B08-SOW-W9098S-20-Q-0077-Attachment 001.docx

Scope of Work for FRS Generator Overhaul Attachment 001 Dated: 6 February 2020

1. Background The Forward Repair System (FRS) is a mobile/deployable maintenance and repair shop used by the multiple Department of Defense military branches. A 35 KW Generator powers the FRS. A customer pump on the generator is used to provide hydraulic power from the generator to the FRS Crane. A custom programmed control panel is used to control the generator. Drawings RIA149333 and RIA151367 show the different versions of the generators that are in service.

2. General Contractor Requirements The contractor shall overhaul the FRS generators IAW the parameters outlines in this Scope of Work (SOW). The contractor shall provide all of the tools, equipment, and supplies required to perform he overhaul. The overhaul shall be performed IAW with Cummins specifications and service manuals. The customer pump and custom programmed control panel are not included in the original specifications and service manuals therefore the contractor must be an authorized Cummins service center.

3. Transportation The contractor shall be required to transport the generators from Rock Island Arsenal to their service shop for work and returned to Rock Island Arsenal once the work is completed.

4. Initial Classification The generators are required to be classified as either “Like New” or “Used” condition. The condition of the generator will determine the level of service required. The classification is to be performed by visual assessment.

A. Like new Condition - A generator is considered Like New when there is minimal to no signs of usage or wear. Interior paint is to be clean and shiny. Housings are to be free from any dents or damage. There can be no fluid leakage. Some dust is permitted on the generator is this is the result of long term storage.

B. Used Condition – A generator is considered Used is it fails and of the like new criteria.

5. “Like New” Generator Evaluation/Service (Clin 0001) Like New generators are required to be evaluated prior to being service. The evaluation process is outline below.

A. Oil and coolant levels are to be checked and topped off as required.

B. The Hydraulic pump is to be removed from the generator. The pump will be damaged if operated without fluid.

C. The control panel must be a 2100 series digital control panel. A new contrail panel is to be installed if it is not a 2100 series digital control panel. Most generators have already been upgraded to the 2100 series control panel. If replacement is required, the control panel shall be covered under paragraph 11 and a contract modification will be issued prior to proceeding.

D. A Load Bank test on the generator shall be performed IAW service documentation.

E. If the generator will not start, it is to be evaluated. An estimate to bring the generator to a starting condition is to be provided to RIA-JMTC. No further work is to be performed until the estimate has been approved by the COR and contracting officer. A contract modification will be issued to authorize the contractor to proceed.

F. The generator will be started and run for one hour at full load.

G. Load test requirements

1. The generator will have no leaks during the load test.

2. Water temperature must be monitored during the load test and cannot exceed the Cummins service manual requirements.

3. Oil pressure must be monitored during the load test and cannot exceed the Cummins service manual requirements.

4. Crankcase pressure must be monitored during the load testing and must meet the service manual requirements.

5. Any lose part noticed during load test must be tightened as required.

H. If the generator fails any of the load test requirements, it is to be evaluated. An estimate to repair the cause of the failure will be prepared and submitted to the COR for approval. No other work will be performed on the failed generator until approval is provided by the COR to the contractor. A contract modification will be issued to authorize the contractor to proceed.

I. Paragraph 7 and 8 contain the mandatory replacement part list for a “Like New” Generators.

6. “Used” Generator Evaluation/Service (Clin 0002) Generators classified as used are required to be evaluated prior to being serviced. The evaluation process is outlined below.

A. The generator is to be inspected for any missing parts or major damage that would prevent operation. An estimate to bring the generator to operating condition will be prepared and submitted to the COR for approval. No other work will be performed on the failed generator until approval is provided by the COR to the contractor. A contract modification will be issued to authorize the contractor to proceed.

B. The Hydraulic pump is to be removed from the generator. The pump will be damaged if operated without fluid.

C. The control panel must be a 2100 series digital control panel. A new contrail panel is to be installed if it is not a 2100 series digital control panel. Most generators have already been upgraded to the 2100 series control panel. If replacement is required, the control panel shall be covered under paragraph 11 and a contract modification will be issued prior to proceeding.

