A02 SOW Gynasticator Upgrades Project Services (27 Mar 20) (updated).docx

GYMNASTICATOR UPGRADES

1. GENERAL: The MG3000 Mechanical Gymnasticator is a machine designed to “exercise” the recoil mechanism of a howitzer.

1.1. Purpose: The purpose of this project is to upgrade and modernize the control systems of the gymnasticators at the Rock Island Arsenal-Joint Manufacturing & Technology Center (RIA-JMTC). The upgrades shall provide the control systems with the ability to deliver real-time test data, positional results, and pass/fail outcomes. This will support, at a minimum, the M1A1, M178/M182, M119, M119A3, M109, and M35 weapons systems. The contractor shall provide all necessary resources required to install the upgrades as well as provide training to RIA-JMTC personnel.

1.2. Training: The contractor shall provide training for RIA-JMTC personnel on site during normal working hours at a mutually agreed time/schedule by the contractor and RIA-JMTC personnel. Training shall last a minimum of 8 hours and shall cover programming, operation and maintenance. The contractor shall provide necessary training materials. Training shall provide attendees with insight and instruction on the use of the upgraded machinery. The training shall supply the attendees with the proper hands-on learning experience and intelligence to operate the upgraded systems. The training shall cater to both novice and experienced individuals.

2. OVERALL DESCRIPTION / SPECIFICATIONS / STATEMENT OF WORK: The contractor shall provide labor, material, and reference material to provide upgrades to the existing MG3000 Mechanical Gymnasticators and training at RIA-JMTC. The gymnasticators to be upgraded are: RIA#34691 model: MG3000 serial#: CB404 (otherwise termed the “Original Gymnasticator”), and RIA#34696 model: MG3000 serial#: 005 (otherwise termed the “2014 Gymnasticator”).

2.1. Objective: Provide control system modernizations for existing RIA MG3000 Mechanical Gymnasticators and hands-on training onsite at JMTC.

2.2. Services

2.2.1. Original Gymnasticator (RIA#34691)

2.2.1.1. The contractor will remove the existing control system components

2.2.1.2. The contractor will remove and relocate the control components from the 2014 Gymnasticator (RIA#34696) and install them into the Original Gymnasticator (RIA#34691)

2.2.1.3. The existing control panel will be re-installed

2.2.1.4. A CompactLogix PLC or equivalent, a PanelView Plus Operator Interface or equivalent, and hardwire controls shall be provided

2.2.1.4.1. The provided PLC shall have integrated motion and Ethernet capabilities and be optimized for sequencing, motion and process. The provided operator interface will be designed for monitoring and controlling devices, enabling operators to interact with control systems via intuitive touch-screen inputs

2.2.1.5. A variable frequency drive (VFD) motor trip shall be provided

2.2.1.5.1. The motor trip shall interrupt the current flow when the motor becomes overloaded or experiences mechanical issues

2.2.1.6. The contractor will provide a Windows computer station with a printer

2.2.1.7. The contractor shall provide and install Temposonics sensors or equivalent

2.2.1.7.1. The provided sensors are to be non-contact linear position sensors and liquid level transmitters that utilize magnetostrictive technology for position measurement

2.2.1.8. The contractor will provide and install new wiring

2.2.1.9. A new Igus hydraulic and electrical cable track system or equivalent system shall be provided

2.2.1.9.1. The cable track system shall help guide and protect cables and hydraulic lines

2.2.1.10. The existing hydraulic system from the 2014 Gymnasticator (RIA#34696) will be removed and installed into the Original Gymnasticator (RIA#34691)

2.2.1.11. There will be no required software changes for this system. JMTC will be responsible for ensuring the M119A3 is programmed for this gymnasticator

2.2.1.11.1. The contractor shall ensure that the old software functions as intended

2.2.1.12. The contractor shall test and commission the existing control system on the original gymnasticator

2.2.1.13. The contractor shall include a spare parts package, including all recommended standard wear items to maintain operation of the gymnasticator system

2.2.2. 2014 Gymnasticator (RIA#34696)

2.2.2.1. The contractor will provide and install a new control system into the 2014 Gymnasticator (RIA#34696)

2.2.2.2. The contractor shall install a new Maple System Operator Interface or equivalent

2.2.2.2.1. The operator interface shall feature LCD and VFD displays, keypads and legends

2.2.2.3. A new National Instruments CompactRIO controller or equivalent shall be installed

2.2.2.3.1. The high-performance embedded controller shall contain a real-time processor and a user-programmable FPGA. It shall have integrated vision, motion, industrial, communication, and human machine interface (HMI) capabilities

