AMAD SOW 052421.pdf

CIP#

STATEMENT OF WORK

PROCURE ONE (1) NEW AIRCRAFT MOUNTED

ACCESSORY DRIVE (AMAD) GEARBOX TEST

STAND WITH OPERATOR TESTING STATION

FOR THE F/A-18 E/F PLATFORM

FRC-SW, Building 379, San Diego, CA 92135

Prepared by:

Fleet Readiness Center Southwest (FRC-SW) – North Island

Procure One (1) New AMAD Gearbox Test Stand for Bldg.379

1.0 SCOPE:

1.1 This Statement of Work (SOW) describes the minimum specifications and requirements necessary to purchase one (1) new Aircraft mounted Accessory Drive (AMAD) Gearbox

Test Stand, for the F/A-18 E/F Super Hornet Platform. No building modifications or alterations are prescribed for this project or within this SOW.

1.2 DESCRIPTION:

The purpose of this SOW is to provide details for a “Turn-Key” operation for a commercial vendor to provide parts, labor, and materials delineated and specified by this SOW to include: manufacture, pre-shipment/Point-of-Origin testing, shipping, rigging/installation, start-up, commissioning, and training for one (1) AMAD Gearbox Test Stand, located at

Fleet Readiness Center Southwest (FRC-SW) in San Diego, CA, in Building 379. The quality, size, and capacity shall be no less than the minimum specification outlined in Section

5 of this SOW.

2.0 APPLICABLE DOCUMENTS AND REFERENCES:

2.1 GOVERNMNET DOCUMENTS:

SPECIFICATIONS, STANDARDS, AND HANDBOOKS

The following specifications, standards, and handbooks form a part of this document to the extent specified herein. Unless otherwise specified, the issues of these documents are those listed in the latest issue of the Department of Defense Index of Specifications and

Standards and supplement thereto.

2.1.1 Federal Documents:

a. US NAVY: OPNAVINST 3960.16A: Navy Test, Measurement, and Diagnostic

Equipment (TMDE), Automatic Test Systems (ATS), and Metrology and

Calibration (METCAL) (2011).

b. FED-STD-H28A - Screw Thread Standards for Federal Services (1994 edition).

c. MIL-STD-130N – Identification Marking of U.S. Military Property (2007 edition)

(Copies of Federal and military specifications, standards, and handbooks are available from the Superintendent of Documents, U.S. Government Printing Office, Washington, DC 20402-0001)

d. MIL-PRF-81836B – Filter and Disposable Element, Fluid Pressure (1998 edition)

e. MIL-S-8512D – Support Equipment, General Specification for Design (2002 edition)

2.1.2 Local Documents:

a. LES NI F18-0022-07 Rev. A: Local Engineering Specification and Acceptance

Test Procedure for the AMAD E/F Gearbox

b. FRCSWINST 11300.2F - Energy and Water Management Program (26 Aug 2008

Effective Date or latest)

c. FY21 NAVAIR METCAL scheduling letter

d. NPSL-BP-01, Metrology engineering FST, NAVAIR North Island, NAVY

Primary Standards Lab North Island

REFERENCED PUBLICATIONS: The product offered shall comply with the following codes and specifications, where applicable. Unless a date or version is specified, the latest edition of the referenced publications in effect at the time of the bid shall govern. In case of a conflict between the requirements in this specification and those listed in the references, the supplier shall notify Designated Government Representative (DGR) for immediate resolution. The following other Government documents and publications form a part of this specification to the extent specified herein.

a. 29 CFR PART 1910 - General, 2011 edition.

(Application for copies should be addressed to: The Superintendent of Documents, U.S. Government Printing Office, Washington, DC 20402-0001)

2.2 NON-GOVERNMENT DOCUMENTS:

The following documents form a part of this document to the extent specified herein. Unless otherwise specified, the issues of these documents are those cited in the solicitation or contract. The product offered shall comply with the following codes and specifications where applicable. Unless a date or version is specified, the latest edition of the referenced publications in effect at the time of the bid shall govern. In case of a conflict between the requirements in this specification and those listed in the references, the supplier shall notify the DGR.

2.2.1 NATIONAL ELECTRICAL MANUFACTURERS ASSOCIATION (NEMA).

a. NEMA ICS 1: Industrial Control and Systems General Requirements (2000 Ed.

2015R)

b. NEMA ICS 6 – Industrial Control and Systems Enclosures (1993 edition)

c. NEMA MG-1 – Motors and Generators (2016 edition)

(Application for copies should be addressed to the National Electrical Manufacturers

Association, 1300 N 17th Street, Suite 1847, Rosslyn, VA 22209)

2.2.2 NATIONAL FIRE PROTECTION ASSOCIATION (NFPA)

a. NFPA 70 - National Electrical Code, (2011 edition).

b. NFPA 79 - Electrical Standards for Industrial Machinery, (2012 edition)

(Application for copies should be addressed to the National Fire Protection

Association, 1 Batterymarch Park, Quincy, MA 02269-9101)

2.2.3 INTERNATIONAL ORGANIZATION FOR STANDARDIZATION (ISO)

a. ISO 4413: Hydraulic fluid power-General rules and safety requirements for systems and their components

b. ISO 4414: Pneumatic power-General rules and safety requirements for systems and their components