D. A Load Bank test on the generator shall be performed IAW service documentation.

E. If the generator fails any of the load test requirements, it is to be evaluated. An estimate to repair the cause of the failure will be prepared and submitted to the COR for approval. No other work will be performed on the failed generator until approval is provided by the COR to the contractor. A contract modification will be issued to authorize the contractor to proceed.

F. The generator will be started and run for one hour at full load.

G. Load test requirements

1. The generator will have no leaks during the load test.

2. Water temperature must be monitored during the load test and cannot exceed the Cummins service manual requirements.

3. Oil pressure must be monitored during the load test and cannot exceed the Cummins service manual requirements.

4. Crankcase pressure is to be monitored during load testing and must meet the Cummins service manual requirements.

5. Any lose part noticed during load test must be tightened as required

6. Overall condition is to be evaluated during and after the load testing for deficiencies. Frame damage, housing damage, engine damage, etc. are to be noted. Cracked or heavily rusted panels are too be noted. Latches are to be checked for operation and deficiencies are to be noted. The condition of the rain cap and shield are to be inspected and deficiencies are to be noted. Any torn or damaged insulation or insulation structure is to be noted. Circuit breakers are to be inspected for condition and proper operations. Any other deficiencies are to be noted. Only condition issues with non-mandatory replacement parts are to be noted.

7. The mandatory replacement parts for “Used” condition are listed in paragraphs 9 and 10.

H. If the generator fails any of the load test requirements, it is to be evaluated. An estimate to repair the cause of the failure will be prepared and submitted to the COR for approval. No other work will be performed on the failed generator until approval is provided by the COR to the contractor. A contract modification will be issued to authorize the contractor to proceed.

I. If the Generator fails any of the second load testing it is to be evaluated. An estimate is to be prepared to repair the deficiencies and submitted to the COR. No other work is to be performed until approval is provided by the COR. A contract modification will be issued to authorize the repairs.

7. Mandatory replacement parts for “Like New” condition for Tier 0,1,3 (Cline 3)

Mandatory replacement parts for "Like new" tier 0,1,2 (Clin 0003)

(AR STAND FOR AS REQUIRED)

A. Like new basic service requirements – Once the generator has passed the load bank testing basic service will be performed.

1. Fuel and air filters are to be changed IAW with the service manuals.

2. Oil is to be changed IAW the service manuals.

3. Interior paint is to be touched up.

4. Engine coolant is to be drained, purged, and replaced with new coolant according to the service manuals.

5. The Belt is to be tensioned IAW service manuals.

6. The generator is to be lightly cleaned as required.

7. The hydraulic pump is to be replaced with a new pump unless the pump fittings have been plugged and capped.

8. No further Load testing is required.

9. The fuel tank is to be filled with Five (5) gallons of fuel.

8. Mandatory replacement parts for “Like New” condition Tier 3 (Clin 0004)

Mandatory replacement parts for "Like New" tier 3 (Cline 0004)

(AR STAND FOR AS REQUIRED)

A. Like new basic service requirements – Once the generator has passed the load bank testing basic service will be performed.

1. Fuel and air filters are to be changed IAW with the service manuals.

2. Oil is to be changed IAW the service manuals.

3. Interior paint is to be touched up.

4. Engine coolant is to be drained, purged, and replaced with new coolant according to the service manuals.

5. The Belt is to be tensioned IAW service manuals.

6. The generator is to be lightly cleaned as required.

7. The hydraulic pump is to be replaced with a new pump unless the pump fittings have been plugged and capped.

8. No further Load testing is required.

9. The fuel tank is to be filled with Five (5) gallons of fuel.

9. Mandatory Replacement parts for “Used” Tiers 0,1,2 (Clin 0005)

Mandatory replacement parts for "USED" tier 0,1,2 (Cline 0005)

(AR STAND FOR AS REQUIRED)

A. Used Service Overhaul

1. The generator is to be torn down to the frame rails and base. The bare enclosure/panels/skid, generator, engine, and radiator are to be removed.

