PGS_Specification_v_1.6_122016.pdf

System Performance Specification

For

Prompt Gamma Simulator for

White Sands Missile Range Nuclear Effects Laboratory (NEL)

Survivability, Vulnerability and Assessment Directorate

U.S. Army Program Executive Office for

Simulation, Training, and Instrumentation (PEO STRI)

12350 Research Parkway

Orlando, FL 32826-3276

PREPARED BY: DATE:

Erick Serrano, PE

Lead Systems Engineer

PM ITTS IMO

APPROVED BY: DATE:

Derek Vick

Chief Engineer

PM ITTS IMO

DISTRIBUTION LIST STATEMENT D:

Distribution Authorized to DoD and U.S. DoD Contractors.

erick.serrano Typewritten Text 01/12/2017 erick.serrano Typewritten Text

PRF-PT-00659

V1.2, 20 Dec 2016

DISTRIBUTION LIST STATEMENT D:

Distribution Authorized to DoD and U.S. DoD Contractors.

ii

Performance Specification Revisions

Revision Number Date Log of Changes Made and

Description of Reason Changes Approved By

1.1 11/17/16 - Add last sentence to Section 3.3.7.1.1.5.3

- Appendix A: Revise Government Furnished Enclosure Dimensions (Revise height to 14 Feet and length to 50 Feet, Add Peak Height Dimension at 17 Feet, Add 10’x10’ Dimension to Control Room)

Erick Serrano

1.2 12/20/16 As a Result of a Draft RFP Question:

- Revise Section 3.2 for the Environmental Operating Temperature of the PGS to be: 70oF- 75oF.

Erick Serrano

DISTRIBUTION LIST STATEMENT D:

Distribution Authorized to DoD and U.S. DoD Contractors.

iii

Table of Contents

Para./Section Title Page

1. Scope

1.1 Identification

2. Applicable Documents

2.1 Government Documents

2.2 Non-Government Documents

2.2.1 American National Standards Institute (ANSI)

2.2.2 Electronic Industries Alliance (EIA)

2.2.3 Institute of Electrical and Electronics Engineers (IEEE)

2.3 Order of Precedence

3. Requirements

3.1 Performance Requirements

3.2 Environmental conditions

3.3 Transportability

3.3.1 Materials and processes

3.3.1.1 Parts

3.3.1.1.1 Custom designed microelectronic devices

3.3.1.1.2 Power supplies

3.3.1.2 Materials

3.3.1.2.1 Flammable materials

3.3.1.2.2 Fungus-inert materials

3.3.1.2.3 Hazardous materials

3.3.1.2.4 Metals

3.3.1.2.5 Ozone-Depleting Substances (ODS)

3.3.1.2.6 Wood products

3.3.1.2.7 Radioactive material

3.3.1.3 Processes

3.3.1.3.1 Protective finishes and coatings

3.3.1.3.1.1 Painting, and preparation for

3.3.1.3.2 Corrosion prevention

3.3.2 Nameplates or product markings

3.3.2.1 Unique Identification

3.3.2.2 Controls and indicating devices

3.3.2.2.1 Terminals, terminal blocks and strips

3.3.2.2.2 ESD marking

3.3.2.2.2.1 ESD sensitive assemblies

3.3.2.2.2.2 ESD sensitive equipment

3.3.2.2.2.3 External equipment terminals

3.3.2.2.3 Fluid and gaseous lines

3.3.2.3 Reference designators

3.3.2.4 Cable and wire markings

DISTRIBUTION LIST STATEMENT D:

Distribution Authorized to DoD and U.S. DoD Contractors.

iv

3.3.2.4.1 Cable marking method

3.3.2.4.2 Cable marking information

3.3.2.4.2.1 “W” and “P” cable designations

3.3.2.4.2.2 To-from designators

3.3.2.4.2.3 Assembly/part number

3.3.2.5 Safety markings

3.3.3 Interchangeability

3.3.4 Safety

3.3.4.1 Emergency equipment power disconnect

3.3.4.2 Temperature sensing alarms

3.3.4.3 Equipment energized from multiple power sources

3.3.5 Human engineering

3.3.6 Security and privacy

3.3.7 Logistics

3.3.7.1 Maintenance

3.3.7.1.1 Qualitative maintainability requirements

3.3.7.1.1.1 Special tools

3.3.7.1.1.2 Built-In Test (BIT)

3.3.7.1.1.3 Lamps

3.3.7.1.1.4 Blown fuse indicator lights

3.3.7.1.1.5 Accessibility

3.3.7.1.1.5.1 Cable slack

3.3.7.1.1.5.2 Parts

3.3.7.1.1.5.3 Assemblies

3.3.7.1.1.5.4 Wiring board extender cards

3.3.7.1.1.5.5 Covers, panels, and doors

3.3.7.1.1.5.6 Handles

3.3.7.1.1.5.7 Hoist Eye-Bolts, Crane Hooks

3.3.7.1.1.5.8 Replacement of modular assemblies

3.3.7.1.2 Circuit cards

3.3.7.1.2.1 Circuit card connectors

3.3.7.1.2.2 Circuit card connectors, power and ground

3.3.7.2 Facilities (building, power, water, cable tray systems, radiation shielding)

3.3.7.2.1 Simulator power requirements

3.3.7.2.1.1 Power-line monitoring/protection

3.3.7.2.1.2 Under/Overvoltage

3.3.7.2.1.3 Voltage transients

3.3.7.2.1.4 Frequency transients

3.3.7.2.1.5 Power interruption

3.3.8 Computer hardware requirements

3.3.8.1 Computer processing requirements

DISTRIBUTION LIST STATEMENT D:

Distribution Authorized to DoD and U.S. DoD Contractors.