2.2.4 NATIONAL INSTITUTE OF STANDARDS AND TECHNOLOGY (NIST), 2013

edition. Traceable Standard/Calibration

a. NIST 2013 edition can be found at:

http://nvlpubs.nist.gov/nistpubs/ir/2013/NIST.IR.7298r2.pdf, and http://www.nist.gov/calibrations/sp250_series.cfm)

(Application for copies should be addressed to:

https://www.asme.org/products/codes-standards/b894103602-2008-acceptance-test-reverification or http://www.ansi.org/ )

2.2.5 TELECOMMUNICATIONS INDUSTRY ASSOCIATION (TIA)

a. TIA-232(F) - Interface Between Data Terminal Equipment and Data Circuit

Terminating Equipment Employing Serial Binary Data Interchange. (1997 edition)

(Application for copies should be addressed to the Telecommunications Industry

Association, 2500 Wilson Blvd, Arlington, VA 22201)

While every effort has been made to ensure the completeness of this list, contractors are cautioned that they must meet all specified requirements cited in this SOW. 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 SOW shall supersede applicable laws and regulations unless a specific exception has been obtained. Deviation from the SOW and specific exceptions shall be obtained in writing from the identified Contracting Officer, Lakehurst and/or the DGR outlined in section 10.4 of this SOW.

3.0 NEW SYSTEMS REQUIREMENTS:

This describes the minimum requirements for the procurement, design, and on-site installation of an AMAD Gearbox Test Stand at FRC-SW North Island, Building 379. The Contractor shall make all the adjustments, replacements, modifications, upgrades, and pass all the environmental, safety, and fire regulations according to the technical requirements included in this SOW section

2.0 and subsequent sections. Specifications and requirements are as follows:

3.1 GENERAL REQUIREMENTS:

The test stands offered shall be new. The machine shall include all new components, parts, and features necessary to meet the performance requirements specified herein. All parts subject to calibration, wear, breakage, or distortion shall be easily accessible for adjustment, replacement, and repair. The Contractor shall not utilize U.S Government personnel, facilities, equipment, or consumable materials for any task related to the paid service provided, except as specifically identified and authorized by the contract.

3.1.1 New Developments: The Contractor shall identify any new developments that would improve the efficiency, accuracy, or productivity of the equipment or would decrease its operating costs. Reports of such developments shall be addressed to the

Contracting Officer (KO).

3.1.2 Measuring and Indicating Device Graduations: All measuring and indicating devices on the equipment shall be graduated in the inch/pound system.

3.1.3 Controls: All electrical and mechanical operating controls shall be located conveniently, to the operator's work station(s).

http://nvlpubs.nist.gov/nistpubs/ir/2013/NIST.IR.7298r2.pdf http://www.nist.gov/calibrations/sp250_series.cfm https://www.asme.org/products/codes-standards/b894103602-2008-acceptance-test-reverification https://www.asme.org/products/codes-standards/b894103602-2008-acceptance-test-reverification http://www.ansi.org/

3.1.4 All written and verbal communication, instructions, manuals, etc., shall be in the

English language.

3.2 ENVIRONMENTAL PROTECTION AND SAFETY REQUIREMENTS:

The completed installation shall meet all applicable Environmental Protection Agency (EPA) and Occupational Safety Health Association (OSHA) restriction for materials classified as hazardous to the environment in effect on the date of contract. During the operation of the equipment at the final location, all equipment shall comply with all applicable EPA and

OSHA regulations in effect on the date of contract regulating the emission of material hazardous to the environment. The Contractor shall coordinate with FRC-SW and Naval Air

Station (NAS) North Island regarding construction site approvals and environmental permits required by Federal, State, Country, and Local Laws. For additional information, the

Contractor is instructed to contact the DGR. Within 30 days from contract award, the

Contractor shall provide in writing the make, model, capacity, physical footprint, a list of components/parts requiring periodic calibration, mechanical, and electrical requirements of the equipment to the DGR.

Waste Disposal: Disposal of non-hazardous solid waste disposal shall be the responsibility of the Contractor. FRC-SW shall assume all responsibility and associated liability for disposal of hazardous waste as defined in California Code of Regulations

Title 22.

3.2.1 Safety and Health Requirements: All machine parts, components, mechanisms, and assemblies furnished for the AMAD Gearbox Test Stand, whether specifically required herein, shall comply with all the requirements of OSHA 29 CFR 1910 and OPNAVINST

5100.23G.

a. Mercury Restriction: The AMAD Gearbox Test Stand shall not contain mercury or mercury compounds, nor be exposed to free mercury during manufacture.

b. Asbestos Restriction: Asbestos and materials containing asbestos shall not be used on or in the Fuel Flow Transmitter Test Stand.

c. Lead: Lead and materials containing lead shall not be used on or in the AMAD

Gearbox Test Stand unless otherwise stated.

d. Polychlorinated Biphenyl (PCB): The use of PCBs on or in the equipment is prohibited.

e. Audible Noise Level: Audible noise emitted by the equipment shall not exceed 84 decibels (dB), measured on the “A” weighted scale of a standard Type II sound level meter, at the operator's work position. Noise generated by the Unit Under Test (UUT) shall be excluded in determining compliance of the equipment with the 84 dB requirements.

f. Lubrication: Means shall be provided to ensure adequate lubrication for all moving parts. Recirculating lubrication systems shall include a filter that is cleanable or replaceable. Each lubricant reservoir shall have at least a 24-hour capacity. Means shall be provided to indicate a low oil condition. The machine shall enter a stop condition upon completion of the current operation should a low oil condition occur.

