1. Statement of Work.pdf

Statement of Work AGT 1500 Electromechanical Fuel System Test Stand and Oil Pump Test Stand

1.0 Scope:

This specification establishes the requirements for design, delivery, and install of one Electromechanical Fuel System test stand to meet all testing requirements of NMWR 9- 2910-231 WP 0009 (pages 93-117) and WP 0012 (pages 163-185) and one Oil Pump Test Stand to meet all testing requirements of NMWR 9-2940-200 WP 0008 (pages 87-111). .

The contractor shall provide the resources necessary to design, manufacture, transport, install, site cleanup, calibrate, demonstrate the functional operation, and provide training of Anniston Army Depot (ANAD) operator, Calibration, and Maintenance personnel, and documentation of the AGT 1500 Electromechanical Fuel System Test Stand and Oil Pump Test Stand. The test system fabrication, installation, acceptance, and training of Government personnel must be complete within 365 calendar days of award of contract.

This specification describes the minimum anticipated operational and performance requirements.

1.1 COR Statement:

The Contractor shall not proceed with any change(s) in scope of work from sources other than those listed as the Contracting Officer Representative (COR) section of the contract and without written confirmation, signed by the Contracting Officer (KO).

1.2 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 shall take precedence.

2.0 Applicable Documents:

AMERICAN NATIONAL STANDARD RDS INSTITUTE (ANSI)

ANSI AS35411 Fittings & Lubrication ANSI B93.114M Pneumatic Fluid Power Systems - Standard for Industrial

Equipment and Machine Tool Applications

INSTITUTE OF ELECTRICAL AND ELECTRONICS ENGINEERS (IEEE)

IEEE C2 (2002) National Electrical Safety Code IEEE Std 142 (1992) Recommended Practice for Grounding of Industrial and Commercial Power Systems - Green Book

INTERNATIONAL ORGANIZATION FOR STANDARDIZATION (ISO)

ISO 4414: 1998 Pneumatic Fluid Power - General Rules

Relating to Systems

NATIONAL FLUID POWER ASSOCIATION (NFLPA)

NFPA T2.25.1R2 200x Pneumatic Fluid Power - Systems Standards For Industrial

Machinery - Supplement to ISO 4414:1998 NFPA / JIC T2.24, 1R1 Hydraulic Fluid Power - Systems standard for stationary industrial machinery

NATIONAL ELECTRICAL MANUFACTURERS ASSOCIATION (NEMA)

NEMA MG 1 Motors and Generators (DOD adopted) NEMA ICS 1 Industrial Control and Systems: General Requirements

NATIONAL FIRE PROTECTION ASSOCIATION (NFPA)

NFPA 70 (2017) National Electrical Code NFPA 79 Electrical Standard for Industrial Machinery (DOD adopted)

General Industry, OSHA Safety and Health Standards

AMERICAN NATIONAL STANDARDS INSTITUTE (ANSI)

ANSI S3.41 (1990; R 2001) Audible Emergency Evacuation Signal

(ASA 96) FM GLOBAL (FM)

FM P7825a (2003) Approval Guide Fire Protection

INSTITUTE OF ELECTRICAL AND ELECTRONICS ENGINEERS (IEEE)

IEEE C62.41 (1991; R 1995) Surge Voltages in Low-Voltage AC Power Circuits

NATIONAL FIRE PROTECTION ASSOCIATION (NFPA)

NFPA 1221 (2002) Installation, Maintenance and Use of Emergency Services Communications Systems

NFPA 70 (2017) National Electrical Code NFPA 72 (2002) National Fire Alarm Code NFPA 90A (2002) Installation of Air Conditioning and Ventilating Systems NFPA 2001 (2004) Clean Agent Fire Extinguishing Systems

UNDERWRITERS LABORATORIES (UL)

UL 1242 (2000; Rev thru May 2003) Electrical Intermediate Metal Conduit -- Steel

UL 1971 (2002) Signaling Devices for the Hearing Impaired UL 228 (1997; Rev Jan 1999) Door Closers-Holders, With or

Without Integral Smoke Detectors UL 268 (1996; Rev thru Apr 2003) Smoke Detectors for Fire

