BPU SOW - 03 Mar 08.doc

642Combat Sustainment Support Squadron

SOW

Flightline Equipment Engineering Flight 03 Mar 2008

642 CBSSS/GBZO-ENF

STATEMENT OF WORK (SOW)

FOR

BASIC EXPEDITIONARY AIRFIELD RESOURCES (BEAR)

POWER UNIT (BPU)

1. SCOPE

1.1 Scope. This document defines the tasks and support requirements for the procurement of 800 kilowatt (kW) trailer-mounted, EPA compliant diesel engine-driven generator set as described by PD05WRLEEG11 and is to be used in conjunction with PD05WRLEEG11.

1.2 Classification. The BPU will be used as a prime power unit to provide electrical power in support of Basic Expeditionary Airfield Resources (BEAR) forward-operating military bases.

2. APPLICABLE DOCUMENTS. The following documents are applicable to the SOW to the extent specified herein.

2.1 Government documents.

2.1.1 Specifications, standards, and handbooks. The following specifications, standards, and handbooks form a part of this document to the extent specified herein. Although revision letters for specifications are not cited within the text of this SOW, it shall be understood that the below listed revision letters apply to their respective specifications or documents when the specifications or documents are called out within the text.

Department of Defense Specifications

MIL-PRF-49506

Logistics Management Information Department of Defense Standards

MIL-STD-882D Standard Practice for System Safety Department of Defense Handbooks

MIL-HDBK-217F (2)

Reliability Prediction of Electronic Equipment

MIL-HDBK-470 (A) Designing and Developing Maintainable Products and Systems

MIL-HDBK-472 Maintainability Prediction

MIL-HDBK-1568

Material and Processes for Corrosion Prevention and Control in Aerospace Weapons Systems

MIL-HDBK-29612-3A Development of Interactive Multimedia Instruction (IMI) (Parts 1-5)

Department of Defense Manuals

TM 86-01K Air Force Technical Manual Contract Requirements TO 00-5-16 Software Managers Manual USAF Automated Computer

Program Identification Number System (ACPINS) Data Item Descriptions (DIDs)

DI-ADMN-81249A

Conference Agenda

DI-ADMN-81250A

Conference Minutes

DI-ALSS-81529 Logistics Management Information (LMI) Data Product(s)

DI-ALSS-81557

Supplemental Data for Provisioning (SDFP)

DI-CMAN-80639C Engineering Change Proposal (ECP)

DI-CMAN-80640C

Request for Deviation (RFD)

DI-CMAN-80642C Notice of Revision (NOR)

DI-CMAN-81218

Product Base Line Index (PBLI)

DI-ILSS-80872

Training Materials DI-ILSS-81335 Design Review Data Package DI-IPSC-81442A Software Version Description

DI-MCCR-80700

Computer Software Product End Items DI-MFFP-81403 Corrosion Prevention and Control Plan DI-MGMT-80227 Contractor's Progress, Status and Management Report

DI-MISC-80508B Technical Report/Study Services

DI-MISC-81454A Automated Computer Program Identification Number (ACPIN) Data and Control Record DI-NDTI-80809B Test / Inspection Report

DI-NDTI-80808 Test Plans / Procedures

DI-SAFT-80101B System Safety Hazard Analysis Report

DI-SAFT-81626 System Safety Program Plan

(Unless otherwise indicated, copies of the above specifications, standards, and handbooks are available from the Standardization Document Order Desk, 700 Robbins Avenue, Building 4D, Philadelphia PA 19111-5094.)

2.1.2 Purchase Description (PD)

PD05WRLEEG11

Basic Expeditionary Airfield Resources

(BEAR) Power Unit (BPU)

2.2 Non-Government publications. The following documents form a part of this document to the extent specified herein. Unless otherwise specified, the issues of the documents which are DOD adopted are those listed in the issue of the DODISS cited in the solicitation. Unless otherwise specified, the issues of documents not listed in the DODISS are the issues of the documents cited in the solicitation.