v

3.3.8.2 Computer operations control function

3.3.8.3 Peripherals

3.3.8.3.1 Open System Architecture

3.3.8.4 Scaleable Architecture

3.3.8.5 Hardware failure

3.3.9 Computer software requirements

3.3.9.1 Programming Language

3.3.9.2 Integrity in Handling Calendar Dates

3.3.9.3 Computational system

3.3.9.3.1 Simulator computer system

3.3.9.3.2 Application software

3.3.9.3.3 Diagnostic software

3.3.9.3.3.1 Computer and peripheral diagnostic programs

3.3.9.3.3.2 System daily readiness check program

3.3.9.3.4 Information Assurance

3.4 Site Integration of Simulator at WSMR

3.4.1 Workmanship

3.4.1.1 Cleaning

3.4.1.2 Threaded fasteners

3.4.1.3 Wiring

3.4.1.4 Shielding

4. Verification

4.1 Methods of Verification

4.2 Classes of Verification

4.3 Inspections and Tests

4.3.1 Visual Inspections

4.3.2 Functional Tests

4.3.2.1 Electrical Tests

4.3.2.2 Daily Operational Readiness Tests (DORTs)

4.3.3 Operation and Mission Tests

4.3.4 Product Assurance Tests

4.3.5 Non-Functional Examinations

APPENDIX A – Building Facility – For Information Purposes APPENDIX B – Acronyms

DISTRIBUTION LIST STATEMENT D:

Distribution Authorized to DoD and U.S. DoD Contractors.

System Performance Specification For

Prompt Gamma Simulator for White Sands Test Center Nuclear Effects Laboratory (NEL)

Survivability, Vulnerability and Assessment Directorate

1. Scope

As part of the Nuclear Effects Test Capability Modernization (NETCM) Program, the U.S. Army Program Executive Office Simulation, Training and Instrumentation (PEO STRI), Project Manager for Instrumentation, Targets and Threat Simulators (PM ITTS), Instrumentation Management Office (IMO) has a requirement from the U.S. Army Test and Evaluation Command, Survivability, Vulnerability and Assessment Directorate (SVAD) to develop a short-pulse, high dose-rate, Prompt Gamma Simulator (PGS) to conduct testing on Circuit Card Assemblies (CCAs), Line Replaceable Units (LRUs), small test systems and light armored vehicles for Nuclear Weapons Effects survivability validation at White Sands Missile Range (WSMR), New Mexico. NEL comprises a variety of laboratories and test facilities focused on the nuclear effects on military equipment.

This specification establishes the performance requirements for the development, design, fabrication, integration, demonstration, testing, installation, training, and delivery of all capabilities of the PGS at WSMR. The PGS will be installed at the SVAD Nuclear Weapons Effects (NWE) test facilities at WSMR in a government provided building facility.

1.1 Identification

The NETCM modernization program will deliver the following turnkey system, complete with all ancillary systems (including but not limited to: oil system, gas system, chilled water system, water purification, control system), ready for operation by the WSMR, SVAD technical team:

1) Prompt Gamma Simulator

2. Applicable Documents

The following documents with the exact issue listed form a part of this specification to the extent specified herein. This specification is designated as a first tier document. The documents referenced directly in this specification are designated as second tier documents and are considered part of this specification to the extent specified herein.

Documents referenced in successive tiers are not part of this specification and are to be used for guidance only.

2.1 Government Documents

OSHA 1910.302-308: Design Safety Standards for Electrical Systems OSHA 1910.1096: Ionizing Radiation Standard QSTAG 244 – Nuclear Hardening Criteria for Military Equipment (Unclassified), Edition 4, Volume I (Confidential), Volume II (Secret), January, 1992.

DISTRIBUTION LIST STATEMENT D:

Distribution Authorized to DoD and U.S. DoD Contractors.

QSTAG 1031 – Consistent Sets of Nuclear Hardening Criteria for Classes of Equipment (Unclassified), Edition 1, Volume I (Confidential), Volume II (Secret), 6 September 1996

Mil-Std-883 – Test Method Standard for Microcircuits DODI 3150.09: The Chemical, Biological, Radiological, and Nuclear (CBRN)

Survivability Policy STANAG 4145: Nuclear Survivability Criteria for Armed Forces Material and

Installations – AEP-4 AR 70-75: Survivability of Army Personnel and Materiel AR 15-41: Nuclear and Chemical Survivability Committee

2.2 Non-Government Documents

2.2.1 American National Standards Institute (ANSI)

ANSI Z35.1-72: Accident Prevention Signs, Specification for ANSI Z35.4-73: Informational Signs Complementary to ANSI Z35.1, Accident

Prevention Signs, Specification for ANSI Z53.1-79: Safety Color Code for Marking Physical Hazards

2.2.2 Electronic Industries Alliance (EIA)

EIA RS 471 Symbol and Label for Electrostatic Sensitive Devices

2.2.3 Institute of Electrical and Electronics Engineers (IEEE)

IEEE 200-1975 (Rev 1988) Standard Reference Designations for Electrical and Electronics Parts and Equipment (ANSI/IEEE Y32.16)

IEEE STD 510-1983: Practices for safety in high voltage and high power testing

2.3 Order of Precedence

In the event of a conflict between the text of this specification and the references cited herein, the text of this specification takes precedence. Nothing in this specification, however, supersedes applicable laws and regulations unless a specific exemption has been obtained.

DISTRIBUTION LIST STATEMENT D:

Distribution Authorized to DoD and U.S. DoD Contractors.

3. Requirements

The following sections describe the system performance requirements for the PGS.

3.1 Performance Requirements

The table below lists the Key Performance Parameters (KPPs) of the PGS.

KPP Threshold Value Objective Value

Exposure Area ≥ 0.5 m2 ≥ 1.25 m2

Peak Dose Rate ≥ 1.0 x 1010 rad(Si)/sec ≥ 3.0 x 1010 rad(Si)/sec

Pulse Width 20 ± 2 ns 20 ± 1 ns

The terms used in the KPP table are defined as follows:

1) The exposure area is defined as the area over which the peak dose rate is at least 25% of the maximum.

