SOW1.pdf

642 COMBAT SUSTAINMENT GROUP 7 FEB 2008

FLIGHT LINE ENGINEERING FLIGHT

WARNER ROBINS ALC, ROBINS AFB, GA 31098

CAGE 98752

STATEMENT OF WORK

FOR

72KW/90KVA GENERATOR SET

1 SCOPE

1.1 This Statement of Work (SOW) defines the tasks and support requirements for the procurement of a 72 kW/90 kVA Generator Set as described by PD08WRGBGBEA04.

Also referred to as a Ground Power Unit (GPU), the machine is used to provide 400 Hz AC power, 28VDC power, and 270 VDC power for various aircraft maintenance tasks on current Air Force aircraft.

2 APPLICABLE DOCUMENTS AND REFERENCES

2.1 Government documents. The following documents form a part of this SOW to the extent specified herein. Although revision letters for specifications/documents may not be cited within the text of the SOW or the PD, 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. All documents cited as references in both this SOW and PD08WRGBGBEA04 shall be the latest revision unless specifically stated otherwise.

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-1568 Material and Processes for Corrosion Prevention and Control in Aerospace Weapons Systems

MIL-HDBK-217F (2) Reliability Prediction of Electronic Equipment MIL-HDBK-29612-3A Development of Interactive Multimedia Instruction (IMI)

(Parts 1-5)

Department of Defense Manuals

TM 86-01M Air Force Technical Manual Contract Requirements

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-ILSS-80872 Training Materials DI-ILSS-81335 Design Review Data Package

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-NDTI-80566A Test Plan DI-NDTI-80603A Test Procedure

DI-NDTI-80809B Test / Inspection Report DI-SAFT-80101B System Safety Hazard Analysis Report DI-SAFT-81626 System Safety Program Plan

Purchase Description

PD08WRGBGBEA04 72KW/90KVA GENERATOR SET

(Copies of these documents, with the exception of PD08WRGBGBEA04, are available online at http://assist.daps.dla.mil/quicksearch/ or www.dodssp.daps.mil or from the Standardization Document Order Desk, 700 Robbins Avenue, Building 4D, Philadelphia, PA 19111-5094.

Copies of PD08WRGBGBEA04 are available from the Primary Contracting Officer.)

2.2 Non-Government publications. The following documents of the exact revision listed below form a part of this document to the extent specified herein.

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 PD08WRGBGBEA04 the matter shall be referred to the Primary Contracting Officer (PCO) for resolution. If a difference in interpretation of contract requirements exists as specified herein between the contractor and any Government representative, the issue shall be referred to the PCO for resolution. Nothing in this document, however, supersedes applicable laws and regulations unless a specific exemption has been obtained. Additionally the terms "First Article" and "First Production" are to be used interchangeably in both this text (SOW) and PD08WRGBGBEA04, and the term "ARO" as used in PD08WRGBGBEA04, this text (SOW), and associated DD 1423's denotes "after the effective date of the contract/order".

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.

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 Program Schedule. The contractor shall prepare and update a monthly program schedule throughout the First Article period of the contract and until the completion of the first full quarter of production GPU acceptance. At the end of this first quarter of full rate production the program schedule shall become quarterly and shall remain as such until the acceptance of the last deliverable item on the contract. All program schedules shall be completed IAW the applicable DD 1423. This schedule shall identify the status of all portions of the contract and will be identified in a contractor's milestone chart. This will include but not be limited to: events such as reviews, meetings, percentage of Technical Order (TO) completion, provisioning data, tests, and identification/delivery of contract line items. IAW DD1423 ELIN A004 (DI-MGMT- 80227/T)

3.2 Program Reviews

3.2.1 Post Award Conference (PAC). The Government will convene the PAC with the contractor at WR-ALC, Robins AFB, GA. The PCO will coordinate the date and time of the conference with the contractor. The PAC shall be held within 60 days of contract award.

3.2.2 Preliminary Design Review (PDR) and Critical Design Review (CDR). The contractor shall host a PDR within 60 days ARO and a CDR within 180 days ARO, or at any time proposed by the contractor and approved by the Government within 200 days ARO. The PDR shall be held at Robins AFB, GA and the CDR shall be held at the Government approved, contractor proposed location. Both reviews will involve formal technical reviews of the proposed design and program risks will be reviewed on a technical and schedule basis. The PDR shall address at a minimum: design analysis as required in 3.5.4 of this document, equipment layout drawings, environmental concerns, mechanical design, packaging (layout), safety, dimensional data, manufacturability data, parts considerations, human engineering elements, corrosion aspects, reliability and maintainability aspects, and quality considerations.

