M00146-15-T-9013_Released.pdf

CHERRY POINT SATELLITE CONTRACTING OFF.

ATTN: SCOTT BELIVEAU

PSC BOX 8018

BLDG. 159, MCAS

CHERRY POINT NC 28533-0018

252-466-5044

252-466-8492

UNDER DPAS (15 CFR 700)

11. DELIVERY FOR FOB

RFQ

SEE SCHEDULE

14. METHOD OF SOLICITATION

IFB RFP

CODE

SEE ADDENDUM

BLOCK IS MARKED

DESTINATION UNLESS

12. DISCOUNT TERMS

(No Collect Calls)

13b. RATING

13a. THIS CONTRACT IS A RATED ORDER

X

CODE

M00146-15-T-9013 02-Apr-2015

b. TELEPHONE NUMBER

252-466-5044

8. OFFER DUE DATE/LOCAL TIME

02:00 PM 15 May 2015

5. SOLICITATION NUMBER 6. SOLICITATION ISSUE DATE

AUTHORIZED FOR LOCAL REPRODUCTION

PREVIOUS EDITION IS NOT USABLE

STANDARD FORM 1449 (REV 3/2005)

Prescribed by GSA

FAR (48 CFR) 53.212

(TYPE OR PRINT)

(SIGNATURE OF CONTRACTING OFFICER) 31c. DATE SIGNED

ADDENDA ARE

26. TOTAL AWARD AMOUNT (For Govt. Use Only)

22. UNIT 23. UNIT PRICE 24. AMOUNT21. QUANTITY

CODE 10. THIS ACQUISITION IS

UNRESTRICTED

FAX:

NAICS:

TEL:

CODE 18a. PAYMENT WILL BE MADE BYOFFEROR

SUCH ADDRESS IN OFFER

17b. CHECK IF REMITTANCE IS DIFFERENT AND PUT

BELOW IS CHECKED

TEL.

M00146

SIZE STD:

9. ISSUED BY

FACILITY

CODE

17a.CONTRACTOR/

18b. SUBMIT INVOICES TO ADDRESS SHOWN IN BLOCK 18a. UNLESS BLOCK

15. DELIVER TO CODE N65923 16. ADMINISTERED BY

FLEET READINESS CENTER EAST CODE 6.1.522

JAMES RHODES

CODE 6.1.522 MCAS

CHERRY POINT NC 28533-0021

TEL: 252-464-7784 FAX:

7. FOR SOLICITATION

INFORMATION CALL:

a. NAME

SCOTT BELIVEAU

2. CONTRACT NO. 3. AWARD/EFFECTIVE DATE 4. ORDER NUMBER

(TYPE OR PRINT)

30b. NAME AND TITLE OF SIGNER 30c. DATE SIGNED 31b. NAME OF CONTRACTING OFFICER

30a. SIGNATURE OF OFFEROR/CONTRACTOR 31a.UNITED STATES OF

AMERICA

27a. SOLICITATION INCORPORATES BY REFERENCE FAR 52.212-1. 52.212-4. FAR 52.212-3. 52.212-5 ARE ATTACHED.

25. ACCOUNTING AND APPROPRIATION DATA

1. REQUISITION NUMBER

19. ITEM NO. 20. SCHEDULE OF SUPPLIES/ SERVICES

SEE SCHEDULE

334519

TO ISSUING OFFICE. CONTRACTOR AGREES TO FURNISH AND DELIVER ALL ITEMS

SET FORTH OR OTHERWISE IDENTIFIED ABOVE AND ON ANY ADDITIONAL SHEETS

SUBJECT TO THE TERMS AND CONDITIONS SPECIFIED HEREIN.

SB

HUBZONE SB

SET ASIDE: 100 % FOR

OFFEROR TO COMPLETE BLOCKS 12, 17, 23, 24, AND 30

SOLICITATION/CONTRACT/ORDER FOR COMMERCIAL ITEMS

N6592315SU00080

ARE NOT ATTACHED

27b. CONTRACT/PURCHASE ORDER INCORPORATES BY REFERENCE FAR 52.212-4. FAR 52.212-5 IS ATTACHED. ADDENDA ARE ARE NOT ATTACHED

TEL: EMAIL:

1 COPIES

(BLOCK 5), INCLUDING ANY ADDITIONS OR CHANGES WHICH ARE

SET FORTH HEREIN, IS ACCEPTED AS TO ITEMS:

.OFFER DATED YOUR OFFER ON SOLICITATION

28. CONTRACTOR IS REQUIRED TO SIGN THIS DOCUMENT AND RETURN 29. AWARD OF CONTRACT: REFERENCE

X

8(A)

SVC-DISABLED VET-OWNED SB

EMERGING SB

X

X

32g. E-MAIL OF AUTHORIZED GOVERNMENT REPRESENTATIVE

SOLICITATION/CONTRACT/ORDER FOR COMMERCIAL

ITEMS (CONTINUED)