2) The radiation responsible for the dose rate shall be a spectrum of electromagnetic radiation having photon energies above 0.5 MeV. The end point energy of the radiation spectrum shall be above 3 MeV but not greater than 8 MeV.

3) The radiation pulse width shall be defined as follows:

a. The jitter in the timing of the peak dose rate shall be less than 10ns.

b. The pulse shall have a rise time from 10% to 90% of the maximum of not more than 7.5 ns.

c. The dose rate in the pulse shall fall to 10% of the maximum within 20 ns

(±2 ns threshold, ±1 ns objective) of the start of the main pulse.

d. The rise and fall of the pulse shall be well characterized by smooth, monotonic curves such as a linear or Gaussian curve. At any given time during the pulse, the radiation flux shall not vary from such a curve by more than 10% of the maximum.

e. Radiation that arrives prior to and after the main pulse shall contain less than 10% of the total fluence.

DISTRIBUTION LIST STATEMENT D:

Distribution Authorized to DoD and U.S. DoD Contractors.

The table below lists the Key System Attributes (KSAs) of the PGS.

KSA Threshold Value Objective Value

Duty Cycle

≥ 10 shots per 8-hour day (48 minute turnaround between shots)

≥ 25 shots per 8-hour day (19 minute turnaround between shots)

Pulse to Pulse Variance/Repeatability*

≤ 10% ≤ 5%

Maintenance Workforce

≤ 3 Personnel ≤ 2 Personnel

Operations Workforce ≤ 2 Personnel 1 Person

Number of shots before planned major maintenance

≥ 400 shots ≥ 1000 shots

Reliability ≥ 500 shots ≥ 1500 shots

Simulator Footprint** ≤ 1800 ft2 ≤ 1500 ft2

Diode Centerline Height

66 ± 12 in 66 in

* Amplitude, rise time and pulse width

** Simulator and ancillary equipment only, not to include the control room. Refer to Appendix A for preliminary building layout.

Maintenance and Operations Workforce are not necessarily exclusive groups of personnel. The assigned maintenance personnel can also be operations personnel.

The Reliability KSA refers to system operational time before failure requiring greater than one week of down time. This one week includes any non-operational times while waiting for specialized repair personnel and their labor and also any long-lead time repair parts and specialized equipment.

The Planned Major Maintenance and Reliability KSAs differ in that reliability refers to an unplanned failure of the system requiring extensive (longer than one week) repair time.

Planned Major Maintenance would have all repair parts, and specialized personnel and equipment scheduled or on-hand for the maintenance effort.

3.2 Environmental conditions.

Final operating location of the PGS will be in a conditioned building with cooling and heating capabilities. The equipment shall withstand the following environmental conditions without deterioration:

DISTRIBUTION LIST STATEMENT D:

Distribution Authorized to DoD and U.S. DoD Contractors.

Temperature: 70oF – 75oF

Relative humidity: 30% to 65%

3.3 Transportability.

The final operational location of the PGS will be at a future building structure at WSMR.

3.3.1 Materials and processes.

Materials and processes shall be in accordance with the following requirements.

Commercial and Non-Developmental Items (CaNDI) are exempt from these requirements, unless otherwise specified in this section. CaNDI must comply with the Government’s definitions in order to be exempt.

3.3.1.1 Parts.

The PGS hardware shall be comprised of CaNDI to the maximum extent practicable.

3.3.1.1.1 Custom designed microelectronic devices.

The use of custom designed microelectronic devices shall be avoided unless no reasonable alternative exists.

3.3.1.1.2 Power supplies.

All power supplies to be used in the PGS shall be commercial items to the maximum extent practicable.

3.3.1.2 Materials.

Materials selected for the simulator hardware shall meet the primary design requirements of their application and the following additional performance requirements:

When it is commercially practicable, materials selected shall allow simulator-peculiar parts to be repairable by commonly applied commercial processes. For example, where a weldable metal will perform as well as a non-weldable metal in a part that could be repairable by welding, the selected material shall be the weldable metal.

Materials selected shall withstand, without deterioration, the effects of the environment in which the equipment will be operated, stored, and transported.

Materials selected shall preclude exposure of personnel, facilities, and the environment to toxic, explosive, radioactive and fire hazards. Use of materials should minimize the exposure of personnel to radiation to avoid the use of easily activated materials.

3.3.1.2.1 Flammable materials.

Materials shall be noncombustible or fire retardant in the most hazardous conditions of atmosphere, pressure, and temperature to be expected in their application.

Nonpermanent fire retardant additives shall not be used to achieve fire retardation.

3.3.1.2.2 Fungus-inert materials.

When the specified environment is conducive to fungus growth, the equipment shall be fabricated using fungus-inert materials.

DISTRIBUTION LIST STATEMENT D:

Distribution Authorized to DoD and U.S. DoD Contractors.

3.3.1.2.3 Hazardous materials.

The simulator shall not expose personnel or the environment to excessive levels of toxic, carcinogenic, teratogenic, and otherwise hazardous materials as defined by OSHA, Environmental Protection Agency (EPA) and State and local authorities. If hazardous materials must be used in order to meet the performance requirements of this specification, only Government-authorized materials shall be used, the hazardous items shall be suitably marked, and all due precautions shall be taken to prevent whatever harm the hazardous material may cause.

Additionally, the contractor shall ensure that operation and maintenance procedures comply with Federal, State and local environmental and occupational safety laws and regulations.

3.3.1.2.4 Metals.

Metals shall be corrosion-resistant, or shall be coated or metallurgically processed to resist corrosion. The environmental conditions to which the equipment will be exposed shall not cause corrosion and shall not cause deterioration of metal parts.

3.3.1.2.5 Ozone-Depleting Substances (ODS).

The use of substances classified as Class I ODS, shall be avoided unless there is no suitable non-ODS alternative available.

3.3.1.2.6 Wood products.

Wood products shall be treated for preservation, fire-retardation, and termite protection, and shall conform to commercial Grade B or better.