2.2.2.4. A new Allen Bradley VFD or equivalent shall be installed

2.2.2.4.1. The VFD shall be able to control the speed of the motor by changing the frequency of the applied voltage

2.2.2.5. The contractor will supply and install an Allen Bradley uninterruptible power supply (UPS) or equivalent

2.2.2.5.1. The UPS shall be an autonomous source of alternate power and used to supply sensitive electronic loads

2.2.2.6. A LaserJet printer or equivalent system shall be installed

2.2.2.7. The contractor shall provide and install new wiring

2.2.2.8. A new Igus hydraulic and electrical cable track system or equivalent system shall be provided

2.2.2.8.1. The cable track system shall help guide and protect cables and hydraulic lines

2.2.2.9. New Temposonics rods or equivalents shall be installed

2.2.2.9.1. The rods shall be high performance rod-style sensors for in-cylinder applications, for precise position measurements in hydraulic cylinders

2.2.2.10. Server communications will be set up for reporting

2.2.2.11. A new hydraulic system shall be provided and installed into the 2014 Gymnasticator (RIA#34696)

2.2.2.12. The contractor shall install software into the 2014 Gymnasticator (RIA#34696) and ensure that it functions properly

2.2.2.12.1. All component test program software shall be open source

2.2.2.13. The contractor shall include a spare parts package, including all recommended standard wear items to maintain operation of the gymnasticator system

2.3. Testing

2.3.1. The contractor shall test and commission the upgraded control system as described below:

2.3.1.1. Utilize existing National Instruments test procedures for M1A1 (already programmed).

2.3.1.2. Utilize existing National Instruments test procedures for M178/M182 (already programmed).

2.3.1.3. M119A3 (new test) Program:

2.3.1.3.1. Check nitrogen pressure before and after the Gymnastication of the recoil mechanism.

2.3.1.3.2. Set limit for a retraction of 24 ± 1 in. (609.6 ± 25 mm).

2.3.1.3.3. Employ a safety device to ensure rods remain in the retracted position.

2.3.1.3.4. Gymnasticate the recoil mechanism 40 cycles at 0° elevation.

2.3.1.3.5. After the first five cycles, secure the recoil mechanism in a retracted position and examine the rods for scratches. Polish out all scratches.

2.3.1.3.6. Cycle the mechanism five more times and examine the rods for scratches. Polish out all scratches.

2.3.1.3.7. Cycle 30 more times and examine rods for recurring scratches. If scratches still occur, the recoil mechanism shall be disassembled and the cause corrected.

2.3.1.3.8. The recoil mechanism must function without erratic movement, and a definite buffing action must be apparent before entering the battery position.

2.3.1.4. M35 (new test) Program:

2.3.1.4.1. The contractor shall create a program to Gymnasticate the M35 mount. The contractor shall create and add a program to the gymnasticator in the north bay of B208.

2.3.1.4.2. JMTC has already built a fixture, has all the necessary tooling, and modified the tube to make the M35 mount physically compatible with the gymnasticator.

2.3.1.4.3. The program must pull the recoiling mass 20+/-0.5 inches out of the battery and allow the mass to counter recoil freely.

2.3.1.4.4. All Gymnastication will be done at 0 degrees elevation.

2.3.1.4.5. Forty cycles for each mount are required. The program will need to be able to pull the recoiling mass out of the battery and hold it in position so that the sliding surfaces can be inspected.

2.3.1.4.6. The program will need to be able to measure and report counter-recoil cycle time and counter-recoil velocity at 16.5 inches out of battery.

2.3.1.4.7. The existing Temposonics (measuring gun tube position over time) on the gymnasticator can be utilized to gather this data.

2.3.1.4.8. The results will be printed at the gymnasticator.

2.3.1.4.9. The contractor shall provide all labor needed to perform the control upgrade (modify the internal machine program settings), needed to adapt the Gymnasticator to the M35 mount, ensure required test results are provided, and train JMTC operators on the procedure to run the M35 program.