All oil holes, grease fittings, and filler caps shall be accessible.

g. Interchangeability: All parts subject to replacement shall be manufactured to definite dimensions and tolerances. Replacement parts shall be interchangeable without requiring modification. Replacement parts are those that are subject to wear or failure such as gears, bearings, shafts, feed screws, drive belts, pumps, and seals. Electrical replacement parts shall include but not be limited to, motors, relays, fuses, switches, magnetics, pushbuttons, light bulbs, braking mechanisms, and solid-state devices.

Tooling and accessories normally supplied as standard items shall also be considered replacement parts. Foreign-sourced replacement parts shall be interchangeable with domestically supplied components or be readily available from a domestic source.

3.3 DETAIL TASKS:

The machine shall be constructed of new parts free from defects and repairs. The structure shall withstand all forces encountered during operation of the machine to its maximum rating and capacity without distortion.

3.3.1 Surfaces: All surfaces shall be clean and free of harmful or extraneous materials. All edges shall be either rounded or beveled unless sharpness is required to perform a necessary function. The condition and finish of all surfaces shall be in accordance with the manufacturer's commercial practice.

3.3.2 Painting: The machine shall be painted in accordance with the manufacturer’s commercial practice. All paint shall be of the lead-free type.

3.3.3 Workmanship: Workmanship of the machine shall meet all requirements specified herein and shall be of a quality equal to that prevailing among manufacturers producing equipment of the type covered by this purchase description.

3.3.4 Solid-State Components: The use of selenium in solid-state components shall be restricted to those devices that protect other solid-state components from voltage surge.

3.3.5 Marking on Instruments, Control Panels, and Plates: Characters shall be engraved, etched, embossed, or stamped, in boldface on a contrasting background. All plates shall be corrosion resistant.

3.3.6 Castings and Forgings: All castings and forgings shall be free of defects, scale, and mismatching. No processes such as welding, peening, plugging, or filling with solder or paste shall be used for reclaiming any defective part.

3.3.7 Fastening Devices: All screws, pins, bolts, and other fasteners shall be installed to prevent unintentional loosening. Fastening devices subject to removal or adjustment shall not be permanently installed.

3.3.8 Threads: All threaded parts, either US or SI used on the machine and its related attachments and accessories shall conform to FED-STD-H28 and the applicable

"Detailed Standard" section referenced therein.

3.3.9 Welding, Brazing, or Soldering: Welding, brazing, or soldering shall be employed only where specified in the original design. None of these operations shall be employed as a repair measure for any defective part.

3.3.10 Maintainability: The equipment shall be designed and constructed to permit maintenance personnel to easily service the equipment using a minimal number of tools. All parts subject to wear, breakage, or distortion shall be accessible for adjustment, replacement or repair. Consistent with required maintenance and design of the equipment, the Contractor shall provide any special tools required to service the Unit. The equipment shall be equipped with access covers to facilitate inspection, cleaning, and repair, or replacement of parts.

3.4 ACCEPTANCE TEST PLAN:

A draft acceptance plan shall be delivered to Contracting Agency, and provided to FRC-

SW’s DGR for acceptance, not more than 45 days following contract award. FRC-SW reserves the right to comment on the draft plan and require revisions incorporating such comments at no change in contract price. A final acceptance test plan incorporating FRC-SW comments shall then be delivered to the FRC-SW DGR for final approval.

3.4.1 Acceptance sign-off shall be completed as two (2) separate acceptance criteria events, at point of origin and at the final destination. This acceptance is intended to be a verification of the performance of this system.

3.4.2 The Contractor shall perform a fit check of the system. Any deficiencies discovered during this verification shall be corrected by the Contractor via an Engineering

Change Order (ECO) received from the US Government and/or its designated engineering representatives. Acceptance will be provided by FRC-SW’s DGR.

3.4.3 The Government shall perform an inspection of the system and document the inspection to verify its compliance at origin location. Additionally, the second inspection shall be performed and documented to demonstrate the performance of the system at Final destination. The Contractor shall prepare for a review to be conducted at FRC-SW – North Island should a major performance issue arises. The

Contactor shall repair and/or stiffen the system via an ECO should a performance issue arises during this validation. Acceptance will be provided by FRC-SW’s DGR and signed off by DGR, FRC-SW engineer, and Lakehurst representative.

3.4.4 The Contractor shall conduct the final inspection for acceptance in the presence of

FRC-SW’s Engineers, KO, and DGR.

3.5 INSTALLATION:

The maximum lead time for delivery of the test bench shall be no greater than 48 weeks from award date, with a working schedule of Monday through Friday, 0600 to 1430 PST hours, respecting federal holidays, furloughs, base closures, and other dates that the base might not be operational. Access to the base should be coordinated with FRC-SW DGR at the time of contract award. Installation, verification, start-up, final acceptance, and training (at customer location) shall be no greater than four (4) weeks. Completion date shall be no greater than one (1) year from date of contract award.

3.6 CALIBRATION

3.6.1 The Contractor shall comply with all Calibration Requirements listed under

Applicable Documents (NPSL-BP-01).

3.7 DELIVERABLES:

3.7.1 Installation & Integration: Contractor shall install and integrate new hardware/software as specified in this SOW. System level functional tests will be performed after installation and integration.