Reliability Information Analysis Center (RIAC)

NPRD-95

Nonelectronic Parts Reliability Data 1995

(Application for copies should be addressed to Reliability Information Analysis Center, 201 Mill Street, Rome NY 13440.)

2.3 Order of precedence. In the event of a conflict between the text of this document and the references cited herein, the text of this document takes precedence. Nothing in this document, however, supersedes applicable laws and regulations unless a specific exemption has been obtained.

3. REQUIREMENTS.

3.1 Program management.

3.1.1 Program manager. The contractor shall identify to the Government and maintain a single point of contact (Program Manager) for all matters under this contract. The contractor shall also ensure that all program management personnel assigned to the program shall be available, as required, to meet program objectives. The contractor shall prepare a monthly contractor’s progress, status and management report. This report shall identify the status of all portions of the contract and shall be identified in the contractor's milestone chart. The program report shall include all events such as reviews, audits, tests, identification, and delivery of the contract line items. (DI-MGMT-80227, Contractor's Progress, Status and Management Report)

3.1.2 Plant access. The contractor shall arrange for full access to applicable contractor facilities and offices by Government representatives conducting any business, making observations, or performing inspections required by public law or by this contract.

3.1.3 Production release. Reserved.

3.1.4 Program schedule. The contractor shall prepare and update a monthly program schedule in accordance with the DD Form 1423. This schedule shall identify the status of all portions of the contract and will be identified in the contractor's milestone chart. This will include all events such as reviews, meetings, tests, identification and delivery of contract line items. (DI-MGMT-80227, Contractor's Progress, Status and Management Report)

3.1.5 Conflict of requirements. In the event of any conflict of requirements specified herein, the conflict shall be referred to the PCO for resolution. If a difference in interpretation of contract requirements exists as specified herein between the contractor and any Government representative, the contractor shall seek clarification from the PCO.

3.2 Program reviews.

3.2.1 Post Award Conference (PAC). The PCO will coordinate the actual date and time of the PAC with the contractor. The contractor shall participate in the PAC with the Government at the contractor’s facility within 45 days after contract award.

3.2.2 Technical design and program reviews. The contractor shall host a preliminary design review 3 months after contract is awarded, or at the contractor’s request as approved by the Government. The contractor shall host a critical design review 6 months after the contract is awarded, or at the contractor’s request as approved by the Government. Both PDR and CDR shall include formal technical reviews of the proposed design and program risks shall be reviewed on a technical and schedule basis. The PDR shall include, but is not limited to, preliminary calculations, any necessary design studies or analyses including design analysis as required in 3.6.4, preliminary drawings, including equipment layout drawings (packaging), proprietary or restricted design processes/components/information, electrical and mechanical design, environmental control and thermal design aspects, software design, training materials, lists of materials/parts/processes, human engineering elements, corrosion control, maintainability, production capability and manufacturing, and quality considerations. The CDR shall include at a minimum all areas of the PDR, although at a much greater level of detail and completeness. Final drawings, final calculations, any mockups or any assemblies shall be made available for the Government review as well. All applicable comments from the PDR initiative shall be incorporated into the CDR design documentation. The contractor shall prepare all necessary detailed status reports for the program and technical design review meetings, conference agendas, and conference minutes. The contractor shall prepare formal documentation of the PDR and CDR. (DI-ILSS-81335, Design Review Data Package)

3.2.3 Program Management Review support. The contractor shall participate in and support all reviews, audits, and meetings as requested by the PCO. Reviews shall be held at the contractor’s facility.

3.2.4 Conference room. The contractor shall provide a conference room suitable for meetings of up to 30 Government representatives, plus contractor personnel in support of scheduled meetings.