2.4. Specifications

2.4.1. The gymnasticator shall have a minimum pull force of 36,000 lbs.

2.4.2. The gymnasticator shall have a minimum recoil compression of 36”

2.4.3. The gymnasticator shall have a recoil compression rate of 18±1 seconds per 36” in extension and 15±1 seconds per 36” in retraction

2.4.4. The upgraded systems shall be able to gymnasticate weapon systems, including the M35, M119A3, M1A1 and M182 as well as being capable of performing qualification testing for the M1 Abrams Tank, the M109 Self-Propelled Howitzer, and the M119 Towed Howitzer

2.4.5. The contractor shall supply requirements information regarding the procedure of performing qualification testing for the M35 Howitzer

2.5. Contractor to Provide:

2.5.1. The contractor shall provide all relative documentation, including instructions, software information and drawings of space and utility requirements.

2.5.2. The contractor shall provide all resources required to design, manufacture, deliver, install, calibrate (if needed), demonstrate functional operation, and provide operator and maintenance training for the gymnasticators.

2.5.3. The entirety of this project shall be completely stand-alone.

2.6. JMTC to Provide:

2.6.1. RIA-JMTC will provide the required utilities at a location as close as possible but not more than 20 feet from that specified in the contractor's drawings.

2.6.2. RIA-JMTC will provide all recoil assemblies and slave components required for functional testing of the gymnasticators.

2.6.3. RIA-JMTC will provide all labor and materials required to mount and dismount the recoil assemblies and slave components during functional testing of the gymnasticators.

3. HOURS OF OPERATION: The contractor is responsible for conducting business, between the hours of 0600AM - 0430PM Monday through Friday except Federal holidays or when the Government facility is closed due to local or national emergencies, administrative closings, or similar Government directed facility closings. The contractor is authorized to work during normal business hours, Monday –Friday, 06:00 AM to 04:30 PM. If work needs to be completed outside of these hours, the contractor must obtain approval from the Contracting Officer Representative (COR). For other than firm fixed price contracts, the contractor will not be reimbursed when the government facility is closed for the above reasons. The Contractor must at all times maintain an adequate workforce for the uninterrupted performance of all tasks defined within this PWS when the Government facility is not closed for the above reasons. When hiring personnel, the Contractor shall keep in mind that the stability and continuity of the workforce are essential.

4. OTHER QUALIFICATIONS: All work shall be performed in a neat and “work-man-like” manner, and in accordance with “OSHA” safety regulations. All work must meet the “EPA”, State of Illinois, and / or Department of the Army Environmental Regulation.

5. POST AWARD CONFERENCE / PERIODIC PROGRESS MEETINGS: The Contractor agrees to attend any post award conference convened by the contracting activity or contract administration office in accordance with Federal Acquisition Regulation Subpart 42.5. The contracting officer, Contracting Officers Representative (COR), and other Government personnel, as appropriate, may meet periodically with the contractor to review the Contractor’s performance. At these meetings the contracting officer will apprise the contractor on how the Government views the Contractor’s performance and the Contractor will apprise the Government of problems, if any, being experienced. Appropriate action shall be taken to resolve outstanding issues. These meetings shall be at no additional cost to the government.

5.1. A site visit is recommended for this requirement.

6. DATA RIGHTS: The Government has unlimited rights to all documents/materials produced under this contract. All documents and materials, to include the source codes of any software, produced under this contract shall be Government owned and are the property of the Government with all rights and privileges of ownership/copyright belonging exclusively to the Government. These documents and materials may not be used or sold by the contractor without permission from the Contracting Officer. All materials supplied to the Government shall be the sole property of the Government and may not be used for any other purpose. All manuals and technical materials shall be provided with 2 sets of printed hard copy and 1 – CD/DVD in Microsoft or .PDF formats. This right does not abrogate any other Government rights.

7. PERSONNEL QUALIFICATIONS: The contractor shall provide the experienced and qualified personnel consistent with best commercial practice.

8. SAFETY & ENVIRONMENTAL:

8.1. Safety: The contractor is responsible for complying with all federal, state, and local safety and environmental regulations, including, but not limited to Occupational Safety and Health Act, Environmental Protection Agency (EPA), Illinois Environmental Protection Agency (IEPA), and Army regulations. Contractor must adhere to all Rock Island Arsenal Safety requirements, policies and statutes. The contractor shall be responsible for obtaining any hot work/open flame permits required, and coordinating with the Rock Island Arsenal Fire Department in accordance with (IAW) RIAR 420-2, Chapter #7 – Special Operations, Welding, Cutting and Tar Kettles, specifically Section 7-2, pages 27 and 28. To contact Fire Department for flame permit, contractor shall call (309) 782-6116 or x6116 if call from on-post.