3.7.2 Prints and/or Drawings Documentation and Manuals: Contractor shall provide all prints, drawings, specifications, and documentation to complete this project in the form of three (3) electronic sets in CD/DVD format and three (3) hard copy sets to

FRC-SW DGR before the final completion date and not later than five (5) working days after completion of all work. Contract shall be signed off by FRC-SW DGR and representatives after all manuals, documentation, and training requirements have been satisfied.

3.7.3 Operation Manuals: Shall cover in detail all phases and cycles of operation such as start-up, maintenance, idle, shut down, trouble shooting, programming, running programs, printing, re-starting systems, etc. All manuals shall include the Contractor contact information, complete parts list, preventive maintenance cycles, any/all information and documentation necessary to properly service, operate, maintain, adjust, calibrate, and perform all functions pertaining to the equipment.

3.7.4 Any and all adjustments made to the equipment during testing, acceptance, and warranty period shall be properly noted by the Contractor. Updated manuals with any and all adjustments, updates, or changes made to the system shall be provided to the

Government at no additional cost.

3.7.5 Maintenance Manuals: Shall properly identify in detail the extent of preventive maintenance, materials, liquids, substances, parts, and chemicals used during preventive maintenance, repair, and/or troubleshooting of equipment. A complete list of all materials, chemicals, substances, and parts used for the maintenance and operation of the equipment shall be provided to the Government.

3.7.6 Calibration Manuals: Shall properly identify, in complete detail, the extent of required machine calibration, and shall be delivered to Government not less than 60 days prior to machine delivery at Final Destination.

3.7.7 List of Components Requiring Calibration: A complete list of all machine components requiring calibration and the standards used for their calibration shall be provided to the Government not later than 90 days following contract award.

3.8 FINAL ACCEPTANCE:

3.8.1 Test Plan: Contractor shall give a 30-day notice before anticipated completion of the project. Any tests shall be coordinated through the Contracting Agency and the FRC-

SW DGR.

3.8.2 Acceptance Test: Contractor shall schedule and coordinate acceptance test with the

Contracting Agency and the FRC-SW DGR.

3.8.3 Final Inspection/Acceptance (Destination): Final Inspection and acceptance test shall be performed on the AMAD Gearbox Test Stand to ensure conformance with this

SOW, at the destination. Acceptance test shall be performed only after the work and installation has been completed. The AMAD Gearbox Test Stand shall pass the examination, tests, and inspections to be accepted.

3.8.4 Verification: The meaning of verification for the purpose of this contract is to assure that the items installed and/or connected by the Contractor are correct for proper machine functionality.

3.9 INSPECTIONS:

3.9.1 Safety: FRC-SW Safety reserves the rights to inspect, clear, and certify all work at the time of completion. All work performed shall pass all of the tests and inspections required by OSHA 29 CFR 1910, Government/Federal Regulations, and FRC-SW

Safety before closeout of project.

3.9.2 Fire and Safety: A final inspection and certification is required by the FRC-SW fire department and safety department at the time of completion.

3.9.3 Environmental: FRC-SW Industrial Hygienists and Environmental Department will inspect, clear and certify all work at the time of completion according to the applicable documents and requirements cited in this SOW.

3.10 QUALITY ASSURANCE:

3.10.1 Responsibility for Inspection: The Government reserves the right to perform any inspections set forth in the SOW where such inspections are deemed necessary to assure supplies and services conform to prescribed requirements. The Contractor shall be responsible for the performance of all inspection requirements specified herein. Except as otherwise specified in the contract, the Contractor may use his own continental United States facility or any other continental United States facility suitable for the performance of the inspection requirements specified herein, unless disapproved by the Government. The Government reserves the right to perform any inspections set forth in the purchase description where such inspections are deemed necessary to assure supplies and services conform to prescribed requirements.

3.10.2 Responsibility for Compliance: All items shall meet all requirements of this SOW.

3.10.3 Classification of Inspections: The inspection requirements specified herein are classified as follows:

a. Inspection Conditions: All inspections, tests, and examinations shall be performed in an indoor facility with ambient conditions of 55° F to 90° F and

20% to 90% relative humidity.

b. Contract Quality Assurance Inspection (Origin): Contract quality assurance inspection shall be applied at the Contractor’s facility prior to being offered for acceptance under the contract and packaging for shipping to final installation destination. The machine shall pass the examination, all tests, and the contract quality assurance inspection to be acceptable. Contracting

Agency and FRC-SW DGR will be physically present for Origin Testing at manufacturer’s factory, and minimum of two (2) copies (digital and hardcopy formats) of the testing reports shall be made available to the Government.

c. Final Inspection/Acceptance (Destination): Final Inspection and Acceptance test shall be performed on the AMAD Gearbox Test Stand to ensure conformance with this SOW. The acceptance test shall be performed only after the AMAD Gearbox Test Stand is installed at its final location. The machine shall pass the examination and all tests to be accepted.

d. Examination: The equipment shall be examined for design, dimensions, construction, materials, components, electrical equipment, and workmanship to determine compliance with the requirements of this specification.

e. Responsibility for Inspection: The Government reserves the right to perform any inspections set forth in the SOW where such inspections are deemed necessary to assure supplies and services conform to prescribed requirements.

4.0 Training:

The training shall be for minimum five (5) technical workgroups with a maximum of ten (10) personnel per group: Engineering, Maintenance (Electricians & Mechanical/Pipefitters), Calibration Engineers, Calibration Technicians, and Operators. Training shall be in the complete range of operation and maintenance requirements of the machine. The training shall be performed at customer’s facility and shall be 8 hours a day, between 0600 and 1430 hours excluding any weekends, federal holidays, furloughs, and base closures. The course shall utilize as-built drawings and manuals provided under this contract, and shall include hands-on portions.

