Notice of intent to Sole Source TWT requirement

NOTICE OF INTENT TO SOLE SOURCE The 10th Contracting Squadron, Operational Contracting Office, United States Air Force Academy (USAFA) Colorado, intends to solicit and negotiate with only one source for the Trisonic Wind Tunnel Control System requirement detailed below. The one source is Calspan Aero Systems Engineering (Calspan ASE), Inc. (Cage Code: 54933) This procurement is for the acquisition of a sole source commercial item using simplified procedures in accordance with FAR Part 13. The North American Industrial Classification System (NAICS) number is 334516 and the business size standard is 1,000 employees. This synopsis is for informational purposes only and does not constitute a solicitation for bids or proposals. DO NOT submit an official bid/quote at this time. Background/history The Department of Aeronautics, United States Air Force Academy, has a requirement to repair/replace components of the Trisonic Wind Tunnel (TWT). The TWT is a blown-down tunnel capable of operating from Mach 0.3 to 4.5 with dynamic pressures as high as 35 pounds per square inch (psi) in the test section. The tunnel is over 60 years old with a control system from the 1980's. The TWT is powered by air stored in large tanks pressurized to 600 psig. The primary parameters that must be controlled are 1) the pressure in the stilling chamber at the upstream end of the wind tunnel and 2) the position of the model support system in the wind tunnel test section. The pressure control system was installed in 1988, and consists of a Moog chassis containing a series of signal conditioners, controllers and amplifiers, and an Allen-Bradley programmable logic controller (PLC). These devices control hydraulic valves that open or close the pressure control valves and move the model support mechanism. The PLC also serves as an interlock to prevent operation of the wind tunnel unless required conditions are satisfied. The existing model positioning system (MPS) is part of the permanently installed equipment of the TWT. The MPS is used to pitch a model in the tunnel while the tunnel is running. The TWT is used for both classroom demonstrations and funded research projects. The existing MPS pitches to + 30.0/-20.0 degrees. A new system must control the pitch and roll of the model in the test section while supporting the model on the sting balance to collect force and moment data. The TWT was built in 1959 with the Aeronautics Laboratory. The control system was last upgraded in the 1980s by Fluidyne, which is now owned by Calspan ASE. The TWT is critical for cadet research. Since the TWT is capable of near-hypersonic speeds, it is becoming more heavily used given the increased emphasis on hypersonic weapons in the National Defense Strategy. The TWT is an important capability supporting the Department of Aeronautics recurring accreditation by the Accreditation Board for Engineering & Technology (ABET). In order to be accredited as an aeronautical engineering degree-granting institution, USAFA needs to retain a robust experimental fluids discipline which includes experimental facilities for student courses. The TWT is consistently highlighted as one of the unique capabilities of the aeronautical engineering program by the ABET accreditors and losing this facility would endanger the accreditation of the aeronautical engineering program. SALIENT CHARACTERISTICS/REQUIREMENT SPECIFICATIONS At a minimum, the contractor must install a compatible control system capable of performing the following functions: Control the stilling chamber pressure. Position the model in the test section to include pitch and roll. Prevent operation of the wind tunnel unless all systems are operable and in the proper state. Shut down the wind tunnel in the event of emergency conditions such as electrical power failure, loss of hydraulic pressure, excessive stilling chamber pressure or operator pressing an emergency stop. Warn personnel and operators if personnel are in potentially hazardous locations. Provide physical barriers and interlocks as appropriate to prevent operation of the wind tunnel if safety of personnel is at risk. Provide control of all wind tunnel functions/parameters manually and through a computer interface. Seamlessly integrate with legacy measurement equipment. The control system must be capable of remote operation from a vendor-supplied modular device in addition to a vendor-supplied fixed control station. The tunnel control system must provide tunnel parameters (at least stilling chamber pressure and model position) to any contractor-provided data acquisition system and readable by an operator-provided data acquisition system. It is recommended that these parameters be provided both via message-based communication (e.g., Ethernet) and analog voltage output for reading by an external data acquisition system. The contractor must thoroughly describe and document the feedback control loop required to maintain the pressure in the stilling chamber within operator-specified limits and control the rise time of the pressure. This must include control signals sent to the existing hydraulic valves that control the actuators opening the valves to the high-pressure system. The contractor must work with Aeronautics Laboratory personnel to consider all potential emergency scenarios (loss of power, loss of hydraulic pressure, etc.) and build into the design of the control system features to immediately shut off the wind tunnel in an emergency after returning the model positioning system to a - home position. The home position should be adjustable by the tunnel operator. The contractor must design an interlock system to provide suitable warning to personnel that the tunnel is ready to run or that any systems are in a potentially hazardous state. The contractor must thoroughly document the logic necessary to require all systems to be functional and in proper states before the valves in the high pressure system can be opened. The contractor must design and install an upgraded MPS. The MPS is defined as the electronic hardware, software and mechanical linkages/parts required to control the location and orientation of the model. The existing MPS is designed only to provide pitch motion. The upgraded MPS must provide, at a minimum, pitch, roll and vertical translation. The MPS must be capable of setting the pitch and roll angles to within 0.1 degrees of the desired set point. The range of pitch must be no less than the current MPS range, with the center of rotation 6 inches upstream of the existing pod pivot pin. The range of roll must be +90/-90 degrees. The MPS must be able to vary the center of rotation of the model between 6 and 17 inches upstream of the existing pod pivot pin. The MPS must be able to plunge, meaning translate vertically in the