3.3.1.2.7 Radioactive material.

The use of materials susceptible to activation in the operating environment of the simulator shall be avoided. Radioactive materials shall not be utilized unless specifically authorized in writing by the Government.

3.3.1.3 Processes.

Processes shall be in accordance with established industry standards (e.g., American Society for Testing and Materials (ASTM), American National Standards Institute (ANSI), Institute of Electrical and Electronic Engineers (IEEE), etc.). The following additional requirements shall apply to the fabrication of Simulator Peculiar Equipment (SPE), unless otherwise specified.

3.3.1.3.1 Protective finishes and coatings.

Class I ODS-based primers, coatings, and solvents shall be avoided.

3.3.1.3.1.1 Painting, and preparation for.

Surfaces to be painted shall be prepared and painted in accordance with the paint manufacturer’s recommendations. Class I ODS-based solvents shall be avoided in the surface preparation process.

DISTRIBUTION LIST STATEMENT D:

Distribution Authorized to DoD and U.S. DoD Contractors.

3.3.1.3.2 Corrosion prevention.

The simulator shall not be subject to corrosion and shall not be subject to other forms of physical deterioration in its intended use. The following is a list of characteristics that may contribute to such corrosion and deterioration and shall be avoided:

Crevices susceptible to moisture collection.

Galvanic metal couples over 100 mV potential difference.

Moisture-tight designs without proper seals.

Unprotected bearings.

Untested adhesively bonded designs (stress and humidity tests).

Metallic construction where nonmetallic is suitable.

Hardware requiring field maintenance for corrosion control.

3.3.2 Nameplates or product markings.

Simulator equipment and cables shall be identified and marked in accordance with the following requirements. Markings shall be permanent, securely fastened, and shall withstand the operational and storage environment of the simulator, environmental testing, and cleaning procedures. Legibility shall be as required for ready readability.

Markings shall be of a color which is in contrast to the color of the background surface.

Markings of items shall not adversely affect the life and utility of the item.

3.3.2.1 Unique Identification

Each single hardware article or a repairable unit formed by a grouping of subassemblies, components or constituent parts shall have a Department of Defense human and machine readable unique identification (UID) with bar code label marking per ANSI/AIM BC1 containing information as defined in MIL-STD-130, Figure 2.c (construct #2). The UID shall be derived by concatenating data identifier 17V, Cage Code 57039, followed by the item part number, followed by the serial number.

3.3.2.2 Controls and indicating devices.

Markings shall be provided on the front of each exterior and interior panel, panel door, control mounting surfaces of each chassis, sub panel, etc., to clearly (though necessarily briefly) designate the functions and operations of all controls, fuses, and indicating devices mounted thereon, protruding through, or available through access holes therein. All markings shall be located on the panel or chassis in correct relationship to the respective designated items.

3.3.2.2.1 Terminals, terminal blocks and strips.

All terminals, terminal blocks, and terminal strips shall be identified and marked in a clear and permanent manner to facilitate replacement of connections. Where space limitations prohibit marking on the terminal, terminal block, or terminal strip, the marking shall be on the chassis adjacent to the terminal, terminal block, or terminal strip.

DISTRIBUTION LIST STATEMENT D:

Distribution Authorized to DoD and U.S. DoD Contractors.

3.3.2.2.2 ESD marking.

Unless otherwise specified herein, electrostatic discharge (ESD) sensitive assemblies and equipment shall be marked as follows.

3.3.2.2.2.1 ESD sensitive assemblies.

Electrostatic discharge sensitive assemblies shall be marked with either the EIA RS-471 or the military symbol as illustrated in Figure 1. The symbol shall be located in a position readily visible to personnel when the assembly is incorporated in its next higher assembly.

(RS-471)

Figure 1. ESD Symbols.

3.3.2.2.2.2 ESD sensitive equipment.

Equipment containing ESD sensitive parts and assemblies shall be marked with the EIA RS-471 or military symbol. The symbol shall be located on the exterior surface of the equipment and readily visible to personnel prior to gaining access to ESD sensitive parts and assemblies within the equipment. The following ESD caution statements shall be placed adjacent to the ESD sensitive symbol:

3.3.2.2.2.3 External equipment terminals.

The EIA RS-471 or military symbol shall be applied on the exterior of the equipment cabinet adjacent to external terminals connected internally to ESD sensitive parts and assemblies.

3.3.2.2.3 Fluid and gaseous lines.

Fluid lines shall be marked with the type of line; e.g., Supply, Return, Drain, Vent. All pressurized lines shall also be marked with the direction of flow. Where hazardous fluids or dangerous gases are utilized or where inadvertent cross connection of lines could result in a dangerous mixture, the name of the material conducted by the lines shall also be part of the line markings. Marking shall be legible, permanent, and shall

CAUTION

CONTAINS PARTS AND ASSEMBLIES

SUSCEPTIBLE TO DAMAGE BY

ELECTROSTATIC DISCHARGE

DISTRIBUTION LIST STATEMENT D:

Distribution Authorized to DoD and U.S. DoD Contractors.

be on bands of material suitable for the environment. Location of markers shall be within one foot of line connection points, oriented for readability by maintenance personnel.

3.3.2.3 Reference designators.

Reference designators in accordance with Section 4 of IEEE 200-1975 (Unit Numbering Method) shall be employed to identify and mark the location of electrical and electronic parts and equipment in the entire simulator. The assignment of reference designators shall begin at the unit level of assembly and shall continue down to the basic part level of assembly as defined in IEEE 200-1975. All unmodified GFE shall be identified on related system or assembly drawings and schematics with assigned unit or assembly level reference designators. Marking and location of reference designators shall be in accordance with paragraphs 8.2 and 8.2.1 of IEEE 200-1975. Method, permanency, and legibility of reference designators shall be as specified in 3.3.2. Cables and wires are exempt from the requirements of IEEE 200-1975, paragraphs 4.1.5.5 (Inter-subassembly and Inter-unit Cable Connections) and 8.2.3 (Cable Assemblies); but shall be subject to the identification and marking requirements of 3.3.2.4 below.