Protective Signaling Systems UL 268A (1998; Rev thru Apr 2003) Smoke Detectors for Duct Application UL 38 (1999; Rev thru Jun 2001) Manual Signaling Boxes for Fire Alarm Systems UL 464 (2003) Audible Signal Appliances UL 521 (1999; Rev thru Oct 2002) Heat Detectors for Fire Protective Signaling Systems UL 6 (2000; Rev thru May 2003) Rigid Metal Conduit UL 797 (2000; Rev thru May 2003) Electrical Metallic Tubing – Steel UL 864 (1996; Rev thru Aug 2001) Control Units for Fire Protective Signaling Systems

Government Documents: The following documents form a part of this specification to the extent specified herein. Unless otherwise indicated, the issue in effect on date of request for proposal shall apply.

• NMWR 9-2910-231 – National Maintenance Work Requirement Fuel System

Assembly dated 06 January 2016

• NMWR 9-2940-200 – National Maintenance Work Requirement Engine Oil

Pump Assembly dated 14 December 2015

3.0 Safety and Environmental Practices and Guidelines; The Contractor shall conform to all federal OSHA standards applicable to the work performed and all safety practices and guidelines contained within this Statement of Work. Contractor shall strictly adhere to the contract clause entitled "Accident Prevention", Army Material Command (AMC) Regulation (R) 385-100, Safety and Occupational Health Regulation ANADR 385-1, Engineering Manual (EM) 385-1-1, 29 Code of Federal Regulations (CFR) 1926/1910, other related Department of Transportation (DOT) Regulations (49 CFR), and all local policies.

If a contractor employee is observed performing an activity in a manner inconsistent with any of the above cited regulations or is engaged in any activity that is dangerous to life, limb, or government property, the ANAD Safety Representative shall have the authority to notify the employee and/or the contractor’s on-site supervisor of the hazardous activity and require correction of the hazardous activity. This authority does not preclude the Safety Representative from notifying the Contracting Officer’s Representative of the hazardous condition or safety violation in appropriate situations.

If necessary, the ANAD Safety Representative shall have the authority on behalf of the Contracting Officer to require the contractor and/or its employee to stop the hazardous activity until corrective action is taken to eliminate a hazardous condition or safety violation. Said action shall not be considered to be the basis of a claim and shall be at no cost to the Government.

Contractor will notify ANAD Safety Office immediately of Reports of Inspections and/or Notices of Violation or other enforcement actions (including warning letters) received from by local, State, and Federal Regulators in which the violation is attributed to the action of the contractor or its subcontractors while working or providing services on ANAD installation.

Contractor will provide ANAD with a copy of the Inspection Report, Notice of Violation or other enforcement action, and all supporting documentation.

Contractor shall comply will all national, state, and local Environmental Laws and Regulations. Contractor shall comply with Green Procurement Requirements. Verification will be made to ensure adherence to National Environmental Policy Act Documentation. Contractor shall conform with Environmental Management System and have an assigned Environmental Compliance Officer Point of Contact (ECOPC). All contractor employee on site will be trained on generation of solid waste, generation of hazardous waste, use of hazardous materials, protection of worksite resources, prevention of spills, corrective action for noncompliance, noise, mercury materials, universal waste, and pollution prevention.

4.0 Responsibilities:

4.1 Contractor:

Contractor shall be responsible for the design, fabrication, and installation of all equipment and upgrades listed in contract on one AGT 1500 Electromechanical Fuel System Test Stand and one AGT 1500 Oil Pump Test Stand at ANAD building 128. Contractor shall ensure all employees needing access to ANAD can pass a criminal background check to gain access to ANAD. Contractor shall provide training to ANAD employees on proper operation of all software, equipment operation, and equipment maintenance. This training shall include a minimum of two test stand operators, one maintenance specialist, and one engineer being trained on location at ANAD per stand purchased. All work shall be complete within one year of contract award.

4.2 Government:

Government shall provide all test documents, one electromechanical fuel system, and one oil pump for design purposes. Government shall provide all electrical utilities and compressed air required for proper operation of test stands. Government shall provide all oil and calibration fluid for test stand operation.