SEE SCHEDULE

19. ITEM NO. 20. SCHEDULE OF SUPPLIES/ SERVICES 21. QUANTITY 22. UNIT 24. AMOUNT

PAGE 2 OF

23. UNIT PRICE

ACCEPTED, AND CONFORMS TO THE CONTRACT, EXCEPT AS NOTED:

32a. QUANTITY IN COLUMN 21 HAS BEEN

RECEIVED INSPECTED

32b. SIGNATURE OF AUTHORIZED GOVERNMENT

REPRESENTATIVE

32c. DATE 32d. PRINTED NAME AND TITLE OF AUTHORIZED GOVERNMENT

REPRESENTATIVE

32e. MAILING ADDRESS OF AUTHORIZED GOVERNMENT REPRESENTATIVE 32f. TELEPHONE NUMBER OF AUTHORIZED GOVERNMENT REPRESENTATIVE

37. CHECK NUMBER

FINALPARTIALCOMPLETE

36. PAYMENT35. AMOUNT VERIFIED

CORRECT FOR

34. VOUCHER NUMBER

FINAL

33. SHIP NUMBER

PARTIAL

38. S/R ACCOUNT NUMBER 39. S/R VOUCHER NUMBER 40. PAID BY

41a. I CERTIFY THIS ACCOUNT IS CORRECT AND PROPER FOR PAYMENT

41b. SIGNATURE AND TITLE OF CERTIFYING OFFICER 41c. DATE

42a. RECEIVED BY (Print)

42b. RECEIVED AT (Location)

42c. DATE REC'D (YY/MM/DD) 42d. TOTAL CONTAINERS

STANDARD FORM 1449 (REV 3/2005) BACK

Prescribed by GSA

FAR (48 CFR) 53.212

AUTHORIZED FOR LOCAL REPRODUCTION

PREVIOUS EDITION IS NOT USABLE

M00146-15-T-9013

Section A - Solicitation/Contract Form

SUMMARY INFORMATION FOR VENDORS

1. Point of Contact:

Scott Beliveau/Contract Specialist

Phone: 252.466.5044

E-mail: scott.beliveau@usmc.mil

2. Small Business Set-Aside: This requirement is 100% set-aside for small business concerns. The NAICS assigned to this requirement is 334519 with a corresponding size standard of 500 employees. Therefore, quotations from large business concerns will not be considered for evaluation.

3. Quotation due date/time: Quotations submitted in response to this requirement must be received at the location specified in paragraph 2) of Addendum to FAR 52.212-1 (See Section L) no later than 2:00 p.m. (EST) on 15 May

2015.

4. Address for submission of Vendor’s quote: Quotations submitted in response to this requirement must be submitted to the location specified in paragraph 2) of Addendum to FAR 52.212-1 (See Section L).

5. Advice to Vendors: Vendors are advised to read this document in its entirety, paying particular attention to the information provided in Section C – Purchase Description/Specification, Section L - Instructions, Conditions and

Notices to Vendors, and Section M- Evaluation Factors for Award.

6. Content of Vendor’s Quote: At a minimum, the vendor’s quote must includeall of the information requested in paragraph 3) of the Addendum to FAR 52.212-1 located in Section L. Information must be presented in the same order as listed in the instructions.

7. Evaluation of Quotes: Quotes received in response to this requirement will be evaluated in accordance with the information provided in Section M- Evaluation Factors for Award.

8. Site Visit: A Site Visit relating to the above requirement is scheduled to be conducted on 16 April 2015 at 10:00 am EST at the Fleet Readiness Center (FRC) East, MCAS Cherry Point, NC. See paragraph 5 of the Addendum to

FAR 52.212-1 located in Section L.

mailto:scott.beliveau@usmc.mil

Section B - Supplies or Services and Prices

ITEM NO SUPPLIES/SERVICES QUANTITY UNIT UNIT PRICE AMOUNT

0001 1 Each

V-22 APU ENGINE TEST SYSTEM

FFP

V-22 APU ENGINE TEST ASSEMBLY AND VIBRATION ANALYSIS

SYSTEM IN ACCORDANCE WITH THE PURCHASE DESCRIPTION /

SPECIFICATION, SECTION C.

MILSTRIP: N6592315SU00080

Section C - Descriptions and Specifications

Purchase Description/Specification for V-22 APU

Engine Test Assembly and Vibration Analysis System

1.0 SCOPE

1.1 This purchase description/specification defines the minimum essential requirements for one (1) V-22 APU

Engine Test Assembly (ETA) and six (6) Engine Vibration Analysis System (EVAS) to be used in the Gas Turbine

Engine Test Cells 7, 8, 9, 10, 11, and 12 located in Building 137 at Fleet Readiness Center East (FRC East), Marine

Corps Air Station (MCAS) Cherry Point, NC. The V-22 APU ETA and the EVAS shall consist of the design, manufacture, delivery, installation, and acceptance testing of all necessary equipment assemblies, components, and related programming required to successfully test the V-22 APU (Part Number 901-364-201-105/7) and monitor, record, and analyze vibration in all six (6) Test Cells for all engine types.