2. The Individual parts are to be pressure washed, steam cleaned, and or degreased as required.

3. Sealed electrical components are to be inspected and re-epoxied as required.

4. Mandatory parts outlined in paragraph 9 are to be replaced IAW service manual requirements.

5. Engine coolant is to be drained, purged, and replaced with new.

6. The interior of the generator assembly is to be painted or touched up as required.

7. A second load test is to be performed on the generator.

i. The Generator will be run for One (1) hour at full load.

ii. The generator will have no leaks during the load test.

iii. Water temperature must be monitored during the load test and cannot exceed the Cummins service manual requirements.

iv. Oil pressure must be monitored during the load test and cannot exceed the Cummins service manual requirements.

v. Crankcase pressure must be monitored during the load testing and must meet the service manual requirements.

vi. Any lose part noticed during load test must be tightened as required.

10. Mandatory replacement parts for “Used” condition Tier 3 (Clin 006)

Mandatory replacement parts for "USED" tier 3 (Cline 0006)

(AR STAND FOR AS REQUIRED)

A. Used Service Overhaul

1. The generator is to be torn down to the frame rails and base. The bare enclosure/panels/skid, generator, engine, and radiator are to be removed.

2. The Individual parts are to be pressure washed, steam cleaned, and or degreased as required.

3. Sealed electrical components are to be inspected and re-epoxied as required.

4. Mandatory parts outlined in paragraph 9 are to be replaced IAW service manual requirements.

5. Engine coolant is to be drained, purged, and replaced with new.

6. The interior of the generator assembly is to be painted or touched up as required.

7. A second load test is to be performed on the generator.

i. The Generator will be run for One (1) hour at full load.

ii. The generator will have no leaks during the load test.

iii. Water temperature must be monitored during the load test and cannot exceed the Cummins service manual requirements.

iv. Oil pressure must be monitored during the load test and cannot exceed the Cummins service manual requirements.

v. Crankcase pressure must be monitored during the load testing and must meet the service manual requirements.

vi. Any lose part noticed during load test must be tightened as required.

11. Unidentified Repair/Replacement (Clin 0007) If there are repairs that are needed but were not identified or specified in this SOW then the contractor is required to notify the COR. The contractor will provide an itemized report and estimate identifying the additional repairs with the associated cost of the repairs. The COR and JMTC will review the repairs and cost and determine if they are fair and reasonable. A contract modification will be issued prior to the contractor proceeding with any work associated with the repairs.

12. Reporting Each completed generator shale be returned to RIA-JMTC with a detailed report identifying all replacements that occurred to the unit. The report shall also be dated and include the unit serial number.

13. ID Tagging Completed generators are to have ID tagging installed upon completion of the overhaul.

1. Unique Identification (UID) tag – A metallic UID tag is to be installed. The UID tag shall contain the following information:

A. (17V) Contractors Cage code B. (1P) RIA149333 or RIA151367 as applicable C. (S) Unit serial number D. UID symbol

2. RESET Tag - A hard plastic tag is to be installed. The RESET tag shall contain the following information:

A. RESET

B. Letter abbreviation for the month and Four (4) Digit year C. Number of Run hours at RESET D. Unit serial number

14. Warranty Contractor to provide 90 day warranty from the date that the overhauled generator is accepted by RIA-JMTC for parts and a 1 year warranty on labor from date of acceptance. The warranty shall cover all work performed and parts replaced under this SOW. If warranty re-work is required the COR will communicate with the contractor to schedule for the re-work to be performed during the warranty period.

15. Environmental Contractor must follow all applicable local, state, and federal environmental laws and regulations.

16. Schedule A. After a generator is received by the contractor, the contractor will have Five (5) business days to perform the initial evaluation of the generator and notify the COR with their findings.

B. The COR and RIA-JMTC will review the contractors findings to determine if the generator is finically feasible to repair. The COR and RIA-JMTC will reply to the contractor with Five (5) business days If the repairs are feasible. The Contractor will receive a contract modification to authorize the work is approved before they can proceed with the repairs.

C. After receipt of the contract modification authorizing the repairs, the contractor will have Fifteen (15) business days to perform the repairs and return the completed generator back to RIA-JMTC.

17. Quality assurance Surveillance Plan (QASP) image1.emf