3.3.2.4 Cable and wire markings.

Disconnectable cables and wires shall be permanently and legibly marked in accordance with the following requirements, which shall apply to all equipment categories. Types of disconnectables include plugs, jacks, lugged terminals, push-on captivated wires. Jumpers or links located on terminal boards, jacks or plugs are exempt from such marking. Soldered or wire wrap connections are also exempt from such marking. Markings shall not damage the wires or cables attached to and shall be located within approximately 8 cm from the connector, terminal or plug, oriented in such a manner as to be readable without removal of the wire or cable or support clamps.

3.3.2.4.1 Cable marking method.

The following methods shall be used to mark cables and wires:

Molded on the cable.

Stamped on the cable.

Securely attached, appropriately marked plastic bands. (no less than .25 mm thickness).

Bands of appropriately marked heat shrinkable tubing.

3.3.2.4.2 Cable marking information.

The following information shall be marked on all disconnectable cables.

3.3.2.4.2.1 “W” and “P” cable designations.

A “W” designation (W1, W2, etc.) shall be assigned to uniquely identify cables and wires. The numerical portion of the “W” designations shall be consecutive throughout the simulator. In addition, each connector within the same cable shall be identified with a “P” designation (P1, P2, etc). The numerical portion of the “P” designations shall be

DISTRIBUTION LIST STATEMENT D:

Distribution Authorized to DoD and U.S. DoD Contractors.

consecutive for a given cable. The “W” and “P” designations shall be marked on cables in accordance with Figure 2.

3.3.2.4.2.2 To-from designators.

In addition to the “W” and “P” designations, cable and wire markings shall also include “to-from” reference designators to identify the locations where they are connected.

Cables and wires internal to subassemblies are not required to be marked with the “from” designator. The “to-from” designators shall be marked on cables in accordance with Figure 2.

3.3.2.4.2.3 Assembly/part number.

Simulator-peculiar wires, cables, and harnesses shall also be identified and marked with the applicable assembly or part number. The number may be included with other required cable markings where space permits. Otherwise, a separate marking shall be made adjacent to the “W”, “P”, and “to-from” designator markings.

DISTRIBUTION LIST STATEMENT D:

Daisy chain, continuous ribbon cable with clamp on connectors:

UNIT 6

W1P1 6A1J1

W1P2 6A2J1

NOTE (1) PREFIX MAY BE OMITTED FOR WIRES OR CABLES LOCATED ENTIRELY WITHIN THE

SAME CABINET.

NOTE (2) FOR PURPOSES OF THESE MARKING REQUIREMENTS, UNITS COMPRISED OF MULTIPLE

CABINETS OR BAYS PERMANENTLY WELDED OR BOLTED TOGETHER SHALL BE

CONSIDERED AS HAVING SEPARATE CABINETS.

NOTE (3) THE UNDERLYING CRITERIA FOR WIRE AND CABLE MARKING SHALL BE EASE OF

MAINTENANCE AND REDUCTION OF CHANCES FOR MISCONNECTION.

W2P2 5A2J2/4A1J1

W2P1 4A1J1/5A2J2

P/N 927D1057

W3P1 6A1J1/7A1J3/8A5J4

P/N 927D1058

A1CB1-1/A2TB3-10 A2TB3-10/A1CB1-1

W3P2 7A1J3/6A1J1

W3P3 8A5J4/6A1J1

Terminal wire marking:

Multiple destination cable:

W1P3 6A3J1/8A2J1

Basic inter-cabinet cable:

W1P4 8A2J1/6A3J1

W1P5 8A1J1

UNIT 8

Figure 2. Examples of Cable Markings

DISTRIBUTION LIST STATEMENT D:

Distribution Authorized to DoD and U.S. DoD Contractors.

3.3.2.5 Safety markings.

Danger, caution, and warning signs, labels, and markings shall be used to warn of specific hazards such as voltage, current, thermal, physical, radiation. Method, permanency, and legibility of equipment safety markings shall be as specified in 3.3.2.

Guards, barriers, and access doors, covers, or plates shall be marked to indicate the hazard which may be present upon removal of such devices. When possible, marking shall be located such that it is not removed when the barrier or access door is removed.

Additionally, hazards internal to units shall be marked adjacent to hazards if they are significantly different from those surrounding items.

Safety alerting standards shall conform to ANSI/NEMA Z535-2011 series.

Laser labels shall be in accordance with 21 CFR 1040.

3.3.3 Interchangeability.

Where practicable, parts shall be made identical and interchangeable. For example, circuit card types shall be kept to as few as practicable so that a large inventory of spare circuit cards is unnecessary.

3.3.4 Safety.

3.3.4.1 Emergency equipment power disconnect.

The simulator power distribution system shall include the power disconnects required by OSHA 1910.302 - 308. Each of the disconnecting points shall be legibly and permanently marked to indicate its purpose and operating instructions. The marking method, permanency, legibility, durability and lettering shall be as specified in paragraph 3.3.2.

3.3.4.2 Temperature sensing alarms.

All heat producing equipment cabinets shall be equipped with temperature sensing devices, which shall be integrated into an over-temperature alarm system.

3.3.4.3 Equipment energized from multiple power sources.

A warning label in accordance with Figure shall be securely affixed to electrical and electronic units which have more than one source of electrical power. The warning label shall be located in such a manner as to allow operation and maintenance personnel to identify all of the circuits providing electrical power, and the location and designation of the de-energizing switches. Method of applying, permanency, legibility, and lettering shall be as specified in 3.3.2.

DISTRIBUTION LIST STATEMENT D:

Distribution Authorized to DoD and U.S. DoD Contractors.

WARNING

THIS EQUIPMENT ENERGIZED FROM MULTIPLE SOURCES.

TURN OFF THE FOLOWING TO FULLY DEENERGIZE THIS UNIT.