The CDR shall encompass at a minimum: all areas of the PDR, although at a much greater level of detail and completeness, and any mockups or assemblies shall be made available for Government review as well. Both design reviews shall be attended (at a minimum) by the Government program manager, program engineer, program equipment specialist, and United States Air Force (USAF) military personnel. IAW DD1423 ELIN A005 (DI-ILSS-81335)

3.2.3 Conference Room. When meeting and reviews are held the contractor or contractor proposed location, the contractor shall provide a conference room suitable for meetings of up to 15 Government representatives, plus contractor personnel in support of scheduled meetings.

3.2.4 Meeting Agendas. The contractor shall publish an agenda for all meetings and conferences as specified herein (i.e., PDR, CDR, guidance conferences, etc). 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 at least 10 days prior to any meeting. IAW DD1423 ELIN A006 (DI-ADMN-81249A/T)

3.2.5 Meeting Minutes. The contractor shall provide a written record of the discussions, decisions, and action items identified at each meeting. The contractor shall submit meeting minutes no later than 10 days after the meeting IAW DD1423 ELIN A007. (DI-ADMN- 81250A)

3.3 Configuration Management and Control.

3.3.1 Configuration Requirements. After First Article (FA) acceptance, the contractor shall establish and maintain configuration control. The accepted First Article units shall serve as the manufacturing standard. All further units shall be produced to the same design and using the same parts as the First Article unit.

3.3.2 Engineering Change Proposals (ECP). After the First Article/First Production acceptance the contractor shall incorporate all changes via approved ECPs. A Notice of Revision (NOR) shall be submitted with each ECP IAW DD1423 ELIN’s A012 and A013. (DI-CMAN-80639C, DI-CMAN-80642C)

3.3.3 Production Release. The contractor assumes all risks in initiating production before the PCO has determined that the First Article has met all requirements and that the results of FA Testing/Verification have been delivered and accepted and that any deficiencies from the Aircraft Compatibility/Operational Testing have been corrected and incorporated. 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.

3.3.4 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 by the PCO. Any request for change shall be accompanied by complete documentation supporting the need for change. IAW

DD1423 ELIN A014 (DI-CMAN-80640C)

3.4 Maintainability/Familiarization.

3.4.1 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 GPU. The orientation shall include but not be limited to:

operational familiarization, ease of maintaining the unit for both corrective and preventative efforts, support/test equipment review, unit safety features, application of technical manual to modes and effects, troubleshooting/fault isolation, and theory of operation. This orientation shall take place at the contractor facility (within CONUS) within 90 days prior to shipment of the GPU to the OT&E locations. The contractor shall provide all required reference material IAW paragraph 3.4.2 herein for up to 15 DOD personnel. Copies of the latest draft effort in developing the Technical Manual (TM)/ Technical Order (TO) for the GPU shall also be available. The contractor is not required to provide transportation to and from the site, lodging, or meals for the approximately 15 DOD personnel during the orientation. The orientation shall be attended (at a minimum) by the Government program engineer, program equipment specialist, and United States Air Force (USAF) military personnel. IAW DD1423 ELIN B002.

(DI-ILSS-80872/T)

3.4.2 Operation and Maintenance Familiarization/Orientation Material. The contractor shall develop an interactive multimedia system (program media) on CD ROM or DVD to be used during the Operation and Maintenance Orientation and for use in the field for familiarization of operational and maintenance personnel at the organizational level. MIL-HDBK-29612-3A should be used as a general guide, although contractor format is acceptable. This program media shall be in sufficient detail to provide the technician adequate skills to operate and provide general maintenance for the up-keep of the GPU in the field. The program media shall also be in sufficient detail to allow the Air Education and Training Command (AETC) to formulate a training course for future use. The program media shall be compatible with existing Air Force personal computers (Microsoft Windows based operating systems) and consist of all materials (e.g., software, firmware) necessary to execute the Familiarization/Orientation Material.