All printed training aids shall be supplied at no additional cost to the Government. The following items shall be covered during the training:

4.1 Familiarization with the equipment, including description of each system, safety and emergency features, and related technical data to be provided.

4.2 Demonstration of all operation, safety, and emergency aspects of the equipment.

4.3 Hands-on operation by receiving facility personnel with assistance from the Contractor.

4.4 Upon completion of training, facility personnel shall be capable of fully operating the equipment without assistance. The facility personnel shall demonstrate their understanding of the equipment and signed-off by their supervisors with no exception. Training duration shall not be less than 40 hours.

4.5 Government to receive two (2) electronic sets in CD/DVD format and three (3) hard copy sets of all training materials.

5.0 Specifications:

The AMAD Gearbox Test Stand shall provide hydraulic and electrical components integrated to provide the required functional capabilities specified below. Any missing requirements not listed below to test the UUT, the Contractor shall conform to the Acceptance Test Procedure, designated in section 2.1.2.a of the SOW.

5.1 The test stand and operator station will utilize an existing floor layout.

5.1.1 The unit testing area will be inside a room that is 32’-11” long and 19’ wide.

5.1.2 The operator will be in an adjoining room that is 10’-6’ long and 19’ wide.

Test Stand:

5.2 The Test Stand shall have two (2) built in tanks using MIL-L-23699 Lubricating oil.

5.2.1 The first tank is for filling the UUT.

a. A three (3) Micron or better oil filter will be used before the oil enters the UUT.

b. A visible level gauge will be installed to show oil level of the tank

5.2.2 The second tank is for the Test Bench.

a. A five (5) micron or better filter will be used for the inlet and a ten (10) micron will be used for the return.

b. A visible level gauge will be installed to show oil level of the tank.

5.2.3 Both tanks will have a fluid test port for fluid samples.

5.2.4 Both tanks will use water heat exchangers, using an existing chilled water system ranging from 50-70℉.

a. The Contractor will not modify the chill water system only the chill water lines in the testing area, if needed.

5.3 The Test Stand will have two (2) separate motor assemblies.

5.3.1 The first motor assembly will be for the PTS side of the AMAD.

a. The PTS ranges from 0-18000 RPM, during testing.

b. A speed increaser can be used in conjunction with the motor to achieve the required speeds.

c. A torque sensor shall be mounted between the PTS shaft and speed increaser to measure the torque

5.3.2 The second motor assembly will be for the ATS side of the AMAD.

a. The ATS motor ranges from 0-18000 RPM.

b. A speed increaser can be used in conjunction with the motor to achieve the required speeds.

c. A torque sensor shall be mounted between the PTS shaft and speed increaser to measure the torque

5.3.3 Both the ATS and PTS motor assemblies will use a coupling shaft between the speed increaser and the UUT.

a. The Contractor shall provide new support equipment drive shafts based of the existing shafts.

b. The existing drive shaft(s) P/N is SKCP 2444-3 Rev. D, by Kamatics.

5.4 The Test Bench will have three (3) separate dynamometers to achieve the necessary horsepower (HP) for each test.

5.4.1 The dynamometers very in performance based off the test parameters of the UUT.

a. The Hydraulic Pump Power ranges from 0-120 HP during testing.

b. The Generator Power ranges from 0-121 HP during testing.

c. The Fuel Pump Power ranges from 0-25 HP during testing.

5.5 An accelerometer(s) shall be placed roughly around the top center of the UUT to measure the vibration of the unit in both the Horizontal & Lateral positions.

Operator Test Station:

5.6 The Test Stand shall utilize a Data Acquisition and Control System consisting of:

5.6.1 User Interface Operating Software (O/S) shall be Windows 10 Enterprise or above.

5.6.2 Two (2) 32” monitors will be used to show all test data

5.6.3 The controls for the operator shall be wired keyboard and mouse.

5.6.4 The O/S login shall have login(s) for different personnel (Operator, Calibration, Engineering)

5.6.5 Backup of the O/S and test software will be provided to the DGR on a CD/DVD(s).

5.6.6 The test program shall indicate all necessary pressure, flow, speed, vibrations, torque, HP, and temperature values.

a. An error log will record all testing parameters that deviate from normal operation during testing.

b. All sensor readouts will have a colored indicator to show non-nominal operation

5.6.6.b.1 “Yellow” will be for below and above nominal limits

5.6.6.b.2 “Red” will be for exceeded the allowable tolerance

c. Any sensors that exceed the absolute maximum allowable tolerance, during testing, will shut the Test Stand down to a neutral state.

d. The program will record the last readout of all test requirements, for each test, to be used on the UUT test report.

5.6.7 The test program will have the option to be ran in automatic or manual mode.

a. Automatic will run the majority of the testing, only requiring operator input between each test procedure and start up of the Test Stand.

b. Manual mode shall be capable of running the same tests as automatic, but all inputs are performed by the operator.

5.6.8 System shall be capable of storing historical data on parts tested on this machine and capable of printing reports at later dates.

a. The UUT test data report will include the following in the print out.

5.6.8.a.1 Operator Name

5.6.8.a.2 Part No.

5.6.8.a.3 UUT Serial No.