8.2. Environmental: All hazardous wastes, acid, and contaminated material generated by the execution of this project will be disposed of IAW all applicable federal, state, and local laws and regulations. All transport and decontamination will be performed IAW all applicable interstate, federal, state, and local laws and regulations. Any materials and/or wastes generated from this effort shall be labeled with appropriate transportation/disposal documentation for off-site disposal to include but not limited to Hazardous waste manifests and associated Land Disposal Restriction. Prior to discussing any environmental issues with the environmental agency of primacy, the contractor shall contact the Contracting Officer’s Representative (COR) for direction.

8.3. Trash Removal: Trash removal shall occur daily by the contractor until the project is completed. The contractor may use trash bags for garbage removal. All old remnants removal is the responsibility of contractor.

8.4. Ozone Depleting Chemicals (ODCs): The contractor shall assure during execution of the tasks outlined in this SOW that none of the materials used contain Class I OR Class II ODCs as defined by Public Law 102‑484, section 326.

9. SECURITY:

9.1. The RIA-JMTC is an Army installation subject to Department of Defense safeguards, various precautions, and plant protection measures. All of the below requirements will be necessary of contractors visiting RIA to satisfy requirements of this purchase description; Additional requirements will be placed on contractors requiring access to the Army Network, or Common Access Card (CAC), as specifically detailed below. At all times during the execution of this work, contractor personnel will maintain adequate plant protection devises to minimize espionage, sabotage, and other malicious destruction and damage. The contractor shall comply with all security requirements of the Rock Island Arsenal. Rock Island Arsenal island-wide Force Protection levels may be adjusted/changed at any time, which may cause possible delays and will directly affect procedures for accessing the island.

9.1.1. No CAC cards will be issued for this requirement.

9.2. Access and General Protection/Security Policy and Procedures: The contractor and any associated subcontractor employees shall provide all information required for background checks to meet installation access requirements to be accomplished by the installation Director of Emergency Services. All contractor employees must comply with all personal identity verification requirements (IAW FAR clause 52.204-9) as directed by Department of Defense (DoD), Headquarters Department of the Army (HQDA), and any local policy. If the Force Protection Condition (FPCON) changes, the Government may require changes in contractor installation access, security matters, or security processes.

9.2.1. Access to RIA: Contractor and all subcontractor employees performing work at RIA shall comply with adjudication standards and procedures using the National Crime Information Center Interstate Identification Index (NCIC-III) and Terrorist Screening Database (TSDB) and any applicable installation, facility access screening and local security policies and procedures. The COR shall provide guidance to complete the Access Control Records Check Request Form though the Rock Island Arsenal Directorate of Emergency Services.

9.2.2. Random Antiterrorist Measures Program (RAMP) participation: Contractor personnel are subject to RAMP security program (i.e. vehicle searches, wearing of ID badges, etc.). Contractor shall comply with any, and all instructions issued by the Rock Island Arsenal Police Department. The RAMP is discussed in the RIA-JMTC Anti-Terrorism Training.

9.2.3. During FPCONs levels of Charlie or Delta, services may be discontinued/postponed due to a higher National or local security threat. Services will resume when FPCON Level is reduced to Bravo, or lower. FPCON levels are described in Anti-Terrorism Level I Training.

9.2.4. Contractor personnel shall return all Installation Badges and access passes as soon as possible prior to contract completion. RIA-JMTC electronic keys and access passes are accountable items, shad shall be returned within 24-hours of no longer being needed. Items will be returned to the COR or placed in a drop box at an RIA-JMTC access point.

9.3. Security Training: The contractor shall complete the following training:

9.3.1. Anti-Terrorism, Level I: All contractor employees, including subcontractor employees, requiring access to Army installations, facilities, or controlled access areas shall complete Anti-Terrorism (AT) Level I Awareness training. The COR will be provided a copy of the Rock Island Arsenal –Joint Manufacturing and Technology Center (RIA-JMTC) AT Level I Awareness Training and assure that the training is complete. The contractor shall sign a memorandum of record for each contractor employees and subcontractor employee to the RIA-JMTC Operations Center prior issuing any electronic keys or access pass being authorized.

