DRAFT PWS_LOCOMOTIVE INSPECTION SUPPORT.pdf

Periodic Inspection and Repair of Locomotives Support

DRAFT

Performance Work Statement

1.0 General

1.1 Introduction

The mission of the U.S. DOT Volpe Center is to improve the nation's transportation system by anticipating emerging issues and advancing technical, operational, and institutional innovations. The Infrastructure Systems and Engineering Technical Center maintains cognizance and promotes technical support in the inspection, maintenance, and rehabilitation of the existing and future transportation infrastructure, including vehicles, guideways, and intermodal facilities.

The Infrastructure Engineering and Deployment Division is providing technical support for modernizing the aging fleet of Army locomotives. Utilizing a contracting mechanism, the Volpe Center is improving the reliability and maintainability, and increasing safety for U.S. Army rail operations.

1.2 Objective

Improve safety and the operational capability rate of the Army’s fleet of locomotives. The Army requires expert field service support to repair and maintain locomotives to establish an increasing locomotive operational capability rate. Currently the Army does not have the capability to properly support the fleet of modern ultra-low emitting locomotives and to provide quick assessments and periodic critical technical support on conventional locomotives. This comes at a critical time for Army Rail as the Headquarters Department of the Army (HQDA) is working to remove from service a portion of the Army’s conventional locomotives from the overall locomotive fleet and heightens the importance that the GenSet locomotives remain in top operating condition and are ready to operate when required.

1.3 Scope of Work

The U.S. Army owns and operates twenty-nine ultra-low emitting multi-engine GenSet locomotives at ten different Army rail installations in the United States. Training, maintenance, and periodic inspections are required to retain operational capability of the locomotive fleet. This contract will provide locomotive repairs, technical support and inspections in support to the Army’s GenSet fleet of locomotives in addition to supporting the Army’s conventional fleet of locomotives by troubleshooting non-operational units.

1.4 Background

In June 2017 the Volpe Center began technical support to the U.S. Army fleet of GenSet locomotives.

This support ended on September 30, 2022. The need for technical locomotive support still exists today.

1.5 Type of Contract

This is an indefinite delivery/indefinite quantity (IDIQ) task order (TO) type contract.

1.6 Period of Performance

Annually funded multi-year effort. Initial effort, base contract item work identified in Table-1 must be completed within one year from contract award.

1.7 Place of Performance

This contract requires specific technical tasks to be performed on the GenSet locomotives at the ten (10) locations in Appendix-C, and also to provide technical support to any of the additional nineteen (19) locations where the conventional locomotives are located also identified in Appendix-C.

2.0 Requirements/Tasks

The Contract is designed for one base year support with three option years. The tasks for the base and contract options are summarized in table-1 below.

Table 1, Task Summary for Base and Options

Task Base Year Option-1 Option-2 Option-3

1 - PM yes yes yes yes

2 - Airbrake 7 sets 5 sets 5 sets 5 sets

3 – Lube oil yes no no no

4 - Training yes yes yes yes

5 – Ncompass Support yes yes yes yes

6 - Emergency Support yes yes yes yes

7 – Conventional locomotives yes yes yes yes

8 – Fuel injectors no 3 locomotives 3 locomotives 3 locomotives

2.1 Task One, Preventive Maintenance and Inspections

This task is required for Base contract and all Options. The Contractor shall inspect all GenSet locomotives in accordance with Code of Federal Regulations Title 49-Transportation (49CFR), Periodic(184 days) and Annual locomotive inspection requirements. Refer to Appendix-B for inspection criteria to be performed in conjunction with the federally mandated inspections, and Appendix-C for GenSet locomotive identification and locations. The contractor shall fill out one GenSet Field Service PM Sheet (attached in Appendix-B) per locomotive for each inspection and provide one electronic copy per locomotive to the COR at the completion of each support trip.

2.2 Task Two, Airbrake and Filters

The contractor shall provide and install parts and material identified inTable-1, perform air brake support replacing and cleaning filters in accordance with 49CFR one-year airbrake maintenance and three-year airbrake maintenance schedules, and replace New York Air Brake (NYAB) CCB26 airbrake control module systems on seven (7) GenSet locomotives (locomotives TBD). For Base contract effort, two (2) complete CCB26 module kits will be provided, and five (5) sets will be reutilized. For Options, five sets to be reutilized per option.