5.6.8.a.4 Test Date

5.6.8.a.5 Pass/Fail for each test requirements

5.6.8.a.6 The snapshot data for each test

b. The program shall store the last five (5) minutes of testing for playback for troubleshooting purposes.

c. Contractor shall provide a wired printer for printing of test reports.

5.6.9 Capable of displaying remotely to troubleshoot the Test Stand on a separate PC.

6.0 SYSTEMS:

6.1 Hydraulic System. The hydraulic system shall conform to ISO 4413, and shall be complete, including all valves, pumps, heat exchangers, piping and tubing.

6.2 Pneumatic System. The pneumatic system shall conform to ISO 4414, and shall be complete, including all valves, piping and tubing.

6.3 Electrical System. The machine shall conform to NFPA 79. The existing source voltage available at the facility is 480 VAC ± 10%, 60 Hz. The machine’s electrical system shall be tolerant of fluctuation of ± 10%. The electrical system shall be complete. This shall include any electrical transformer(s) that may be required to modify the existing source voltage to the proper operating voltage of the equipment. A properly rated and fused single disconnect device shall be utilized on the machine with means of lockout in the off position only. All electrical enclosures shall conform to the requirements of NEMA ICS 6. All circuits are protected from overload protection and properly grounded.

6.4 Motors. Motors shall be rated for continuous duty and shall have ball or roller bearings of the sealed and permanently lubricated type. All motors shall meet the requirements of

NEMA MG-1. Each motor shall have an identification plate to identify manufacturer, model identification, serial number, voltage, amperage, HP, phase, frequency and frame number.

Motor HP shall be the manufacturer’s standard or standard optional HP as indicated on the manufacturer's design and construction drawing(s).

6.5 Solid-State Components. Electrical devices used to power electrical servo and spindle motors of control voltage delivered to solid-state electrical components shall be solid-state devices. Such devices shall be capable of handling the electrical load imposed by operation of the machine to its maximum capability. The use of selenium in solid-state components shall be restricted to those devices that protect other solid-state components from voltage surge.

6.6 Facility Connections. Electrical connections made to the facility electrical system shall conform to NFPA 70.

7.0 Marking on Instruments, Control Panels, and Plates.

Characters shall be engraved, etched, embossed, or stamped in boldface on a contrasting background. All plates shall be corrosion resistant.

7.1 Nameplate. A nameplate shall be permanently and securely attached to each machine. The nameplate shall contain the information listed below. If the machine is a special model, the model designation shall include the model number of the basic standard machine and a suffix identified in the manufacturer's permanent records.

7.1.1 Nomenclature

7.1.2 Manufacturer's name

7.1.3 Manufacturer's model designation

7.1.4 Manufacturer's serial number

7.1.5 Power input (volts, total amps, phase, frequency)

7.1.6 Contract Number

7.1.7 Date of manufacture

7.2 Identification Marking of Military Property. An Item Unique Identification Marking shall be provided in accordance with MIL-STD-130N and all applicable documents within the standard with Machine Readable Information (MRI) for item identification marking and automatic data capture. The application of Human Readable Information shall be used in combination with MRI and free text.

7.3 Lubrication Plate. A lubrication plate shall be permanently and securely attached to each machine. The plate shall contain the following information:

7.3.1 Points of lubricant application

7.3.2 Servicing interval

7.3.3 Type of lubricant

7.3.4 Viscosity

7.3.5 Military or Federal Specification for each lubricant (If applicable)

7.3.6 Size and type of each lubricant filter

8.0 Technical data.

All documentation, i.e. operation manuals, maintenance manuals, programming manuals, student training materials, drawings, vendor literature, laminated note cards, metal name and service plates, service bulletins, upgrade bulletins, and all associated charts/graphs, shall be written in the English language and be grammatically correct. All technical data shall identify manufacturer’s name, model number, serial number and contact number. The technical data shall be delivered not later than 45 days after contract award. The machine schematics & layout shall be furnished in both Contractor’s Native CAD that can be converted into Solidworks and

PDF formats.

8.1 Manuals/Drawings. The Contractor shall furnish three (3) hard copies of all technical, training, and maintenance manuals and drawings containing all information in compliance with modifications of the system. The manuals shall provide the data necessary for the programming, operation, and maintenance of the machine and ancillary equipment. The

Contractor shall also furnish one digital copy of the above technical manuals and drawings in

Adobe's Postscript (*.PDF) file format or Excel on CD-ROM(s), as appropriate. The digital manuals and drawings shall be organized, indexed and referenced similar to the equivalent hardcopy format (i.e. volume, manual, section, etc.).

8.2 Training Manuals: Shall cover, in detail, all phases and cycles of operation such as start-up, maintenance, idle, shut down, trouble shooting, programming, running programs, printing, re-starting systems, etc. Manuals shall include the Contractor’s contact information, parts list, preventive maintenance cycles, any/all information and documentation necessary to properly service, operate, maintain, adjust, and perform all functions within the equipment.

8.3 Onsite Adjustments. Any and all adjustments made to the equipment during testing, acceptance, and warranty period shall be properly noted by the Contractor. Updated manuals with any and all adjustments, updates, or changes made to the system shall be provided to the

Government at no additional cost.

8.4 Maintenance Manuals: Shall properly identify in detail the extent of preventive maintenance, materials, liquids, substances, parts, and chemicals, used during preventive maintenance, repair, and/or troubleshooting of equipment. A complete list of all materials, chemicals, substances, and parts used for the maintenance and operation of the equipment shall be provided to the Government.