Approximately fifteen copies of the draft version program media shall be available for use at the Operation and Maintenance Orientation for DOD personnel. Feedback from the 15 DOD personnel attending the Operation and Maintenance Orientation shall be gathered and used to develop the final version of the program media to be used for organizational level familiarization. The program media shall be subject to final Government approval before final delivery. Final delivery of 2 copies of the program media shall be made to WR-ALC IAW DD Form 1423. One copy of the program media shall sent with each GPU as pack up data. Note:

excluding the First Article/First Production GPU's, no generator set delivery acceptance will occur without completed and Government accepted Orientation Material. IAW DD1423 ELIN B002. (DI-ILSS-80872/T and MIL-HDBK-29612-3A)

3.4.3 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 (program media) identified in 3.4.2.

3.5 Systems Engineering.

3.5.1 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 GPU design based on safety analysis results such that the associated risk is reduced to a level acceptable to the Government. IAW DD1423 ELIN’s A009 and A010. (DI-

SAFT-81626, DI-SAFT-80101B)

3.5.2 Reliability and Maintainability.

3.5.2.1 Reliability.

3.5.2.1.1 Basic Reliability Model. The contractor shall develop and maintain a basic reliability model for the GPU based on requirements levied in 3.10.10 of PD08WRGBGBEA04. 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 3.5.4 herein) and reviewed at the design reviews.

3.5.2.1.2 Basic Reliability Prediction. The contractor shall prepare and maintain a basic reliability prediction for the GPU (see 3.10.10 of PD08WRGBGBEA04); it shall be based upon the associated basic reliability model (see 3.5.2.1.1 herein). 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 3.5.4 herein) and reviewed at the design reviews.

3.5.3 Corrosion Control. The contractor shall establish, conduct, document, and maintain a corrosion prevention control program using MIL-HDBK-1568 for guidance. IAW DD1423

ELIN A011. (DI-MFFP-81403)

3.5.4 Design Analysis. A design analysis of the GPU and each subsystem shall be performed to verify compliance with this SOW and PD08WRGBGBEA04. The analysis shall include, but is not limited to, a system hazard analysis (see 3.7 and 4.6.1 of the PD); a basic reliability model (see 3.5.2.1.1 herein) and predictions (see 3.5.2.1.2 herein); and an air transportability analysis for C-130 transport (see 3.9.11.2 and 4.6.1 of the PD). An initial design analysis shall be provided at the PDR; updated versions of the analysis shall be provided at the CDR and with the first article test report. IAW DD1423 ELIN A008. (DI-MISC-80508B)

3.6 Product Qualification.

3.6.1 Cables. Interface cables required between the GPU and aircraft/equipment are identified below by part number and cage code and shall be the sole responsibility of the contractor to provide. Both First Article GPU's shall be furnished with one115 VAC cable part number JB8817-60 (with RVS) CAGE 0SMN2, or JB8816-60NJ (without RVS) CAGE 0SMN2, or equivalent (depending upon contractors line drop compensation design); one 230 VAC cable part number MS21378-15 CAGE 96906 or equivalent; one 28VDC cable part number MS90347-22, CAGE 96906 or equivalent; and one 270 VDC cable part number 5PTV6002- 101, CAGE 81861 for use during test activities. Additionally each production GPU shall be shipped with one part number JB8817-60 (with RVS) CAGE 0SMN2, or JB8816-60NJ (without RVS) CAGE 0SMN2, or equivalent 60 foot 115 Volt AC interfacing cable.

3.6.2 Users Operational Test Location(s). After successful completion and Government approval of all Aircraft Compatibility testing, one FA/FP GPU shall be shipped to Dyess AFB, TX and the other FA/FP GPU shall be shipped to Charleston AFB, SC. Shipment from the Aircraft Compatibility test location (Edwards AFB, CA) to the Operational Test and Evaluation (OT&E) locations shall occur within thirty (30) days of Aircraft Compatibility test completion/approval.

3.6.3 Transportation/Shipping. The contractor's shipping responsibility shall be as specified in the contract and shall include at a minimum: all liability and costs incurred to move all equipment to/from and between locations for testing and/or demonstration purposes.