SWITCH

LOCATION

SWITCH

IDENTIFICATIONCIRCUIT

Figure 3. Multiple Power Source Label

3.3.5 Human engineering.

Human engineering shall be designed into the simulator for ease of servicing, maintenance, repairs and disassembly and reassembly. Movable hoist and crane systems shall be provided with the simulator for these purposes.

3.3.6 Security and privacy.

All equipment cabinet doors shall be equipped with key operated locks. All cabinet locks shall be keyed alike.

Simulator operation through physical controls and control computer shall be password protected to allow unauthorized use of simulator.

3.3.7 Logistics.

Operation, maintenance and sustainment shall be inherent to the design and operation of the simulator to achieve reliable system operation at reduced sustainment costs.

3.3.7.1 Maintenance.

3.3.7.1.1 Qualitative maintainability requirements.

General maintainability characteristics of the simulator equipment shall be as specified in the following paragraphs.

3.3.7.1.1.1 Special tools.

There shall be no need to use special tools for equipment maintenance unless common tools are inadequate. Special tools shall be retained in holders in a central location compartment as part of the simulator.

3.3.7.1.1.2 Built-In Test (BIT).

The simulator shall be provided with a fault management and diagnosis inherent of the control system to achieve reliability requirements and low repair cycle times.

DISTRIBUTION LIST STATEMENT D:

Distribution Authorized to DoD and U.S. DoD Contractors.

3.3.7.1.1.3 Lamps.

All lamps used shall be replaceable from the front.

3.3.7.1.1.4 Blown fuse indicator lights.

Blown fuse indicator lights shall be provided and shall be visible on the outside of the equipment racks when all doors are closed and when standing in front of the racks.

3.3.7.1.1.5 Accessibility.

Simulator equipment shall provide for the necessary access to its interior parts, terminals, and wiring, for adjustments, required circuit checking, and the removal and replacement of maintenance parts. Accessibility for testing shall not apply to parts located in non-repairable assemblies. For routine servicing and maintenance, unsoldering of wires, wire harnesses, parts, or subassemblies shall not be required in order to gain access to terminals, soldered connections, mounting screws, and the like.

The following additional requirements shall also apply.

3.3.7.1.1.5.1 Cable slack.

Adequate cable slack and cable bending features shall be provided to assure full extension access to multiple equipment extensions during maintenance without stressing the cables and associated connectors. Adequate cable slack shall also be provided in the cables behind equipment panels to permit removal of each instrument, display, or control panel and disconnection from associated cables in one maintenance operation from the front of the equipment without stressing the cables and associated connectors. The need for rear access to disconnect or reconnect the equipment from associated mounting, shall be prevented by selection and use of appropriate hardware fasteners.

3.3.7.1.1.5.2 Parts.

Replaceable parts shall be readily removable. For example, replaceable parts shall not be permanently mounted by means such as rivets, spot welding, or hard curing compounds. No unsoldering of connections shall be necessary in order to remove front panels or sub chassis for maintenance purposes.

3.3.7.1.1.5.3 Assemblies.

All parts shall be readily accessible for maintenance. Tracks, rollers, hinges, pivots, or a combination thereof shall be installed for providing accessibility to units, assemblies, subassemblies, and parts. Locking devices shall be provided to lock the chassis in the servicing position and in the fully opened and fully closed positions. Each major assembly, subassembly, and unit of the simulator shall permit access to its interior components and parts for maintenance. It shall not be necessary to displace or remove wires, cables, subassemblies, or assemblies in order to gain access to mounting screws, test points, adjustment points, lubricating points, and the like. Where visual inspection is necessary, and open access is not feasible, transparent access panels shall be used. The placement of parts shall be such as to provide space for the use of test probes and maintenance tools. Assemblies subject to replacement or service shall not be permanently fastened. PGS components/assemblies that are custom designed, DISTRIBUTION LIST STATEMENT D:

Distribution Authorized to DoD and U.S. DoD Contractors.

are to substantially similar to components that have successfully been used in other pulsed power machines with well modeled, predictable performance and low failure rates.

3.3.7.1.1.5.4 Wiring board extender cards.

Where connector termination points are not accessible for testing, extender cards shall be provided. Extender cards shall have matching indexing system and shall be identified with their corresponding wiring boards. Insulating materials shall not be applied to the conducting surfaces of extender cards.

3.3.7.1.1.5.5 Covers, panels, and doors.

Hinged covers and doors shall be equipped with means to retain them in their open positions. When opened, hinged covers and doors shall not cause the equipment to become unbalanced. Removable covers for which no convenient location is available during maintenance shall be equipped with a chain or lanyard fastened to the equipment. Front panels containing parts that require maintenance, such as instruments, switches, potentiometers, and the like, shall be hinged. Where parts or assemblies are mounted on hinged doors, on panels, and on covers, the electrical ground return shall not depend on the hinge contact for electrical continuity. Means shall be provided on hinged panels to retain the panels in the open position to permit accessibility to all parts mounted on the panels, to prevent damage to the panels, and to prevent injury to personnel performing maintenance.

3.3.7.1.1.5.6 Handles.

Handles and handgrips shall be provided for removing units or chassis from enclosures.

Handles on enclosures shall be recessed.

3.3.7.1.1.5.7 Hoist Eye-Bolts, Crane Hooks.

Heavy duty, weight bearing eye-bolts or crane hooks shall be provided on assemblies that require removal with a crane and hook system for replacement, maintenance, disassembly and reassembly.

3.3.7.1.1.5.8 Replacement of modular assemblies.

Modular assemblies such as circuit boards shall be equipped with connectors so that they may be removed without unsoldering. All modular assemblies shall be designed so that they can be inserted into the equipment in one position only. All sockets within each assembly shall be oriented in the same direction and positioned so that they are visible. Modular circuits shall be grouped in functional units.