8.5 Calibration Manuals: Shall properly instruct, in detail, the extent of calibration of the equipment per References in 2.1.2.d. A complete list of all areas/internal components requiring calibration, and the standards used for calibration, shall be in the official

Calibration Manual as an Appendix not less than 180 days prior to machine delivery.

8.6 Test procedures. Two (2) copies of the manufacturer's standard performance, operational, alignment, accuracy, and repeatability test procedures shall be submitted with the

Contractors’ proposal for Government review not more than 45 days following contract award. The Government will inform the Contractor of the acceptance or the rejection of test procedures.

8.7 Installation at destination. The Contractor shall be responsible for the installation of all equipment in order to make it operational. In addition, the Contractor shall be responsible for the necessary personnel and equipment required for the off-loading, utility hookups, and all other requirements necessary to make the equipment operational prior to the final

Government acceptance phase. The Contractor shall be responsible for all necessary certifications and permits required, for shipping, EPA, or other, by any government agency

(federal, state, and local). The Contractor shall be responsible for the crating and shipment of the Universal Fuel & Control Test Stand to final destination. The minimum installation responsibilities of the Contractor are shown on the included installation responsibilities sheet.

9.0 POST AWARD CONFERENCE:

Within 21 (twenty-one) days from Contract award the Contractor shall conduct an in-person post-award conference with the Government DGR, at the FRCSW San Diego, CA location, to provide a Plan of Action and Milestones (POA&M) report to identify dates for Contractor performance of all major events, from the time of contract award to final completion of all the contractual requirements. The report must be reviewed and approved by the Government. The milestones shall be prepared using a recognized project management technique, such as Critical

Path or other. The Government shall be notified prior to any changes being made to the

POA&M. The Government shall approve all changes prior to the changes being made. Within six to eight (6-8) months of contract award, the Contractor shall complete the installation of the

New System. The Contractor shall be responsible to prepare and submit a program / plan review to FRC-SW for approval. The plan review shall consist of the following:

9.1 Milestones: Contractor to provide a weekly update to the FRC-SW DGR in regards to progress of installation, tests, problems, issues, and scheduling milestones at the project site, in building.

9.2 Program Scheduling: Within seven (7) days from Contract award, the Contractor shall prepare and submit a project plan or schedule chart that delineates itemizing project tasks from contract award to install completion, to include engineering, design, manufacturing, delivery, training, and acceptance.

9.3 Program Review: The Contractor shall be responsible to prepare and submit a program review. The program review shall consist of:

9.3.1 Engineering Documentation

9.3.2 System Documentation.

9.3.3 Validation Plan and Procedure

9.3.4 Validation Report

9.3.5 System User’s Manuals

9.3.6 Calibration Procedures (if required)

9.3.7 Maintenance / Corrective Manuals

9.3.8 Provisioning Technical Documentation

10 SECURITY AND BASE ACCESS:

Upon award, the Contractor shall submit to FRC-SW, Security Department, Bldg. 94-1, Code

7.4, PO Box 357058, San Diego, CA 92135, a letter requesting site clearance for all Contractor personnel who will come on NAS North Island. The letter shall include: the name(s), date of birth, place of birth, citizenship (if other than U.S. – a copy of the resident visa), full SSN, contract number, and contract commencement and end date. Additionally, the Contractor shall send a copy of the clearance request to the DGR, at FRC-SW. Upon Contract Award, Contractor shall verify with DGR for latest security and base access documentation, and procedures before submitting paperwork.

10.1 Vetting: Vetting will necessitate advance planning and the timely exchange of the cited and/or required information, with the Government. For clarification, the procedure requires a minimum of ten (10) business days following receipt of the Personally

Identifiable Information and may be subject to heightened requirements, without advance notice. Contractor shall contact DGR for the latest forms required.

10.2 Check-In: All personnel will be required to “check-in” at the Visitor Control Center

(Bldg. 680), which is located at the Main Gate point-of-entry to Naval Base Coronado , at

NAS North Island, San Diego, CA, between the hours of 0630-1600. Following receipt of a clearance, personnel will then be required to coordinate with their sponsor (e.g.

DGR) and obtain badges through the FRC-SW Quarterdeck, located in Building 94.

10.3 Designated Government Representative (DGR): Dennis Echavarry, FRC-SW Bldg. 90-2, Code 6.3.1.2, P.O. Box 357058, NAS North Island, San Diego, CA 92135-7058, PH:

(619) 545-3071, E-mail: dennis.echavarry@navy.mil.

10.4 Working hours: The Contractor shall adhere to the FRC-SW normal working hours of 8 hours a day for a maximum of 5 workdays Monday through Friday, between 0600 and

1430 hours, excluding any federal holidays, furloughs, scheduled shutdown between

Christmas and New Years, and base closures.

11.0 WARRANTY AND POST ACCEPTANCE SUPPORT:

A warranty shall be provided for a minimum of twelve (12) months (e.g. 365 Days) that follows

“start-up, system(s) testing, and acceptance/recognition of project completion,” by the

Government and final payment acceptance by the Contractor. The warranty shall cover all parts/labor of the identified and accepted system and equipment. This means, parts will be defect free for one-year under normal operating conditions. Replacement of said parts shall be at no additional cost to the Government. This shall include: shipping, handling, and any removal or installation involved in the replacement of said parts. Additionally, the warranty shall name

FRC-SW as the owner of the equipment and/or related structures.