3.2.5 Meeting agendas. The contractor shall publish an agenda for all meetings and conferences including PDR and CDR as specified in 3.2.2 of this document. The contractor shall request from the Government any items or issues to be discussed or presented at the meetings and include as directed such items in the agenda. Agendas shall be submitted within 5 working days prior to any meeting. (DI-ADMN-81249A, Conference Agenda)

3.2.6 Meeting minutes. The contractor shall provide a written record of the discussions, decisions and action items identified at each meeting including PDR and CDR as specified in 3.2.2 of this document. The contractor shall submit meeting minutes no later than 10 days after the meeting in accordance with DD Form 1423. (DI-ADMN-81250A, Conference Minutes)

3.3 Configuration management and control.

3.3.1 Configuration requirements. After the preproduction BPU acceptance, the contractor shall establish and maintain configuration control. One (1) accepted preproduction BPU shall be served as the manufacturing standard. All of the documents used to produce and define the accepted preproduction BPUs shall be identified in a Product Base Line Index. The list shall identify the applicable version number as required. (DI-CMAN-81218, Product Base Line Index (PBLI))

3.3.2 Commercial parts. The contractor shall use standard common commercial parts in the design and fabrication of the BPU to the maximum extent possible without adversely affecting performance.

3.3.3 Engineering Change Proposals (ECP). After the Product Baseline is released, the contractor shall incorporate all changes to master drawing baseline via approved ECPs (DI-CMAN-80639C, Engineering Change Proposal (ECP)). A Notice of Revision (NOR) shall be submitted with each ECP in accordance with DD Form 1423 (DI-CMAN-80642C, Notice of Revision (NOR)).

3.3.4 Production release. Production release is acknowledgment by the Government that the contractor has satisfied all requisites to proceed with delivery of hardware to be furnished under the contract. The contractor assumes all risks in initiating the BPU production before the Government has determined that the preproduction BPUs have met all requirements of preproduction and operational inspections in accordance with 4.1 of the PD05WRLEEG11, the results/test reports of preproduction inspection have been delivered and approved by the Government, and that any deficiencies from the User Operational Test and Evaluation (OT&E) have been corrected and incorporated.

3.3.5 Component changes during production. Notwithstanding any other provisions in the contract, no contractor or subcontractor's change in design, fabrication, assembly, part, material, process, or source of supply shall be made after production release unless such change is approved in writing by ECP or request for deviation/waiver submitted to the Government Program Manager. Any request for change shall be accompanied by complete documentation supporting the need for change. (DI-CMAN-80640C, Request for Deviation (RFD))

3.4. Reserved.

3.5 Training/familiarization.

3.5.1 Operation and maintenance orientation. The contractor shall plan for and conduct a one-time classroom and “hands-on” operation and maintenance orientation for the using activities to familiarize the users with the BPU. The orientation shall be a minimum sixty (60) formal classroom training hours. It is recommended, although not mandated, that Instructor-Led Training (ILT) development, evaluation, and documentation be in accordance with MIL-HDBK-29612, part 2. The orientation shall include but not be limited to: operational familiarization; maintenance of the BPU for both corrective and preventative efforts; support/test equipment review; BPU safety features and procedures; application of technical manual to modes and effects; troubleshooting/fault isolation, and theory of operation. This orientation shall take place at the contractor’s facility (within CONUS) no later than 60 days prior to user Operational Test and Evaluation (OT&E). The contractor shall provide all required reference material for 25 DOD personnel, to include a CD-ROM with a digital copy, in Adobe Acrobat (PDF) format, of all student support materials, which shall be provided at the conclusion of training to all students. Copies of the latest draft effort in developing the Technical Manual (TM)/Technical Order (TO) for the BPU shall also be available and shall be the primary source of data used. The contractor is not required to provide transportation to and from the site, lodging, or meals for the 25 DOD personnel during the orientation.