9.3.2. iWatch (See Something, Say Something) Training: The Contractor and all associated subcontractors shall complete iWatch Training. iWatch Training shall be provided during the Anti-Terrorism Training.

9.4. Federal Marijuana Laws Remain Unchanged: Note: Rock Island Arsenal is under the exclusive federal jurisdiction of the United States. Under federal law, marijuana is still defined as a Schedule I drug, and possession and use of marijuana is still illegal. Any person using or in possession of marijuana on Rock Island Arsenal may be criminally prosecuted in federal district court. In addition, such individuals may be permanently barred from entering Rock Island Arsenal.

9.5. REAL ID: Starting 07-May-2025 all personnel entering Rock Island Arsenal will be required to show a Real ID form of identification.

10. INSPECTION / FINAL ACCEPTANCE

10.1. COR will monitor contractor performance on this Purchase Order. Successful completion of project shall be indicated by successful completion of all items presented in this Scope of Work.

11. INFORMATION TECHNOLOGY SUPPORT: RIA-JMTC IT Support Staff will be engaged in the event any interaction with RIA-JMTC information systems or associated computing devices is required. The Contracting Officer Representative (COR) will send a notification to the RIA-JMTC Help Desk (usarmy.RIA.usamc.mbx.ria-jmtc-helpdesk@army.mil) following the scheduling of a vendor visit. This request will notify RIA-JMTC IT Support Staff that there will be an upcoming requirement to accompany the vendor on the scheduled dates. The vendor shall notify their technician that access to the workstation may not be available outside of normal business hours. The technician will be accompanied by an appropriately trained RIA-JMTC IT Support Staff member at all times while at the workstation. RIA-JMTC will not provide the technician credentials to access the workstation. Access to the workstation will be provided by the RIA-JMTC IT Support Staff escort. Removable Media e.g., CD/DVD/USB/SD/External hard drive will be scanned prior to use. Programs and software must be ran from RIA-JMTC approved/provided media or CD/DVD(s). Vendor Devices will not be allowed to connect to the RIA-JMTC network nor will they be allowed to connect to RIA-JMTC equipment other than to scan and transfer media.

SOFTWARE SUPPORT: Equipment identified by the COR as causing RIA-JMTC to not meet its customers’ orders or security non-compliant shall have the repair service prioritized. The contractor will provide complimentary software diagnosis, software updates, and major upgrades. RIA-JMTC will have access to software and firmware for accreditation. The contractor will notify COR within 15 days of a security update for firmware and or software.

INSPECTION/FINAL ACCEPTANCE:

1. The COR will monitor contractor performance on this contract, in accordance with the Quality Assurance Surveillance Plan (QASP).

2. Upon successful completion of remedial repair, preventative maintenance and software/firmware change the COR will inspect the work and if acceptable sign the contractors service report. The contractor invoicing shall take place after the Service report is received by the COR.

INFORMATION ASSURANCE AND ACCREDITATION

1. Non-Government-Owned computing systems or devices: The Contractor shall comply with AR 25-1 and AR 25-2. The Contractor shall not install or connect non-Government-owned computing systems or devices to Government networks without the COR’s coordinating and obtaining proper authorization from the appropriate Information System Security Manager (ISSM), ensuring that all software has a Government Assess Only Authorization. The non-Government-owned computing systems or devices include, but are not limited to, personal or Contractor-owned thumb drives e.g., memory sticks, flash drives, Universal Serial Bus (USB) drives, jump drives, pen drives, removable or external hard drives, Personal Digital Assistants (PDA), PC Cards/Express Cards, MP3 players, cell phones, digital media, floppy disks, compact disc (CD)/digital video disk (DVD) burners, optical recordings, photo flash cards, laptops, or any devices that can store data.

2. System Accreditation and Re-Accreditation: The Contractor shall assist in providing system accreditation documentation such as required artifacts and shall answer technical questions required for registration for accreditation. All documents shall be IAW Chapter 5, and Appendices D and E, AR 25-2, Information Systems Security (dated 3 August 2007) and DOD Instruction 8510.01, Risk Management Framework (RMF) Program or future DOD regulation that supersedes these regulations. The Contractor shall assist in performing yearly reviews of the accreditation, or whenever changes/additions are made to the system. The Contractor will assist in preparing risk assessments, as required.