Table 2, Three-year Air Airbrake Components to Replace on the 3GS Plate-C Locomotives

Part Quantity 06401870000 Emergency Brake Valve one per locomotive 812-142 Magnet Valve: Over speed, Alerter, Blow Down, EIE (1702 gaskets) four per locomotive 580-012: Auto drain valve w/heater four per locomotive 558296-0150: J-1 safety valve 150 PSI one per locomotive PM301-2A: Check Valve, Main Reservoir with gaskets one per locomotive 500-016: sander control valve two per locomotive 595-075: Horn Magnet valve, front/rear two per locomotive 8321168: double check valve cartridge assembly one per locomotive 705223: no. 8 vent valve w/bracket two per locomotive

The New York Air Brake CCB modules that require overhaul are identified in Figure 1 and Table 2 below.

NYAB Part #: XPOOLPL-1823. Description: Spare pool kit for PL-1823

Figure 1, NYAB CCB26 Air Brake Module Rack and Control Stand Replacement Parts

Table 3, New York Air Brake CCB26 Electronic Air Brake Modules

DECRIPTION PROVIDE/Send to NYAB NYAB PROVIDES BACK

CORE PART NUMBER COMPLETED OVERHAUL PART NUMBER

EBV 780634-1749 (not included in kit) 780634-1789R 21VV (On EBV) 773336 773336R

ERCP 780201-1749 780201-1749R

ERCP GASKET N/A 780623

16CP 784309 784309R

16CP GASKET N/A 775945

20CP 781102-1749 781102-1749R

20CP GASKET N/A 775945

13CP 780627 780627R

13CP GASKET N/A 775941

BCCP 780580 780580R

BCCP GASKET N/A 775942

BPCP 780676-1749 780676-1749R

BPCP GASKET N/A 780624

DBTV 783206 783206R

DBTV GASKET N/A 775943

PSJB 788901 (not included in kit) 788901R RCP 783128-1749 (not included in kit) 783128-1749R

2.3 Task Three, Engine Lubricant and Coolant Exchange (Base Contract item only)

This task is for the Base contract only (not required for Options). For all GenSet locomotives identified except for the four located at Crane, totaling 25 locomotives, the Contractor shall remove engine oil, supply and replace with fresh oil, remove antifreeze, supply and replace with fresh antifreeze. Used oil and antifreeze will be handled locally on Army property.

2.4 Task Four, Locomotive Technical Training

This task is required for Base contract and all options. During planned site-visits to perform inspections and in tandem with the locomotive inspections, the Contractor shall perform locomotive training and allow shadowing to instruct on common maintenance procedures and inspection criteria relative to Code of Federal Regulations for locomotive periodic inspections.

2.5 Task Five, N-Compass Support

This task is required for Base contract and all options. Monthly status reports and remote diagnostic capability. This includes database support and carrier data fees.

2.6 Task Six, Emergency On-Site Support

This task is required for Base contract and all options for GenSet locomotives only. If unexpected locomotive failure occurs and the end-user is unable to resolve the issue, the Contractor shall travel to and provide time and material for repairing or replacing failed locomotive parts and components, and return locomotive to operating status, fault free. This applies to the 29 GenSet locomotives only.

2.7 Task Seven, Conventional Locomotive Contingency Support

This task is required for Base contract and all options. The Contractor shall travel to and perform troubleshooting and diagnostics to determine the root cause of failure of non-operating conventional locomotives identified in Appendix-C. Labor and travel are the only requirements for this task. It is estimated that up to 10% of the fleet of 74 conventional locomotives (quantity of 7 locomotives) could encounter operating issues and require troubleshooting support during this period of performance.

2.8 Task Eight, Engine Fuel Injector Replacements (Option Years only)

This task is required for contract options only (not to be included in Base contract items). The Contractor shall supply and perform injector replacements on six locomotive engines (equivalent to two locomotives) during each of the three option years.

3.0 Contractor Quality Assurance

A qualified government representative will be on site with all work being performed to identify if work performed is as contracted.