5.0 Install Verification

Upon installation of all parts and software contractor shall verify all items are operational by conducting 3 consecutive tests in each stand without failure. To ensure repeatability of test results, results shall fall within correlation test limits. Tests include calibration and acceptance test.

6.0 Warranty

Contractor shall provide a warranty on all parts and software for a term of no less than one year.

Contractor shall respond within 48 hours of notification in event test stand is not operational.

7.0 AGT 1500 Oil Pump Test Stand Requirements

7.1 Software

The application software shall be an advanced package which has the capability to dynamically display every acquired and calculated parameter within the test system listed in NMWR test requirements. During test runs, Data shall be displayed in predefined screens which can be designed to show all data pertinent to the test. During Test Mode, a list of operator-selectable test procedures shall be displayed in a pop up window. A procedure shall be initiated by selecting it from the list. A manual command line text entry shall also allow running each test procedure. The software shall allow real-time recording, operator-initiated snapshots, and flexible storage of all specified data records. The software shall store all specified data on its hard disk during Run Mode.

When a run is complete, the operator (or an automatic sequence) may specify that the data shall be printed or plotted in a report, and save data to hard drive by serial number and unique run identifier for each test. Test procedure shall be designed to be user friendly and intuitive to operate in both manual and automatic modes. All software and hardware shall be capable of operating without network connection. All component test program software shall be open source, meaning the Government shall have the capability and right to make future changes to the component test software as needed.

The software shall be the latest released (stable) version of a commercial application package commonly used for data acquisition, instrument control and industrial automation. The software shall contain all utilities, instrument drivers and libraries required to maintain, or modify the contractor developed test sequences supplied with the system. A copy of any compilers, assemblers, linkers, program editors, or other software tools used to create the contractor-developed test sequences shall be delivered on CD with the test stand. The contractor shall deliver the original install CD (or CDs) containing the executable machine code and/or runtime engine for the application package with the test stand. This will permit re-installation of the software in the event of hard disk failure.

7.2 Controller Hardware requirements

The computer hardware shall be open architecture, consisting of standard computer hardware that can be replaced by commercially available parts. The video display shall be a 24-inch (minimum) TFT active matrix LDC color monitor. The monitor shall be capable of a maximum resolution of 1600 X 1200 pixels and able to display at least 16.7 million colors (24 bit). The monitor shall be installed in a convenient location to allow the operator to view the monitor, operate the console control, and view the unit under test (UUT). The printer shall be capable of printing a minimum of 30 pages per minute (ppm) at 1200 X 1200 dots per inch maximum resolution. The printer shall have a minimum of 24 megabyte (MB) installed RAM memory. The printer shall be easily accessible by the operator. The contractor shall supply two (2) sets of printer replacement cartridges. Unit shall have a minimum 1 terabyte hard drive with a drive to burn physical media such as DVD or CD. Unit shall have minimum 2 USB ports for removable media. Units shall be equipped with an uninterruptible power supply for backup power.

7.3 Flow Requirements

Turbine flow meters are required to be provided for the measurements. The flow measurement shall compensate for changes in oil temperature and specific gravity providing a corrected oil flow rate at ranges indicated in the test specification. Each turbine flow meter shall be configured with the appropriate upstream and downstream flow straighteners. The oil flow measurement system shall be from a nationally-recognized manufacturer and shall be of the modulated carrier pickoff turbine flow meter type design with signal conditioning. Oil used is turbine oil NSN 9150-01-439-2070. Oil shall be filtered by removable media filter by stand just prior to being introduced to oil pump for test.

7.4 Pump Mounting

Stand shall be designed to utilize sealing surface where pump mounts to Accessory Gear Box (AGB) on engine in vertical orientation. Pump mounting surface shall be no more than twelve (12) inches from operator edge of stand to lesson ergonomic impact to operator. Mounting surface shall be between thirty (30) to forty two (42) inches from ground. Pump shall be contained in a mobile transparent safety enclosure during operation. Stand shall be designed to make all adjustments during test without removing enclosure.

7.5 Physical Requirement

Stand shall fit in footprint no more than six (6) feet by twelve (12) feet. Design shall allow for ease of accessibility for maintenance and calibration. Stand shall be configured for maximum ergonomic flexibility with operator in mind. Stand shall have a ventilation system designed to remove oil fumes from operator area.