1.2 The contractor’s effort shall be limited to establishing the test capability utilizing existing structural elements currently in place in the designated area. This shall include but not be limited to the existing engine exhaust ducting, existing monorail, existing electrical components, existing water supply facilities, existing industrial drain systems, existing foundations, and structural test cell elements. In addition, the contractor shall interface with the existing Data Acquisition Systems (DAS).

1.3 The Engine Test Assembly (ETA) shall be developed as part of this upgrade. The ETA assembly shall include two (2) hoist units and one (1) trolley. The ETA assembly shall include all the applicable features of the existing APU test system, and be modified only to accommodate the features unique to the V-22 APU. The ETA shall integrate with the existing computer, Programmable Logic Controller (PLC) and DAS to monitor, measure, control, display, and record all parameters, and functions required for successful testing of the V-22 APU In

Accordance With (IAW) the respective test procedures referenced in Section 2.4. Each ETA assembly shall contain a Central Engineering Company (CENCO) brand or equivalent cradle with hoists, an R J Mack brand or equivalent trolley, and an engine test cart that interfaces with the cradle, all equipment, including but not limited to flywheel and braking hardware required to successfully perform V22 testing. The ETA assemblies shall interface with all existing

CENCO cradles of like kind and docking hardware currently in the test cells. No loss of current capability shall occur at any time throughout the project.

1.4 An Engine Vibration Analysis System (EVAS) shall be devolved as part of this upgrade. The EVAS shall be implemented in all six (6) test cells and shall include capability to analyze all current engine models. The EVAS shall use Yanos Aerospace’s Engine Test Vibration Analysis software and make use of National Instrument’s data acquisition hardware. The EVAS shall include the capability to monitor, record, and analyze eight (8) vibration and/or microphone channels at a time as well as two (2) speed channels. The EVAS shall interface to the existing

CEC vibration system as well as provide all additional hardware and cabling to meet the requirement of this specification. No loss of current capability shall occur as result of the addition of the EVAS

2.0 APPLICABLE DOCUMENTS

2.1 General. While every effort has been made to ensure the completeness of these listings, document users are cautioned to reference the latest revision of the following specifications; and meet all of the specified requirements of this specification, whether or not they are listed in this section.

2.2 Government Documents

2.2.1 Specifications, standards, and handbooks. The following specifications, standards, and handbooks form a portion of this document to the extent specified herein. Unless otherwise specified, the issues of these documents are those listed in the issue of the Department of Defense Index of Specifications and Standards (DODISS) and supplement thereto.

FEDERAL STANDARDS

FED-STD-H28 Screw Thread Standard for Federal Service

MIL-STD-461 Electromagnetic Interference Requirements

MIL-STD-1472 Human Engineering

DEPARTMENT OF DEFENSE HANDBOOKS

Mil-HDBK-1839 Calibration and Measurement

Requirements

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.

OTHER PUBLICATIONS

Federal Communications EMI Regulation

Commission (FCC) Part 18, Subpart A through C

Office of the Chief of Naval Hearing Conservation and Noise

Operations (CNO)

Abatement Chapter 18

OPNAVINST 5100.23

U.S. Department of Labor

OSHA 29 CFR 1910 General Industry

OSHA 29 CFR 1926 Construction Industry

OSHA 29 CFR 1910.147 The Control of Hazardous Energy

OSHA 29 CFR 1910.1200 HazCom Standard & Emergency Planning Community Right-to-Know

EM 385-1-1 Safety and Health Requirements Manual, U.S. Army Corps of

Engineers

When requesting specifications and standards, refer to both the title, and document number. Copies of specifications and standards required in connection with specific procurement functions should be obtained as specified below.

Copies of federal and military specifications required by the prospective suppliers may be obtained from the

Business Service Center, General Services Administration, Washington DC 20405. Copies of all other referenced

Government publications may be obtained upon application to the Superintendent of Documents, Government

Printing Office, Washington DC, 20402.

2.3 Non Government Standards and Guidelines.

IEEE STANDARDS AND GUIDELINES

IEEE Standard 488.1 Standard Digital Interface for Programmable Instrumentation

IEEE Standard 730-1998 Standards for Software Quality Assurance Plans

IEEE Standard 828-1998 Standards for Software Configuration Management Plans

IEEE Standard 829-1998 Standard for Software Test Documentation

IEEE Standard 830-1998 Recommended Practice for Software Requirements

Specification

IEEE Standard 1016-1998 Recommended Practice for Software Design Descriptions

IEEE Standard 1058-1998 Software Management Plans

IEEE Standard 12207 Information Technology Software Life Cycle Processes

IEEE Standard 1028-1997 Standard for Software Reviews

Application for copies should be addressed to the Institute of Electrical and Electronics Engineers, Inc., 445 Hoes

Lane, PO Box 1331, Piscataway, NF 08855.