4.0 Delivery or Deliverables

a. The contractor shall provide a work schedule with their proposal for this task order so it can be reviewed and approved.

b. The Contractor shall provide a report of the findings with recommendations associated with Task 7.

c. Following the completion of each locomotive inspection, the contractor shall complete the locomotive cab card Form FRA F6180-49A (Locomotive Inspection and Repair Record) with the updated inspection dates and provide copies to the Volpe Center COR(digital photograph of each locomotive cab card). Following the completion at each location, the contractor shall submit the PM work sheets for each locomotive. All PM sheets shall include the following information as a minimum:

i. Operating status and work performed on each locomotive.

ii. Issues experienced and abnormalities discovered during the inspection process.

iii. Repairs that are required to take place within the next 184-days, including the list of required parts and components.

Notice to contractors:

All information and data related to this project that the contractor gathers or obtains shall be both protected from unauthorized release and considered the property of the government. The contracting officer will be the sole authorized official to release verbally or in writing, any data, the draft deliverables, the final deliverables, or any other written or printed materials pertaining to this contract. Press releases, marketing material, or any other printed or electronic documentation related to this project, must not be publicized without the written approval of the contracting officer.

5.0 Meetings

One monthly recurring technical support teleconference meeting to occur every third Tuesday of each month. Time is 10:30 to 11:30 AM Eastern Time.

6.0 Required Travel

Travel is required for on-site support.

7.0 Special Instructions

a. Passes and badges: The Contractor employees shall obtain the required employee and vehicle passes.

b. Field Service personnel shall possess expert knowledge of the N-ViroMotive GenSet locomotives and must be capable of installing current and outstanding locomotive component field modifications and upgrades, including software and firmware revisions and updates.

c. The contractor shall have all necessary tools, diagnostic and test equipment to conduct thorough inspections of the locomotives, conduct maintenance inspections, and to perform repairs and diagnostics in the field on-site where the locomotives are located.

d. The Contractor's work shall not interfere with normal Government business. In those cases where some interference is unavoidable, the Contractor shall minimize the impact and effects of the interference.

e. The Contractor shall provide advance access of all of its work schedules to the Government.

The Contractor shall notify the COR of any difficulty in scheduling work due to Government controls.

Appendix A, Locomotives and Locations

Table 4, GenSet locomotives per Road Number

Location Locomotive number Model/Plate

Ft. Riley, KS 6501 3GS21B / plate-L

6504 3GS21B / plate-L

6511 3GS21B / plate-C

Ft. Bragg, NC 6508 3GS21B / plate-C

6515 3GS21B / plate-C

6516 3GS21B / plate-C

Ft. Carson, CO 6506 3GS21B / plate-L

6512 3GS21B / plate-C

Ft. Bliss, TX 6500 3GS21B / plate-L

6513 3GS21B / plate-C

Ft. Hood, TX

6505 3GS21B / plate-L

6517 3GS21B / plate-C

6524 3GS18B / plate-C

6518 3GS21B / plate-C

Ft. Campbell, KY 6519 3GS21B / plate-C

6520 3GS21B / plate-C

Ft. Stewart, GA 6507 3GS21B / plate-L

6514 3GS21B / plate-C

6523 3GS18B / plate-C

Ft. Sill, OK 6509 3GS21B / plate-C

6510 3GS21B / plate-C

6521 3GS21B / plate-C

Ft. Lewis, WA 6502 3GS21B / plate-L

6503 3GS21B / plate-L

6522 3GS18B / plate-C

Crane, IN

6500072 1GS7B

6500365 1GS7B

6500645 2GS14B

6500650 2GS14B

Table 3, GenSet Locomotive Model and Quantity

Locomotive Model/type Quantity 3GS21B AAR Plate-L 8 3GS21B AAR Plate-C 14 3GS18B Tier 4 3

1GS7B 2

2GS14B 2

GenSet Locomotive Qty. 29

Appendix B, Locomotive Inspection Requirements/Criteria

GenSet Field Service PM Sheet.xls

Trucks and wheels: Perform a visual inspection checking for leaks and damage. Inspect truck bolsters and frames, traction motor nose suspension assemblies, traction motor air ducts, elliptical spring packs, coil springs and saddles, all wheel bearings and pedestal liners, swing hangers, swing hanger bearing blocks, brake cylinders, all levers and brake rigging, height of brake rigging and brake heads. Replace all worn out brake shoes as required. Inspect and adjust brake cylinders 3” to 4”. Inspect wheels and record dimensions on flange thickness, flange height, and rim thickness. Inspect wheels for deficiencies.

