Hertz, single phase. A step down transformer with a fused 120 volt, 60 Hertz secondary shall be provided for operation of control and indicating devices. Lower control voltage is acceptable. An input circuit breaker of industrial type with thermal overload and short circuit protection shall be provided (circuit breaker shall conform to Underwriters Laboratories (UL) 489). The Contractor may utilize an existing 120 volt, 60 hertz, single phase power source for lighting. Contractor shall follow requirements as specified in the following: American National Standards Institute/National Electrical Manufacturers Association (ANSI/NEMA) ICS 1 Industrial Controls and Systems and ANSI/NEMA MG 1 Motors and Generators.

C.5.4.8 ELECTRICAL PROTECTION

The contractor shall provide an x-ray system with protection from thermal overload, short circuit, spikes, or surges.

C.5.4.9 MECHANICAL INSTALLATION

The contractor shall provide all labor and materials to move, locate, set and level, align, lubricate and make ready to operate the equipment specified. All machinery shall be installed to the original manufacturer’s tolerances.

C.5.4.9.1. LUBRICATION

The contractor shall provide for any bearings (except sealed-for-life types), mating gears, and sliding parts with accessible lubrication. Oil reservoirs shall be fitted with oil level sight gauges, if applicable. All oil holes, grease fittings, and filler caps shall be accessible. The means shall be provided to insure adequate lubrication for all moving parts.

Recirculation systems shall include filters, which are cleanable or replaceable. Each lubrication reservoir shall have means for determining fluid level. All oil holes, grease fittings and filler caps shall be accessible. Parts consuming fluid shall be clearly identified as such, along with the recommended periods of additions and types of fluids that should be used.

C.5.4.10 MARKING

The contractor shall mark the system in accordance with Military Standard (MIL-STD)-130, Identification Marking of US Military Property.

C.5.4.11 NAMEPLATE

Contractor shall provide a corrosion-resistant nameplate securely attached to the equipment. If the equipment is a special model, the model designation shall include the model of the basic standard item and a suffix identified in the manufacturer's permanent records. As a minimum, the name plate shall provide all information listed below. (The captions may be shortened or abbreviated, provided the entry for each caption is clear as to its identity.)

· Type

· Size

· Nomenclature

· Manufacturer's Name

· Manufacturer's Model Number

· Manufacturer's Serial Number

· Date of Manufacture

· Contractor Number

· Power Characteristic and Rating

· Federal Stock Number or Plant Equipment Code

· U.S. or Country of origin

· Date of Manufacture

· Electrical Power Requirements

Note: The serial number of the equipment shall also be imprinted on the cabinet member in a prominent location.

C.5.4.12 IDENTIFICATION PLATE

Contractor shall provide a separate identification plate of corrosion resistant metal securely attached to each machine. The plate shall be permanently and legibly marked in letters 3/16" and inch high with the caption "Department or Activity Identification" and shall provide blank space for the Government to stamp 25 characters of the same size.

C.5.4.13 LUBRICATION PLATE

If any lubrication is required, then a lubrication plate shall be permanently and securely attached to the system. The plate shall contain the following:

· Points of lubricant application

· Servicing interval

· Type of lubricant

· Viscosity

· Federal or Military Specification (if available)

C.5.4.14 PLATES

All words on indicating plates and on instruction plates shall be in the English language, printed, stamped, stained, engraved, or embossed in boldface characters on a contrasting, non-glare background.

C.5.4.15 HUMAN ENGINEERING

All operating controls shall be located convenient to the operator at the operator’s normal work station. The system shall be designed and manufactured to minimize the possibility of human error and to ensure human and machine compatibility.

C.5.4.16 OPERATING ENVIRONMENT

The system shall be capable of continuous, convenient, efficient and safe operation in a normal factory environment, defined as ambient conditions. System must be capable of 24 hour per day operation, 7 days per week. System shall process 250-300 parts per month.

C.5.4.17 CALIBRATION

Calibration by vendor shall be performed on-site at CCAD after installation. Contractor shall supply information on calibration system to be used to certify system for government review and approval. Government personnel may perform a separate validation of calibration on the equipment after installation and vendor on-site calibration.

C.5.4.18 ACCURACY

The system shall continuously monitor and record the system parameters within the tolerances specified. All digital or analog gauges/readouts shall display the parameters.

C.5.4.19 PART PROGRAM STORAGE

A minimum of 3GB of local part program storage shall be available on the local hard disk drive. Software shall be provided by contractor to quickly transfer programs from the hard drive to RAM memory. All programmable data must be able to be stored on DVD/CD, Hard disk, or equivalent.

C.5.4.20 INTERCHANGEABILITY

To provide for replacement of worn parts, all parts bearing the same part number shall be functionally interchangeable, and shall be dimensionally identical within manufacturing tolerance limits in use by their manufacturer.

C.5.4.21 ACCESSIBILITY

All major assemblies and installed attachments shall be accessible for maintenance, inspection, and repair utilizing common tools. The inspection, adjustment, repair, and replacement of components and accessories shall be accomplished with minimum requirements and minimum disturbance to other components and accessories of the system.

The configuration of the system shall be such that removal of operational parts shall not be necessary for regular maintenance inspection and repair.

C.5.4.22 COMPONENTS FROM OTHER MANUFACTURERS

Any components, which are standard commercial equipment and control system components, and are not manufactured by the Contractor, but were purchased from other commercial sources, shall be identified in the parts lists.