3.6.4 First Article/First Production Test Plan, Procedures and Report. The contractor shall develop a detailed First Article/First Production (FA/FP) in-plant test plan IAW DD1423. The test plan shall address all requirements identified in PD08WRGBGBEA04 and this SOW. After Government approval of the test plan the contractor shall develop a test procedure. The test procedure shall include at a minimum: top level test instructions, simple block style diagrams of test instrumentation connections, and identification of test instruments by manufacturer and model number. After approval the contractor shall schedule the testing to be conducted. Twenty days prior to First Article/First Production in-plant testing, the contractor shall notify the Government of the date, time, and location of the testing. The contractor shall submit a preliminary First Article/First Production Test Report within 30 days of completion of the in-plant testing. No further testing (such as aircraft compatibility and operational test) will occur until the preliminary in-plant test results are submitted and approved. The contractor shall submit a final First Article/First Production Test Report upon completion of the aircraft compatibility and operational testing. The final copy shall include all data submitted in the preliminary version plus identify any issues and corrections that occurred during the aircraft compatibility and the operational testing. In-plant First Article testing will be attended and witnessed by a Defense Contract Management Agency (DCMA) representative, the program engineer, and the program equipment specialist. The aircraft compatibility and OT&E testing will be attended by the program engineer and the program equipment specialist. Reference section 4 of PD08WRGBGBEA04 for further details of these tests. IAW DD1423 ELIN’s A001, A002, and A003. (DI-NDTI-80566A/T, DI-NDTI-80603A/T, DI-NDTI-80809B)

3.6.5 Refurbishing. After completion of in-plant testing and compatibility/operational testing the FA/FP units shall be shipped back to the contractor facility for refurbishment. The FA/FP units shall be retained at the contractor facility until the last shipment on the last delivery order and shall serve as the manufacturing standard(s). The contractor shall be responsible for any repairs that may be necessary to restore the unit to a serviceable condition while retaining configuration integrity. The contractor shall be responsible for all costs associated with delivery of First Article/First Production sets to the contractor's facility for refurbishment.

3.6.6 Production Acceptance Test Procedure And Report. The contractor shall develop production acceptance test procedures based on the requirements specified in PD08WRGBGBEA04. The contractor shall test each unit IAW the approved production acceptance test procedures. The contractor shall enclose an acceptance test report for each GPU with the unit pack up data. IAW DD1423 ELIN’s D001 and D002. (DI-NDTI-80603A/T, DI-

NDTI-80809B/T)

3.7 Technical Data

3.7.1 Technical Order/Manual. The contractor shall submit Technical Manual(s) in accordance with TM-86-01M. Note: excluding the First Article/First Production GPU's, no generator set delivery acceptance will occur without completed and Government accepted technical manuals.

The Technical Manuals shall include complete rebuild/overhaul procedures for the engine and generator, to include generator rewind data. The program equipment specialist and the program engineer shall attend the technical order verification at the contractor's facility.

3.7.2 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 program equipment specialist and the provisioning officer shall attend the provisioning conference at the contractor's facility. The following Data Item Descriptions (DID) apply:

DI-ALSS-81529 Provisioning Technical Documentation (PTD); specific PTD to be submitted is Provisioning Parts List (PPL) and Design Change Notices (DCNs). IAW DD1423 ELIN C001 DI-ALSS-81557 Supplement Data For Provisioning (SDFP). IAW DD1423 ELIN C002.

DI-ALSS-81530 SE Recommendation Data (SERD); Standard Modified Hand Tools List. IAW

DD1423 ELIN C003.

3.7.3 Aircraft Transportability Certifications. The contractor is responsible to provide all required data to the procuring activity in order to obtain all necessary transportability certifications. This data shall be provided with the preliminary first article in-plant test data.

3.8 Quality Assurance Provisions. The contractor shall have an established quality assurance program to ensure that each GPU meets the requirements set forth in PD08WRGBGBEA04 and this text (SOW). The contractor shall be responsible for the performance of all inspection requirements as specified herein and the contract documentation. The contractor's facility shall be used to the maximum extent possible for the performance of the inspection requirements.

The Government reserves the right to perform any of the inspections if deemed necessary to ensure supplies and services conform to the requirements.

3.8.1 Classification of Inspection. Inspections shall be classified as followed:

a. First Article Inspection IAW the approved test plan.

b. Production Inspection IAW the approved test plan.

3.8.2 Warranty. The Contractor shall provide a warranty with each GPU. Details of the warranty process and procedures including, but not limited to: coverage, response time for repair/replacement parts, warranty item identification, etc. within the continental U.S. (CONUS) and outside continental U.S. (OCONUS) shall be provided. The minimum warranty period shall not be less than two years or 2400 operating hours, whichever comes first.

3.9 Notes. This section is used to provide clarifying statements for use with this document (SOW) and PD08WRGBGBEA04.