Traction Motors: Inspect for excessive arcing. Inspect bearing caps and assure that they are not loose or overheated. Inspect motor leads. Inspect brushes and replace as required. Check gear case for tightness and leakage. Inspect for adequate gear case lubrication, fill as required.

Engine/Generator: Inspect generator for: excessive arcing. Inspect brushes. Inspect for thrown solder on the inside of the frame. Inspect to ensure that the inside of generator is free water and oil. Inspect flex plate, and if generator is equipped with screens, ensure they are free of accumulated dirt. Inspection and maintenance should be performed on a systematic basis as outlined in the N-VIRO Maintenance Schedule.

Below Deck: Inspect all steps and handrails for clearance and tightness, Inspect cutting levers, linkage, handle used to uncouple from switching step, coupler, knuckle of pulling face, knuckle pins, lifter and lock, guard arm and knuckle nose, coupler height, coupler shank wear plate, coupler carrier, coupler shank pins and bushings, draft gears, wear plate on bottom of yoke and on draft gear carrier, draft gear pockets, frame, fuel and air tanks, side bearing clearance correct safety hazard stenciling or mandatory stenciling on front of corners of locomotive and locomotive identification, all front and rear hoses and dates, brake cylinder hoses. Drain water and sludge from fuel tank. Inspect main reservoir drain valves for proper setting and operation. Inspect both angle cocks for proper operation.

Perform visual inspection around the unit, checking for leaks and damage Adjust brake cylinder travel to 3"-4" Fill gear cases as required Inspect support bearing oil and fill as required Inspect all gear cases and underneath for leaks or damage Inspect trucks for defects Inspect main reservoir drain valves for proper setting and operation Inspect fuel tank and fittings for leaks - drain condensation Inspect all step treads and handrails for clearance and tightness Inspect both angle cocks for proper operation Inspect knuckles for wear and cracks Measure wheels and record on wheel inspection report Inspect traction motors for defects Inspect traction motor brushes, replace as required

Cab:

Inspect all cab seats for proper operation and safety Inspect and test handbrake operation Inspect electrical cabinet doors and equipment Inspect inside of the electrical cabinet, relays, contactors, ect.

Blow excessive dust and dirt from cabinet.

Inspect cab floor, doors, and weatherstripping Test operation of emergency brake valve Test air gauges Conduct air brake test Perform downloads and review for repairs:

a. Fault log

b. GE download

c. Stat download

d. Download N-Limit/N-Force/ZTR Fault logs & clear

e. Review refusal for shut down in idle limiting and correct issues.

f . Check for proper software version installed.

g. Test idle limiting shut down and restart procedures Test operation of RCL if equipped Test all lights, head, ditch, cab, gauge, ground, engine room, etc.

Test sanders for proper operation Test horn and bell for proper operation Test cab and strip heaters for proper operation

Electrical: Inspect on controller components and mechanisms: control stand and high voltage cabinets, ground relay, CCB26 system, and clear N-Force fault lists. Run N-Force Tests according to N-ViroMotive Locomotive manuals per appropriate model. Inspect control circuit components, electrical cabinets, and all terminal boards and connections. Inspect batteries, field and shunt field contacts, all “high current” resistors choppers, relays, N-Lights and headlights, electrical contact and integrity, all “low current” resistors, Low Voltage Power Supply (LVPS) and battery charging, ditch lights, step lights and number light assemblies. Inspect high voltage components power contactors and power transfer switches, movable mechanical parts, power contactors and reversers, and all high voltage cabling.

Inspect for all covers, guards in place and tight Inspect battery levels, fill if required Check all charging rates Check for low voltage grounds Test operation of ground relay Test battery disconnect switch if equipped Inspect all fuses, circuit breakers, switches, etc.