test section while maintaining desired pitch and roll angles. Pitch, roll and plunge must be individually controllable. The control system and MPS must be able to execute commands to move to a specific pitch, roll and vertical position at a minimum of 10 deg/s in pitch, 30 deg/s in roll, with a vertical translation rate of at least 2 inches/s, simultaneously or in sequence as specified by the operator or computer interface. The MPS and any data acquisition must operate in a move-pause or continuous sweep mode. When in move-pause mode, the MPS will provide a digital signal that the specified position has been reached and data acquisition can start for that position. When in continuous sweep mode, the position must be reported at sufficient rate to record the motion of the model. The control system for the MPS must allow operator-specified rates and maximum acceleration. The MPS must not increase the blockage of the wind tunnel and the system must support a load of 2,000 pounds applied one foot in front of the pivot point. The existing MPS includes a - pod mounted to a - blade. The blade translates vertically, and mechanical linkages move the pod to the angle of attack. Force balance wires and pressure tubing pass through the pod and down the inside of the blade to the bottom of the wind tunnel. The pod accepts a - sting that either interfaces directly with the model or with a force balance that is internal to the model. The MPS must have provision for instrumentation wiring and tubing to accept existing sting and balance hardware. The MPS must allow at least the same amount of tubing and wiring as the existing hardware. The MPS must be modular such that the model mounting system can be modified without redesign of the whole MPS. The contractor must thoroughly describe and document the feedback control loop required to maintain the operator-specified pitch, roll and vertical position of the MPS. This must include control signals sent to the valves or actuators that control the MPS. The contractor must provide a pressure rake which can measure flow quality, including flow angularity, in the test section. The contractor must repair the air leak in the storage tanks. Priced separately as an option, the contractor must modify the nozzle block exchange process to include a simpler and safer means of removing and replacing the tunnel side wall. Priced separately as an option, the contractor must repair the transonic cart to include optical access. Priced separately as an option, the contractor shall provide a Mach 5 nozzle for the wind tunnel. On-site training must be provided to train up to 3 personnel on the operation of the new control system. The contractor must produce a document illustrating the required function of a control and interlock system for the wind tunnel. This must include: Control of the stilling chamber pressure. Position of the model in the test section to include pitch, roll and vertical position. Manual control of all operator-controllable features. An interlock to prevent operation of the wind tunnel unless all systems are operable and in the proper state. Systems to ensure shutdown of the wind tunnel in the event of power failure, loss of hydraulic pressure, emergency stop or excessive stilling chamber pressure. An interlock system to include physical barriers or warning systems to prevent operation of the tunnel if personnel are in potentially hazardous locations. The installation shall come with a standard 2-year warranty with on-site support to troubleshoot and correct any malfunctions. Rationale Calspan ASE is the only source that can provide the needed components and installing while ensuring compatibility, safety, and functionality of the TWT systems. The current control system was designed and built by Fluidyne, which is now Calspan ASE, and the technical data package was retained by Calspan ASE. As a result, Calspan owns the technical data package for the current control system and is best poised to upgrade and modernize the system in accordance with DFAN's requirements. Acquiring from another vendor would require extensive effort and cost to recreate the technical data required to design the control system interface with existing components. It is anticipated that award to any source other than Calspan ASE would result in duplication of cost due to the effort required to recreate the technical data package required for the services needed to engineer the unique components for this specialized facility. In addition, awarding this effort to a vendor without proven expertise in high-speed wind tunnel applications could introduce a significant safety risk. The 600 PSIG of pressure present in the TWT could present a catastrophic risk to personnel or property if not controlled properly by the control system being implemented. Furthermore, Calspan ASE has other significant experience in building and repairing supersonic and hypersonic blow-down wind tunnels similar to the TWT. Any offerors believing they can full fill this requirement as stated above may provide evidence for consideration. Evidence must support the offeror's claim they can fully provide this requirement to include but not limited to: At least 2 examples of similar projects with a price over $2 million, state they would be able to deliver within an 18-month time frame, and provide evidence that the offeror is technically capable of fulfilling this requirement and understands the magnitude of this requirement by submitting an estimated price range. All offerors must certify that they are Buy American Compliant and be registered in SAM.gov and provide CAGE code or Unique Entity ID (if not registered in SAM.gov, must be willing to do so immediately). All qualified sources may submit a response, which if timely received, will be considered by this agency. Information received will be considered solely for the purpose of determining whether a competitive procurement can be conducted. A determination not to compete this proposed procurement based on responses to this notice is solely within the discretion of the Government. Responses must be received no later than 12:00 pm Mountain Time on 6 August 2022. Responses received after this will be considered late and will not be evaluated. The Government does not intend to pay for any information provided under this announcement. Contractors must have a current registration with the System for Award Management (SAM) at https://sam.gov/. The Government intends to award a Firm Fixed Price contract processed IAW FAR Parts 12 and 13. The closing date of this synopsis is 12:00 pm Mountain Time on 6 August 2022. Questions should be addressed to the Primary POC Malissa Crofoot, Contracting Officer, via e-mail to malissa.crofoot.2@us.af.mil. Alternate POC is Casey Pehrson, Contracting Officer, casey.pehrson.2@us.af.mil.