7.6 Flushing Requirement

Stand shall have ability to flush oil pump with oil prior to being tested. Flushing system shall have a separate reservoir and filtration system. Flushing oil does not have a requirement for temperature. Flushing station shall have the ability to operate the pump at low speed so as to complete circulate oil through pump without using high pressure.

7.7 Utilities

The Government will provide utilities within 20 feet of each test stand installation site.

The capacities of the utilities (wire sizes, pipe sizes, etc.) will be based on information supplied by the contractor. The contractor will be responsible for making all test stand utilities connections. The following utilities are available at the installation site:

Electrical: 3 Phase, 60 Hertz, 460 Volts Shop Air: 90 PSI

7.8 Calibration

Contractor shall provide calibration procedures with required material and instructions needed for calibration of all flow and electrical equipment.

8.0 AGT 1500 EMFS Test Stand Requirements

8.1 Software

The application software shall be an advanced package which has the capability to dynamically display every acquired and calculated parameter within the test system listed in NMWR test requirements. During test runs, Data shall be displayed in predefined screens which can be designed to show all data pertinent to the test. During Test Mode, a list of operator-selectable test procedures shall be displayed in a pop up window. A procedure shall be initiated by selecting it from the list. A manual command line text entry shall also allow running each test procedure. The software shall allow real-time recording, operator-initiated snapshots, and flexible storage of all specified data records. The software shall store all specified data on its hard disk during Run Mode.

When a run is complete, the operator (or an automatic sequence) may specify that the data shall be printed or plotted in a report, and save data to hard drive by serial number and unique run identifier for each test. Test procedure shall be designed to be user friendly and intuitive to operate in both manual and automatic modes. All software and hardware shall be capable of operating without network connection. All component test program software shall be open source, meaning the Government shall have the capability and right to make future changes to the component test software as needed.

The software shall be the latest released (stable) version of a commercial application package commonly used for data acquisition, instrument control and industrial automation. The software shall contain all utilities, instrument drivers and libraries required to maintain, or modify the contractor developed test sequences supplied with the system. A copy of any compilers, assemblers, linkers, program editors, or other software tools used to create the contractor-developed test sequences shall be delivered on CD with the test stand. The contractor shall deliver the original install CD (or CDs) containing the executable machine code and/or runtime engine for the application package with the test stand. This will permit re-installation of the software in the event of hard disk failure.

8.2 Controller Hardware Requirements

The computer hardware shall be open architecture, consisting of standard computer hardware that can be replaced by commercially available parts. The video display shall be a 24-inch (minimum) TFT active matrix LDC color monitor. The monitor shall be capable of a maximum resolution of 1600 X 1200 pixels and able to display at least 16.7 million colors (24 bit). The monitor shall be installed in a convenient location to allow the operator to view the monitor, operate the console control, and view the unit under test (UUT). The printer shall be capable of printing a minimum of 30 pages per minute (ppm) at 1200 X 1200 dots per inch maximum resolution. The printer shall have a minimum of 24 megabyte (MB) installed RAM memory. The printer shall be easily accessible by the operator. The contractor shall supply two (2) sets of printer replacement cartridges. Unit shall have a minimum 1 terabyte hard drive with a drive to burn physical media such as DVD or CD. Unit shall have minimum 2 USB ports for removable media. Units shall be equipped with an uninterruptible power supply for backup power.

8.3 Flow Requirements

Stand shall meet all flow requirements called out in NMWR 9-2910-231 WP 0009 and WP 0012 test requirement. Turbine flow meters are required to be provided for the measurements. The flow measurement shall compensate for changes in calibration fluid temperature and specific gravity providing a corrected flow rate at ranges indicated in the test specification. Each turbine flow meter shall be configured with the appropriate upstream and downstream flow straighteners. The fluid flow measurement system shall be from a nationally-recognized manufacturer and shall be of the modulated carrier pickoff turbine flow meter type design with signal conditioning. Flow stand shall operate with CF1487 Viscor calibration fluid NSN 6850-01-234-2260. Fluid reservoir shall be included in the stand and shall filter fluid with removable filter media just prior to be introduced to fuel control.