Inspect all batteries, cables, and connections Check and record battery hydrometer readings

Mechanical: Inspect radiator and cooling fans, plugs and motors, underside of radiators, for leaks in cooling system, air compressor, for excessive water and oil leaks at couplings and flanges, rear and front traction motor blower screens, oil levels and condition. Check for cracks and signs of exhaust leakage.

Inspect for oil seepage and high-pressure fuel rail connections, air box, engine air intake filters and body filters.

Inspect all genset compartments for signs of coolant, oil, or air leaks.

Check all anti-f reeze clamps for tightness Inspect for any loose or broken clamps Inspect all turbo boots and mounting bolts Inspect for any loose brackets Inspect main oil tank for leaks Note oil level in the main tank by glass (top, bottom) fill if needed Inspect oil float to the level of oil in the engine Inspect for exhaust leaks or evidence of exhaust leaks Inspect air compressor Check and record oil level in the air compressor, add if needed Inspect air compressor compartment

Operation: Start each engine independently and inspect the operation of the engine while idling. Check the engine oil pressure and temperature, antifreeze level, and engine oil level, radiator cooling fans and drive lines, compressor load and unload, traction motor blowers, water system and oil systems. Check engine shutdown devices, operation of all lights, operation of cab heaters, fans, air conditioners, low voltage grounds, operation of sanders in both directions, and operation of horn and bell, handbrake, brake piston travel, proper operation of locomotive, and gauges. Perform air system test, and test and verify operation of event recorder. Inspect air brake and control system in accordance with FRA 232.10, and operation of wiper motors.

Maintenance: Maintenance performed is contingent upon the deficiencies and shortcomings that were discovered during inspections. The items in the table below are in addition to the filter replacements.

Manufacturer’s Part Number Part (Annual)

172001015 AIR BRAKE AIR FILTER ASSY. KIT

5000000025 ELEMENT, BREATHER (ENGINE BREATHER)

171001008 OIL FILTER, AIR COMPRESSOR

171001148 AIR FILTER, AIR COMPRESSOR

171002001 FILTER KIT, AIR COMPRESSOR

171003000 A/C OIL CHANGE ROTO H OIL (5 GAL DRUMS)

162001002 CAP FILLER 2" 15 PSI (RADIATOR)

5250000228 FUEL FILTER (25 MICRON, FBO-10)

5000000003 FILTER, SPIN-ON (100 MESH)

119001008 CORROSION INHIBITOR

119001003 FILTER, FUEL (3 MICRON)

164001013 PRIMARY ELEMENT, AIR INTAKE

119001001 FILTER, LUBE OIL

119001004 RESISTOR, CORROSION FILTER

Manufacturer’s Part Number Part (every two years)

5000000025 ELEMENT, BREATHER (ENGINE / BREATHER)

171002001 FILTER KIT, AIR COMPRESSOR

171003000 A/C OIL CHANGE ROTO H OIL (5 GAL DRUMS)

171002000 AIR COMPRESSOR VALVES KITS

162001002 CAP FILLER 2" 15 PSI (RADIATOR)

172001015 AIR BRAKE AIR FILTER ASSY. KIT

171002000 AIR COMPRESSOR VALVES KITS

Appendix C, Conventional and GenSet Locomotives and Locations

Location Qty. All locomotives GenSet Locomotive ID Conventional Locomotive ID & Model

Fort Bliss, TX 5

4600 GM EMD GP-9 120-ton 4623 GM EMD GP-10 120-ton 4625 GM EMD GP-10 120-ton

Fort Lewis, WA 3

Fort Riley, KS 3

Fort Hood, TX 7

1400 GM EMD GP-10 120-ton 4652 GM EMD GP-40-2 120-ton 4655 GM EMD GP-40-2 120-ton

Fort Carson, CO 4

4611 GM EMD GP-10 120-ton 4653 GM EMD GP-40 120-ton

Fort Stewart, GA 5

4630 GM EMD GP 120-ton 4642 GM EMD GP 120-ton

Fort Bragg, NC 3

Fort Sill, OK 3

Fort Campbell, KY 4

1871 GM EMD GP 120-ton 4607 GM EMD GP-10 120-ton

Crane Army Plant, IN 4

65-00072 65-00365 65-00645 65-00650

Fort Leonard Wood, MO 2 4606 GM EMD GP-10 120-ton 4654 GM EMD GP-40-2 120-ton

Fort McCoy, WI 2 4626 GM EMD 120-ton 4636 GM EMD GP-9 120-ton

Fort Irwin (Barstow), CA 4

4609 GM EMD GP-10 120-ton 4616 GM EMD GP-10 120-ton 4621 GM EMD GP-10 120-ton 4633 GM EMD GP-9 120-ton

Sierra Army Depot, CA 3 1874 GM EMD 120-ton 4618 GM EMD 120-ton 4628 GM EMD 120-ton