3.5.2 Operation and maintenance familiarization/orientation material. The contractor shall develop, or facilitate the development of, an internet-based Multimedia Training product conformant to and in compliance with the most current, at time of award, publication of the "Standards and Guidelines for AFCESA Multimedia & Training Products" document provided by HQ/AFCESA, DOD Instruction 1322.20/1322.26, and prevailing industry standards such as SCORM and Section 508 Accessibility guidelines. Some method of book marking or maintaining a student’s place within the course by the use of SCORM CMI data element functions shall be available through the learning management system (LMS). A master copy of all source files, regardless of authoring platform, original source graphics, and media utilized, and not identified as proprietary by the contractor, shall be provided to support further training product development by the Government. Examples include, but are not limited to, all HTML/XHTML/DHTML/XML files, Templates, Adobe Flash (both compiled swf and FLA source files), Adobe Dream weaver source files (to include any template files), JAVA source code (to include associated linked library/class files), compiled applets, Javascript/Vbscript code, Cascading Style Sheets (CSS) and a listing of hypertext links shall be included. Furthermore, it is recommended, although not mandated, that all interactive training products be developed, evaluated and documented in accordance with MIL-HDBK-29612, parts 1-5. The interactive multimedia instruction will be used in the field for familiarization of operational and maintenance personnel at the organizational level. The final deliverable of the course shall be delivered as a SCORM conformant package (PIF), consistent with specification guidelines, and validated through the use of the most current SCORM Conformance Test Suite (CST), for which the corresponding log files shall be provided with deliverable package to verify minimum SCORM conformance. The contractor shall also work with the customer representative to ensure proper operation and integration of this courseware into client LMS as required. This training product shall be in sufficient detail to provide the technician adequate skills to operate and provide general maintenance for the up-keep of the BPU in the field. The training product shall also be in sufficient detail to allow the Air Education and Training Command (AETC) to formulate a training course for future use. This training product shall be subject to preliminary Government approval. Interactive course content should mirror “hands-on” classroom training to the maximum extent possible, with feedback from the 25 DOD personnel attending the Operation and Maintenance Orientation being gathered and used to develop the final version of the training product to be used for organizational level familiarization. The training product shall be subject to final Government approval before final delivery. (DI-ILSS-80872, Training Materials)

3.5.3 Government rights. The contractor shall extend to the Government unlimited usage rights for the duplication and distribution of the operation and maintenance familiarization/orientation material (CD-ROM) identified in 3.5.2. The contractor may identify to the Government any specific proprietary materials or items needing to be limited due to proprietary rights.

3.6 Systems engineering.

3.6.1 System safety. The contractor shall establish, conduct, document, and maintain a system safety program in accordance with 4.1 through 4.8 of MIL-STD-882D. The contractor shall initiate changes in the BPU design based on safety analysis results such that the associated risk is reduced to a level acceptable to the Government. (DI-SAFT-81626 System Safety Program Plan, DI-SAFT-80101B System Safety Hazard Analysis Report)

3.6.2 Reliability and maintainability.

3.6.2.1 Reliability.

3.6.2.1.1 Basic reliability model. The contractor shall develop and maintain a basic reliability model for the BPU engine-generator (see 3.13.1 of the PD). All equipment and associated quantities comprising these parts shall be included in the model. All equipment, including those intended solely for item redundancy and alternate modes of operation, shall be modeled in series. A basic reliability block diagram shall be developed and maintained for the items with associated allocations and predictions in each reliability block. The basic reliability block diagram shall be keyed and traceable to functional block diagrams, drawings, and schematics, and shall provide the basis for accurate mathematical representation of basic reliability. Nomenclature of elements of the item used in the basic reliability block diagrams shall be consistent with that used in functional block diagrams, drawings, schematics, weight statements, power budgets, and specifications. The basic reliability model shall be documented in the design analysis (see 3.6.4) and reviewed at the design reviews.

3.6.2.1.2 Basic reliability prediction. The contractor shall prepare and maintain a basic reliability prediction for the BPU engine-generator (see 3.13.1 of the PD); it shall be based upon the associated basic reliability model (see 3.6.2.1.1). All equipment and associated quantities comprising these parts shall be included in the model except for documented exclusions approved by the procuring activity. Failure rate data (or equivalent reliability parameters) shall be consistent with the level of detail of the basic reliability model and availability of procuring activity approved relevant data sources for a comprehensive prediction (for example, software reliability, human reliability, storage reliability, etc.). The prediction shall be based upon the worst-case service use profile. All data sources for failure rates, failure distribution, and failure rate adjustment factors (for example, stress factors, duty cycle, etc.) shall be identified for each reliability block. Data sources shall be MIL-HDBK-217F (2), NPRD-95, or otherwise approved by the procuring activity. The basic reliability prediction shall be documented in the design analysis (see 3.6.4) and reviewed at the design reviews.