8.4 Electrical Requirements

Stand shall meet all electrical requirements called out in NMWR 9-2910-231 WP 0009 and WP 0012 test requirement.

8.5 Fuel Control Mounting

Stand shall be designed to utilize sealing surface like that where pump mounts to Accessory Gear Box (AGB) in vertical orientation. Pump mounting surface shall be no more than twelve (12) inches from operator edge of stand to lesson ergonomic impact to operator. Mounting surface shall be between thirty (30) to forty two (42) inches from ground. Pump shall be contained in a mobile transparent safety enclosure during operation. Stand shall be designed to make all adjustments during test without removing enclosure.

8.6 Physical Requirements

Stand shall fit in footprint no more than nine (9) feet by nine (9) feet. Design shall allow for ease of accessibility for maintenance and calibration. Stand shall be configured for maximum ergonomic flexibility with operator in mind. Fumes generated shall be vented through roof of building using existing duct work. Air shall be filtered prior to being discharged.

8.7 Utilities

The Government will provide utilities within 20 feet of each test stand installation site.

The capacities of the utilities (wire sizes, pipe sizes, etc.) will be based on information supplied by the contractor. The contractor will be responsible for making all test stand utilities connections. The following utilities are available at the installation site:

Electrical: 3 Phase, 60 Hertz, 460 Volts Shop Air: 90 PSI

8.8 Calibration

Contractor shall provide calibration procedures with required material and instructions needed for calibration of all flow and electrical equipment.

9.0 Structural Requirements for Stands – Both EMFS and Oil Pump Test Stands

9.1 Material

All material used shall be as specified herein. Material not specified shall be of the best quality used for the purpose in good commercial practice. The material shall be free from all defects and imperfections that might affect the serviceability of the finished product. The offerer/contractor is also encouraged to use recovered materials to the maximum extent possible in accordance with paragraph 23.403 of the Federal Acquisition Regulation (FAR).

9.2 Protective treatment Materials used in the construction of the equipment that are subject to deterioration when exposed to climatic and environmental conditions likely to occur during service usage shall be protected against such deterioration in a manner that will in no way prevent compliance with the performance requirements of this specification. As applicable, the protective treatment shall be a color commonly used by the contract on test stands, preferably gray, white, or tan.

9.3 Metals

Metals shall be of corrosion resistant type to the maximum extent possible.

9.4 Dissimilar Metals

Unless suitably protected against electrolytic corrosion, dissimilar metals shall not be used in intimate contact with each other.

9.5 Structure

All components shall be located within an all-metal, fully enclosed cabinet suitably braced to carry the load imposed. The cabinet shall be fully guarded to shield fan blades, heating coils, electrical connections, and any other component parts that may present a safety hazard to the operator. The cabinet shall be so constructed that it will withstand transportation by common carrier without damage. Instrument panels shall be constructed of 11 gage or heavier metal suitable for the purpose. Doors and cabinet panels other than instrument panels shall be a minimum of 14 gage metal. The cabinet or enclosure shall be rated for indoor use and shall provide a degree of protection against dust, falling dirt and dripping non-corrosive liquids.

9.6 Base design

All cabinets and sections of the test stands shall include longitudinal channels or other approved base design to permit the use of a standard fork lift truck for positioning or moving purposes. These provisions shall be a permanent part of the test stand, of sufficient strength and rigidity to support the load without undue stress or strain on the test stand itself, and shall be so arranged as to distribute the floor load evenly over the floor space occupied by the test stand.

9.7 Toe Clearance

Toe clearance shall be provided at the areas frequently accessed by the operator. The toe clearance shall be minimum of 6 inches high and 4 inches deep.

9.8 Leveling

Provisions for leveling the test stand shall be provided.

9.9 Vibration

The cabinet shall be constructed so that vibration from components such as pumps and motors shall not be transmitted through the structural members to any instrumentation, thus impairing readability and accuracy.

9.10 Maintainability

The test stand shall be constructed using commercial off-the-shelf components to the maximum extent possible to ensure the prompt availability of repair parts. The contractor shall provide evidence that repair parts and service for the test stand are readily available. The contractor shall also provide information on the normal maintenance actions required for the test stand including type of maintenance, required interval, and mean time to perform maintenance and number and skill of people required to perform the maintenance actions.