Lima Army Center, OH 2 1675 80-ton 1683 80-ton

Red River Army Depot, TX 2

4604 GP-10

4608 GP-10

Anniston Army Depot, AL 3 1881 GM EMD GP 120-ton 4614 GM EMD GP 120-ton 4620 GM EMD GP 120-ton

Blue Grass Army Depot, KY 4 1636 – 80 ton 1637 – 80 ton 1653 – 80 ton

9.0 Period of Performance

The period of performance for this contract shall be from one date of award through March 30, 2023 with 3(three) 12 month options.

10.0 Travel

Costs for necessary and related travel shall be allowed only when required by the Contracting Officer (CO) or COR. Travel expenses will be negotiated at a firm fixed price before award of each task order.

Travel expenses shall be in accordance with the rates set by Federal Travel Regulations.

1678 – 80 ton

Holston Army Plant, TN 2 1870 GM EMD GP 120-ton 4634 GM EMD GP 120-ton

Hawthorne Army Plant, NV 2 1875 GM EMD GP 120-ton 4643 GM EMD GP 120-ton

Iowa Army Plant, IA 2 1664 – 80 ton 1680 – 80 ton

McAlester Army Plant, OK 9

1877 GM EMD GP 120-ton 1879 GM EMD GP 120-ton 4610 GM EMD GP 120-ton 4612 GM EMD GP 120-ton 4627 GM EMD GP 120-ton 4637 GM EMD GP 120-ton 4640 GM EMD GP 120-ton 4641 GM EMD GP 120-ton 4644 GM EMD GP 120-ton

Milan Army Arsenal, TN 2 4638 GM EMD GP 120-ton 4639 GM EMD GP 120-ton

Pine Bluff Army Arsenal, 1 1656 – 80 ton

Radford Army Pant, VA 3 1645 – 80 ton 4622 GM EMD GP 120-ton 4629 GM EMD GP 120-ton

Tooele Army Depot, UT 5

1646 – 80 ton 1657 – 80 ton 1661 – 80 ton 4635 GM EMD GP 120-ton 4605 GM EMD GP 120-ton

Military Ocean Terminal Concord, CA

1878 GM EMD GP 120-ton

Military Ocean Terminal Southport, NC

1868 GM EMD GP-10

1869 GM EMD GP-10

4632 GM EMD GP-40-2

4646 GM EMD GP-40

4647 GM EMD GP-40

4671 RP-40-2C

4672 RP-40-2C

Fort Eustis, VA 2

1880 GM EMD GP-10

4624 GM EMD GP-10

29 Locations 103 29 total GenSet Locomotives 74 Conventional Locomotives

11.0 Sustainable Acquisition Requirements

To the maximum extent possible and consistent with Federal Acquisition Regulations Part 23, the Government requires during the performance of the work under this Statement of Work (SOW) the Contractor to provide or use products that are: energy efficient (ENERGY STAR® or Federal Energy Management Program (FEMA)-designated); water-efficient; biobased; environmentally preferable (e.g., EPEAT-registered, or non-toxic or less toxic alternatives); non-ozone depleting; or made with recovered materials. Unless otherwise identified in this SOW, each recovered materials or biobased product provided and delivered must meet, but may exceed, the minimum recovered materials or biobased content of an EPA- or USDA-designated product. The sustainable acquisition requirements specified herein apply only to products that are required to be: (1) delivered to the Government during contract performance; (2) acquired by the contractor for use in performing services (including construction) at the Federally-controlled facility; (3) furnished by the contractor for use by the Government; or ( 4) specified in the design of a building or work, or incorporated during its construction, renovation, or maintenance.