3.3.7.1.2 Circuit cards.

Where practicable, functions shall be apportioned to circuit cards so as to take advantage of standardization and commonality of components, such that the need for spare parts inventory is minimized.

DISTRIBUTION LIST STATEMENT D:

Distribution Authorized to DoD and U.S. DoD Contractors.

3.3.7.1.2.1 Circuit card connectors.

Circuit card connectors shall have means of positive connection without diminishing the life of the connector under normal mating and un-mating cycles.

3.3.7.1.2.2 Circuit card connectors, power and ground.

Power and ground connections to circuit boards shall be arranged so that inadvertent insertion of a card in the wrong slot will not result in damage to the card or to other parts of the simulator.

3.3.7.2 Facilities (building, power, water, cable tray systems, radiation shielding).

The Government will provide the building facility structure for the PGS and all required external main power/water connections, cable tray systems for low voltage wiring path and radiation shielding. As part of the building facility, the government will provide the main power and ancillary power provisions at locations specified by the contractor, the domestic water make-up service connection point and low voltage cable trays for path between the simulator and control room. The simulator contractor shall make all final site infrastructure connections for system operation.

3.3.7.2.1 Simulator power requirements.

Simulator main power connection shall be 480V/120V, 3ph, 60Hz. Ancillary equipment power connections shall be 480V/208V/120V, 3ph, 60Hz.

3.3.7.2.1.1 Power-line monitoring/protection.

The simulator shall be protected against damage and malfunctions resulting from power line abnormalities described herein. Appropriate monitors and indicators shall be provided to reveal the nature of the abnormality detected.

3.3.7.2.1.2 Under/Overvoltage.

If power line voltage at the simulator input power distribution panel exceeds the operating limits specified for the simulator by more than + 5 percent for a period of 5 seconds or more, automatic shutdown of the simulator shall occur. When the simulator is supplied by multiphase line power, automatic shutdown of the simulator shall occur when these limits are exceeded on one or more of the phases. A visual indication of the condition shall be provided. If operating limits are not specified elsewhere, the limits shall be presumed to be +6 percent and -13 percent of the nominal power line voltage supplied.

3.3.7.2.1.3 Voltage transients.

Phase-to-phase or phase-to-neutral voltage transients falling within the curve of figure 4 in ANSI/IEEE 446-1987 shall not cause part failures, prevent resumption of normal operation, or require the equipment to recycle when the transients have ceased.

3.3.7.2.1.4 Frequency transients.

The simulator shall continue operation during transients within +3 percent of nominal frequency. A frequency variation of +15 percent for periods up to ten seconds, occurring not more than once every five minutes, shall not result in permanent damage, DISTRIBUTION LIST STATEMENT D:

Distribution Authorized to DoD and U.S. DoD Contractors.

modification of characteristics, and loss or change of computer stored memory information.

3.3.7.2.1.5 Power interruption.

The equipment shall be protected from permanent damage, modification of characteristics, and loss or change of computer stored memory information, resulting from a power interruption with power restored within 1 to 30 seconds and occurring not more than once every five minutes.

3.3.8 Computer hardware requirements.

3.3.8.1 Computer processing requirements.

The Simulator Computer Control System shall have sufficient processing capacity to meet the performance requirements and provide 30% spare capacity.

The main Simulator Computer Control System shall be a remote system located in a separate room than the location of the simulator yet in the same building structure. This control system is intended to be located in the Control Room.

A separate portable computer control system shall be located at the simulator for diagnosis purposes.

3.3.8.2 Computer operations control function.

The computer control function shall provide control of the computational system, including start-up from a powered-down condition, loading the simulator operational programs, bringing the simulator system to operating status, shutdown, trapping unexpected system transient events, operation and management of system components, control of system diagnostics, test and plot of test results. The computer control function shall provide the means to enter commands interactively at the operating system level and observe and record responses to the entered commands.

The use of the computer control function shall not require more than one operator.

3.3.8.3 Peripherals.

Peripherals shall be provided to support the following functions:

a Two 60” LCD displays to be located in the Control Room for display of control information, simulator system status, test data/results/plots, etc… b Storage of software and databases used for operation, maintenance and testing of the Simulator.

c Backup and recovery of information to writable mass storage devices.

d Reading to, and writing from, data storage and transmission media, including:

1) removable hard drives

2) DVD

DISTRIBUTION LIST STATEMENT D:

Distribution Authorized to DoD and U.S. DoD Contractors.

Hard copy output of information necessary to support the operation, maintenance and testing of the simulator in accordance with the requirements of this specification and the intended use of the simulator.

3.3.8.3.1 Open System Architecture.

Hardware components shall conform to non-proprietary standards to allow the interfacing of components and systems manufactured by multiple vendors.

3.3.8.4 Scaleable Architecture.

The simulator computer system architecture shall allow addition and replacement of modular hardware items, specifically mass storage devices, memory, processing units, I/O equipment, and network components, without requiring changes to simulator computer system software that is other than Commercial Item software.

3.3.8.5 Hardware failure.

Failure of a hardware element shall be reported upon occurrence. Adverse effects shall be limited to the subsystem containing that hardware element. If the simulator computer system contains multiple processors, to the extent practicable, failure of a single processor shall not cause degradation of simulator operation in subsystems not controlled by the failed processor.

3.3.9 Computer software requirements.

3.3.9.1 Programming Language.

All non-Commercial Item software shall be provided in ASCII source form. All source code that is compiled and used in generating executable code shall be written in a high-level language, such as Ada or C++, chosen to provide the lowest life-cycle cost for the Army. All source code shall be in conformance with the applicable industry standard for the language used.

3.3.9.2 Integrity in Handling Calendar Dates.

The handling of calendar dates shall not cause erroneous results regardless of the date or dates being processed.

3.3.9.3 Computational system.

The following portions of the computational system shall be Commercial Items:

computers and peripherals, mass storage devices, networked application devices, diagnostic programs for the items already listed, and operating system software. The remainder of the computational system shall consist of Commercial and Non-developmental Items wherever practicable. Computer hardware, software, and network components shall be selected in a manner that minimizes the number of different types of spare parts, maximizes the commonality of software components and minimizes associated logistics support costs.