9.11 Spare Parts Kit

A spare parts kit shall be included with delivery of the test stand. The kit shall include all contractor recommended spare parts for the test stand.

9.12 Name Plate

A nameplate shall be attached to the test stand and shall contain, as a minimum, the following information:

a. Nomenclature.

b. Manufacturer’s name.

c. Serial number.

d. Test stand model designation.

e. Power input (volts, total amperes, phase, and frequency).

f. Short-circuit/over current rating.

g. Contract number or purchase order number.

h. National stock number (if applicable).

i. Date of manufacture.

9.13 Noise Level

Noise emitted by the test stand and the UUT test chamber during UUT testing shall be no greater than 80 decibels as measured per ANSI S12.23-1989. The 80-decibel limit is absolute. Techniques such as sound level averaging or exposure time weighing shall not be used in meeting this requirement. Any shields, baffles, enclosures or other devices required to bring the equipment into conformance with this requirement shall not interfere with safe operation of the test stand.

10.0 Preliminary Acceptance

The test stand shall be ready for the preliminary acceptance inspection/testing no later than 300 calendar days after contract award. This inspection/testing shall be conducted at the contractor’s facility and is to verify that the test stand meets the requirements of this document.

The contractor shall notify the Government, in writing, of any deficiencies discovered. The Government reserves the right to be present at the contractor’s facility during the inspection/testing. The Contracting Officer’s (KO) may give consideration to failures deemed unrelated to the test stand (i.e. acts of God, failure of the unit under test, etc.) or otherwise insignificant. However, the Contracting Officer or his/her designated representative shall have sole authority in resolving disputes that may arise from failures during the final acceptance test.

The test stand shall not be shipped to Anniston Army Depot until successful completion of the inspection.

11.0 SHIPPING, HANDLING, AND STORAGE

The contractor shall be responsible for delivering the test stands to building 128 at Anniston Army Depot. Once the test stands are delivered to ANAD, the contractor shall have 30 calendar days to install the test stand and complete all test stand acceptance requirements. The contractor shall be responsible for all shipping, storage, and handling of the test stand and all materials. The Government shall not be responsible for furnishing any labor, equipment, or warehouse space for the moving or storing of any materials. There are no docks at building 128 for unloading the test stand from a trailer. If a dock is required for unloading the test stand, the test stand will have to be unloaded at building 513 at Anniston Army Depot and then transported to building 128. If the test stand is unloaded at building 513, the contractor will be responsible for all labor and equipment required to move the test stand to building 128. The Government will make available if possible, space for a contractor furnished trailer or van for the storage of the materials. Trailer space will be made available as close to the job site as possible, depending on the parts stored in that area.

12.0 Installation

The test stand shall be installed by the contractor. The contractor shall be responsible for all plant, labor, and materials required for a complete installation. The contractor shall be responsible for insuring that the installation is compatible with existing facilities. Unless otherwise approved by the Contracting Officer, installation shall be done during normal depot working hours. The area where the equipment is to be installed is in operation. The contractor shall not interfere with ongoing Government operations and production unless authorized by the Contracting Officer. The contractor shall protect the surrounding shop area and equipment near the installation site from damage due to dust, debris, etc., during the installation.

12.1 INSTRUCTIONS FOR INSTALLATION

Within 60 days after award of contract, the contractor shall provide ANAD four (4) copies of all documentation and instructions necessary for installation of the test stand. ANAD will use the documentation to review utility and space requirements of the test stand. This documentation is to include, as a minimum, the following:

a. Floor plan drawing of the test stand showing floor space requirements.

b. Space required around the test stand after installation for maintenance purposes.

c. Foundation requirements, if any.

d. Maximum overall length, width, and height dimensions.

e. Approximate weight of the test stand.

f. All utility requirements, including capacities of required utilities and approximate location of utility connections on the test stand.

g. Minimum doorway opening required to bring the test stand into the building where it is to be installed.

h. Industrial waste disposal requirements, if any.

i. Ventilation requirements, if any.

12.1.1 Location

The test systems shall be installed at Anniston Army Depot in building 128. The building is comprised of a conditioned space in a room specific for each test stand.