11.1 Contractor: The warranty shall also include the following provisions.

11.2 Technical Support: A qualifies technical representative shall provide telephone support during normal business hours, Monday through Friday (excluding Federal holidays or shutdown period) during the hours of 0600 and 1430 Pacific Standard

Time.

11.3 Availability: The Contractor’s technical staff must be available to provide support either in-person, or via telephone at no additional charge and/or cost, to the

Government. Additionally, it is incumbent upon the Contract that support of specific issues and/or general inquiries must be provided within twenty-four (24) hours, following notification by the Government.

11.4 Single Point-Of-Contact (SPOC): The Contractor shall provide/identify a SPOC that can be contacted for support via telephone and/or email.

12.0 ASSUMPTIONS, ISSUES AND LIABILITIES:

The Contractor shall be expected to provide “supplies and services” in such a manner, that minimizes the likelihood and/or potential for disruption of production activities, at the

Government facility. Work schedules that are influenced by either a federal holiday or shutdown period will be initiated or resumed on the next regularly scheduled workday of the

Government.

12.1 Shipment and Storage: The Contractor shall be responsible for the shipment and storage of all tools, material, and supplies needed to complete all requirements that are specified in the subject order’s SOW. When required and/or identified as a component of Contractor performance, the Government will be responsible for providing a “lay-down” area. However, any and/or all related security measures and the associated costs are the sole responsibility of Contractor.

12.2 Monetary Amounts and Authorizations: The Contractor is cautioned not to exceed the amount specified herein, without receipt of prior written authorization from the

Contracting Officer. Failure to comply with this requirement will result in rejection of the invoice.

12.3 Additional Costs: FRC-SW shall not be responsible for any additional costs associated with an option or addition that is not formally identified through the issuance of an amendment or modification, by the applicable Government contracting activity.

12.4 Monetary Limitations: The Contractor will insure that all personnel involved in the scope of this work order are aware of the monetary limitations.

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INSTALLATION RESPONSIBILITIES

Government Contractor/Vendor

(XX)

a. Furnish all labor and material handling equipment for off-loading and placing item on foundation.

(XX) b. Provide and install installation hardware (anchor bolts, nuts, etc)

(XX) c. Set-in-place and rough-level the machine on its foundation.

(XX) d. Final Leveling and alignment of machine.

(XX)

e. Provide all necessary materials required to connect machine to the provided utilities and perform hookups.

(XX)

f. Provide all necessary materials, tools, gages, and instrumentation necessary to perform the required tests.

(XX)

g. Provide and charge all systems with fluids in accordance with manufacturer’s instructions.

(XX)

h. Provide materials for the performance testing both the contractor’s facility and at customer facility.

(XX) i. Provide utilities hook-up within 20 feet of the machine.

j. Government will connect utilities to the machine based on the contractor's accepted site drawings.

(XX)

k. Assign one mechanic (mechanical/hydraulic) and one maintenance mechanic (electrical/electronic) to provide information and any additional materials for the contractor's representative during installation, verification, and initial start-up of the machine.

l. No work shall be performed by customer personnel when the contractor’s representative is not in the immediate work area during installation, verification, and initial start-up of the machine.

m. If installed by customer, upon verifying and certifying the machine is correctly installed, demonstrate the operation and performance of the equipment. Verification of installation shall be included within the warranty.

Verification: The meaning of verification for the purpose of this contract is to assure that the items installed and/or connected by

Government personnel are correct.

INSPECTION AND ACCEPTANCE TERMS

Supplies/services will be inspected/accepted at:

CLIN INSPECT AT INSPECT BY ACCEPT AT ACCEPT BY

0001 Origin/Destination Government Destination Government

0002 Destination Government Destination Government

0003 Destination Government Destination Government

0004 Destination Government Destination Government

0005 Destination Government Destination Government

DELIVERY INFORMATION

CLIN DELIVERY DATE QTY SHIP TO ADDRESS UIC

0001 DD-MON-201X 1 FLEET READINESS CENTER SOUTHWEST N65888

Dennis Echavarry

BLDG. 90-2, CODE 6.3.1.2, PO BOX 357058

SAN DIEGO CA 92135-7058

(619) 545-3071

FOB: Destination

0002 DD-MON-201X 1 (SAME AS PREVIOUS LOCATION) N/A

0003 DD-MON-201X 1 (SAME AS PREVIOUS LOCATION) N/A

0004 DD-MON-201X 1 (SAME AS PREVIOUS LOCATION) N/A

0005 N/A N/A N/A N/A

TIME OF DELIVERY

(a) The Government requires delivery to be made according to the following schedule:

REQUIRED DELIVERY SCHEDULE

WITHIN DAYS AFTER

ITEM NO. QUANTITY DATE OF CONTRACT AWARD

CLIN 0001 1 EA Not more than 48 weeks following contract award.

CLIN 0002 1 Lot Immediately following Government Acceptance for functionality under approved Accepted Test Plan (ATP).

CLIN 0003 1 Lot Within 7 days after training completion, unless otherwise specified.

CLIN 0004 1 EA Draft copy to DGR not more than 45 days following contract award;

final version to be utilized in both Origin & Destination Inspections.

CLIN 0005 No Set Qty Immediately upon Final Government Acceptance and Contractor receiving final payment; shall be a minimum period of 365 days.

Section J - List of Documents, Exhibits and Other Attachments

EXHIBIT/ATTACHMENT

DOCUMENT TYPE DESCRIPTION PAGES DATE

Exhibit A CDRLs 5