3.3.9.3.1 Simulator computer system.

The simulator computer system, which consists of the computer hardware and software of the simulator, shall be programmed with algorithms and iteration rates that provide

DISTRIBUTION LIST STATEMENT D:

Distribution Authorized to DoD and U.S. DoD Contractors.

mathematically consistent and stable solutions. Iteration rates for time-critical aspects of real-time dynamics shall be no less than 60 Hertz. Main remote control station and local portable simulator station displays and indications shall be free of discernible stepping, oscillating, jittering, or other erratic behavior.

3.3.9.3.2 Application software.

The application software shall include:

a. Software necessary to operate the simulator in accordance with the functional requirements of this specification.

b. Software used to perform testing, to monitor simulator operations, for simulator diagnostics and to demonstrate compliance of the simulator with this specification.

3.3.9.3.3 Diagnostic software.

Diagnostic software shall test the operation of the computers, peripheral equipment and other simulator hardware, and shall identify malfunctioning components to the lowest replaceable unit. The diagnostic software shall include, but is not limited to, the programs described in the following subordinate paragraphs.

3.3.9.3.3.1 Computer and peripheral diagnostic programs.

Diagnostic programs for the computers and peripherals shall be Commercial Item software where achievable.

3.3.9.3.3.2 System daily readiness check program.

Daily readiness check programs shall enable operating personnel to determine that the simulator is ready for operation. Provisions shall be made for the automatic sequencing through the daily readiness check program, or portions thereof, to verify the desired output at each step. The operator shall have the option of either proceeding, after noting the discrepancies, or stopping the execution. Identification of errors shall be displayed. The system daily readiness check shall require less than 30 minutes to complete.

3.3.9.3.4 Information Assurance

The PGS will be a stand-alone system that is not connected externally to any network.

System design shall protect against unauthorized access to or modification of information, whether in storage, processing or transit, and against denial of service to authorized users or the provision of service to unauthorized users, including those measures necessary to detect, document and counter such threats. Commercial items shall be limited to only to those that have been evaluated and validated in accordance with the criteria, schemes, or programs specified by the National Security Telecommunications and Information Systems Security Policy (NSTISSP) No. 11.

Countermeasures, procedures or other means shall be established to reduce the risks associated with security threats. Computers shall be provided with the Army Gold Master Disk.

DISTRIBUTION LIST STATEMENT D:

Distribution Authorized to DoD and U.S. DoD Contractors.

3.4 Site Integration of Simulator at WSMR

3.4.1 Workmanship.

The following requirements shall apply.

3.4.1.1 Cleaning.

After delivery at WSMR, parts and assembled equipment shall be clean of smudges;

loose, spattered, or excess solder; weld metal; metal chips and mold release agents; or any other foreign material that might detract from the intended operation, function, or appearance of the equipment.

All packaging waste disposal shall be removed by the contractor and the building left free of debris and clean.

3.4.1.2 Threaded fasteners.

Screws, nuts, and bolts shall show no evidence of cross threading, mutilation, or burrs, and shall be firmly secured.

3.4.1.3 Wiring.

Wires and cables shall be positioned or protected to avoid contact with rough surfaces, irregular surfaces and sharp edges, and to avoid damage to conductors and adjacent parts. Harnesses and cable form containment means shall be neat in appearance, uniformly applied, and positioned to retain critical form factors and breakout locations.

The containment means (lacing, ties, tie down straps, etc.) shall not cause the insulation to deform to the point where performance is adversely affected. There shall be no evidence of burns, of abrading, or of pinch marks in the insulation which could cause short circuits or leakage. Sufficient clearance shall be provided between wires or cables and heat generating parts to avoid deterioration of the wires and cables.

3.4.1.4 Shielding.

Shielding on wires and cables shall be secured in a manner that will prevent it from contacting or shorting exposed current-carrying parts. The ends of the shielding or braid shall be secured to prevent fraying.

4. Verification

The complete PGS and major sub-systems shall be subject to the following types of verification for compliance with performance requirements.

4.1 Methods of Verification

The following methods shall be utilized to accomplish the verification of requirements:

1) Analyses

2) Demonstrations

3) Examinations

4) Tests

4.2 Classes of Verification

The PGS system shall be subjected to the following verification classes:

DISTRIBUTION LIST STATEMENT D:

Distribution Authorized to DoD and U.S. DoD Contractors.

1) Developmental Test & Evaluation (DT&E)

2) Functional Verification Demonstration Test

3) Test & Evaluation Verification/Acceptance Testing

4) On-Site Test

The inspections and tests are specified in Section 4.3, below.

4.3 Inspections and Tests

4.3.1 Visual Inspections

The visual inspection shall consist of verification of the availability of the PGS documentation relative to testing requirements, a walk through inspection to determine compliance with requirements, and familiarization with safety and emergency power-off procedures.

4.3.2 Functional Tests

4.3.2.1 Electrical Tests

Electrical tests shall verify compliance with the specified electrical requirements.

Electrical tests shall include power interrupt restarts.

4.3.2.2 Daily Operational Readiness Tests (DORTs)

The DORTs for the PGS, including commercial and on-line and off-line equipment, shall demonstrate compliance with the specified performance requirements.

4.3.3 Operation and Mission Tests

The operation and mission tests shall demonstrate compliance with the specified performance requirements.

4.3.4 Product Assurance Tests

The product assurance tests shall determine compliance with the specified performance requirements.

4.3.5 Non-Functional Examinations

The PGS shall be subject to the non-functional examinations performed to demonstrate that the as-built design satisfies the specified requirements. The examinations will encompass all areas, major assemblies, and subassemblies of the areas of the completely assembled system. The examinations shall verify conformance to the requirements for:

Materials Parts (standard/non-standard) Design…