3.6.2.2 Maintainability. The contractor shall prepare and maintain a maintainability prediction for mean time to repair (MTTR) using MIL-HDBK-470A, Appendix D, and MIL-HDBK-472, Notice 1, for guidance. The model and failure rate data shall be consistent with that of the basic reliability prediction (see 3.6.2.1.2). The maintainability prediction shall be documented in the design analysis (see 3.6.4) and reviewed at the design reviews.

3.6.3 Corrosion control. The contractor shall establish, conduct, document, and maintain a corrosion prevention control program using MIL-HDBK-1568 for guidance. (DI-MFFP-81403 Corrosion Prevention and Control Plan)

3.6.4 Design analysis. A design analysis of the BPU and each subsystem shall be performed to verify compliance with this SOW and each applicable PD. The analysis shall include, but is not limited to, a system safety hazard analysis (see 3.6.1 and 4.6.4 of the PD); a basic reliability model (see 3.6.2.1.1) and predictions (see 3.6.2.1.2); an electrostatic discharge analysis (see 4.6.24 of the PD); a surface transportability analysis (see 4.6.23 of the PD); an air transportability analysis for C-17 transport (see 4.6.19.1 of the PD); a lifting provision analysis (see 4.6.19.3 of the PD) and a BPU life expectancy analysis (see 4.6.22 of the PD). An initial design analysis shall be provided at the PDR; updated versions of the analysis shall be provided at the CDR, at the start of preproduction testing, and with the preproduction test report. (DI-MISC-80508 B, Technical Report/Study Services)

3.7 Software documentation and data deliverables.

3.7.1 Executable code. The executable code shall be compatible with a standard PC running the existing Air Force Standard Desktop Configuration (SDC). The contractor shall own the executable code and shall manage and make in-house revisions/updates as necessary to support the BPU through its life expectancy of 20 years. The contractor shall notify the Government of any and all revisions/updates. The Government pledges to protect the contractor proprietary information embodied in the code and will not disclose this information to a third party contractor without the contractor’s approval. The Government shall have the right to reproduce and distribute the software to users as necessary. (DI-MCCR-80700, Computer Software Product End Items)

3.7.2 Software version description document. The contractor shall submit a software version description document. (DI-IPSC-81442A, Software Version Description)

3.7.3 Automated Computer Program Identification Number (ACPIN) Data and Control Record. The contractor shall request a Computer Program Identification Number (CPIN) for any software configuration entity to be delivered to the Government to support the BPU. To request a CPIN from the Government all custom and/or commercial software packages shall be labeled independently and described thoroughly on AF Forms 1243 in accordance with TO 00-5-16 guidelines. (DI-MISC-81454A, Automated Computer Program Identification Number (ACPIN) Data and Control Record)

4. PRODUCT QUALIFICATION.

4.1 Preproduction test procedures and report. The contractor shall develop detailed preproduction test procedures which must be approved by the Government. The test procedures shall address all requirements identified in the Purchase Description and this SOW. The test procedures shall include data record sheets, charts, graphs, identification of test instruments by manufacturer, model number, and serial number. After approval of preproduction test procedures, the contractor shall schedule the testing to be conducted. Thirty (30) days prior to preproduction testing, the contractor shall notify the Government of the date, time, and location of preproduction testing. The contractor shall submit a preproduction test report upon completion of the preproduction test. (DI-NDTI-80808, Test Plans / Procedures; DI-NDTI-80809B, Test / Inspection Report)

4.2 User Operational Test and Evaluation (OT&E). After completion of preproduction test and approval by the Government of the preproduction test report, five (5) preproduction BPUs will be selected by the Government at random and shall be shipped for the user OT&E. The contractor shall be responsible for all costs associated with delivery of the preproduction BPUs to the OT&E site. The remaining three (3) BPUs shall be refurbished and retained at the contactor’s facility. The Air Force users will conduct all OT&E tests. The contractor shall provide a spare parts kit with each BPU shipped for the user OT&E containing all items required to conduct scheduled maintenance during the test as well as common repair parts predicted to be needed during the OT&E. The contractor shall provide a 75 % complete technical manuals and 100 % complete and approved by the Government internet-based Multimedia Training product to the OT&E location. Contractor’s support must be available (within 48 hours of notification exclusive of weekends and official Government holidays) all time during the user OT&E. All user OT&E shall be completed within allocated ninety (90) days. All tests shall be completed prior to the preproduction BPU acceptance.

4.3 Aircraft transportability certifications. The contractor shall be responsible to provide all required data to the procuring activity in order to obtain all necessary transportability certifications.

4.4 Refurbishing. After completion of preproduction and users OT&E acceptance, the five (5) preproduction BPUs shall be shipped, within 30 days, to the contractor’s facility for refurbishment. One (1) preproduction BPU shall be retained at the contractor’s facility until the last shipment and prior to expiration date of EPA approved diesel engine used on the BPU and shall be served as a manufacturing standard. The remaining seven (7) preproduction BPUs shall be shipped to the location specified in the contract. The contractor shall be responsible for any repairs that may be necessary to restore all (eight) preproduction BPUs to a serviceable condition while retaining configuration integrity. The contractor shall be responsible for all costs associated with delivery of the preproduction BPUs to the contractor's facility for refurbishment. All eight (8) preproduction BPUs shall be a part of production quantity.

4.5 Production acceptance test procedure and report. The contractor shall test each production BPU in accordance with 4.4 of the purchase description utilizing a subset of the preproduction test procedures. The contractor shall enclose an acceptance test report for each production BPU. (DI-NDTI-80809B, Test/Inspection Report)

5. TRANSPORTATION. For acquisition purposes, the transportation requirements shall be specified in the contract or order.

6. TECHNICAL DATA.

6.1 Provisioning. The contractor shall identify and recommend logical spare/repair parts sufficient to meet system/equipment operation and supportability in accordance with the Air Force Initial Provisioning Performance Specification (IPPS). MIL-PRF-49506 should be used as a guide. Format must be consistent with existing Government Provisioning data system (D220). The following Data Item Descriptions (DID) apply: DI-ALSS-81529, Provisioning Technical Documentation: Provisioning Parts List (PPL) Topdown Sequence, Long Lead Items List (LLIL): LLIL-SAIP (Items recommended for Spares Acquisition Integrated with Production and not later than 165 days prior to contractor’s order need date or as determined at the PGC), Design Change Notices (DCNs), DI-ALSS-81557, Supplemental Data For Provisioning (SDFP).

6.1.1 Mission Readiness Spares Package (MRSP). BEAR Primary Power Units are War Reserve Units. Projected deployments are to sites that are not expected to have mature lines of supply for the first 30 days of deployments. Therefore; to bridge the support gap, MRSP kits are required to be deployed with each unit. This requirement is in addition to the identification and stocking of initial spares. The MRSP kit baseline requirement is the parts that are required to conduct the anticipated preventative maintenance and field level repairs for the first 720 hours of unit operations at deployed locations.

6.2 Technical Order requirements.

6.2.1 Technical Order/Manual. The contractor shall submit an Operation Maintenance Overhaul with Illustrated Parts Breakdown manual in accordance with TM 86-01K, Air Force Technical Manual Contract Requirements.

6.2.2 Technical Manual schedule and status report. Technical Manual schedule and status report shall be in accordance with TM-86-01K, Air Force Technical Manual Contract Requirements.

6.2.3 Technical Order verification. Technical order verification shall be in accordance with TM 86-01K at the contractor’s facility.

7. QUALITY ASSURANCE PROVISIONS.

7.1 Responsibility for inspection. The contractor shall be responsible for the performance of all inspection requirements as specified herein. The contractor shall use his facility for the performance of the inspection requirements. The Government reserves the right to perform any of the inspections if deem necessary to ensure supplies and services conform to the requirements.

DISTRIBUTION STATEMENT A. Approved for public release: distribution is unlimited.

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