NATIONAL INSTRUMENTS

National Instruments LabView Development Guidelines

Application for copies should be addressed to National Instruments, 11500 North Mopac Expressway, Austin, Texas

78759.

SOFTWARE ENGINEERING INSTITUTE

Software Engineering Capability Maturity Model

Institute Integration

Application for copies should be addressed to the Software Engineering Institute, Carnegie Mellon University, Pittsburg, PA 15213.

AMERICAN SOCIEITY OF MECHANICAL ENGINEERS (ASME)

ASME A13.1 Scheme for the Identification of Piping Systems

ASME Y14.100-2013 Engineering Drawing Practices

AMERICAN NATIONAL STANDARDS INSTITUTE.

ANSI/ASQC D1160-1995 American National Standard for Formal Design Reviews

Applications for copies should be addressed to the American National Standards Institute, 11 West 42 nd

Street, New

York, NY 10036.

NATIONAL ELECTRICAL MANUFACTURERS ASSOCIATION (NEMA)

250 Enclosures for Electrical Equip.

ICS-1 General Standards for Industrial Controls and Systems

ICS-2 Industrial Control Devices, Controllers and Assemblies

KS-1 Enclosed and Miscellaneous Distribution Equipment Switches

MG-1 Motors and Generators

Application for copies should be addressed to the National Electrical Manufacturers Association, 155 East 44 th

Street, New York, NY 10017.

NATIONAL FIRE PROTECTION ASSOCIATION (NFPA)

NFPA 70 National Electrical Code

NFPA 79 Electrical Standard for Industrial Machinery

NFPA 70E Standard for Electrical Safety in the Workplace

NFPA 101 Life Safety Code

NFPA 423 Standard for Construction and Protection of Aircraft Engine

Test Facilities

Application for copies should be addressed to the National Fire Protection Association, Publication Sales Division, Batterymarch Park, Quincy, MA 02269.

ELECTRONIC INDUSTRIES ASSOCIATION (EIA)

RS-232-C Computer Interface

Application for copies should be addressed to the Electronic Industries Association, 2001 Eye Street NW, Washington, DC 20006.

OTHER DRAWINGS AND DOCUMENTS

T-62T-40LC-2 Test Adapter Manufactured by CENCO

(Drawing 50385) International.

(Attachment 1)

2.4 Unit Reference and Test Publications

CP23-0-RR-994, Revision A, Amendment 1 V22 Auxiliary Power Unit System Engine Manual

Copies of the above publications are available for review at FRC East, MCAS, Cherry Point, NC. Hard copies for the above publications can be obtained at the following NATEC web site:

https://mynatec.navair.navy.mil/

2.4.1 Documents Specific to Crane and Hoist Procurement and Installation:

NAVFAC P-307 Management of Weight Handling Equipment

UFC 3-320-07N Unified Facilities Criteria: Weight Handling Equipment

NFPA 70/NEC Articles 430: Motors, Motor Circuits and Controllers & 610: Cranes and

Hoists

OSHA 29 CFR 1910.179 Overhead and Gantry Cranes

OSHA 29 CFR 1926.406(a) Specific Purpose Equipment and Installations

ANSI MH27.1 Specifications for Patented Track Underhung Cranes and

Monorail Systems

AWS D14.1 Specification for Welding of Industrial and Mill Cranes and

Other Material Handling Equipment

ASME B30.9 Slings

ASME B30.10 Hooks

ASME B30.11 Monorails and Underhung Cranes

ASME B30.16 Overhead Hoists (Under hung)

ASME HST-1–1999 Performance Standard for Electric Chain Hoists

ASTM A275/A275M-06 Standard Test Method for Magnetic Particle Examination of

Steel Forgings https://mynatec.navair.navy.mil/

AISC Manual of Steel Construction: Allowable Stress Design

SAE J514 Hydraulic Tube Fittings

The above documents can be accessed through sponsoring organization web-sites. For details on FRC East weight handling equipment requirements, please contact the Contracting Officer Representative (COR) (See Section G, Note 3.0).

2.5 Other Government Documents, Drawings, and publications. The following other Government documents, drawings and publications form a part of this document to the extent specified herein. Unless otherwise specified, the issues are those cited herein.

FRC East Drawing No. BLDG. 137 APU Test Cell Layout

PE 16208 2-2

(Attachment 2)

NAVFAC Drawing No. 4253056 Test Cell Foundation Plan.

(Attachment 3)

FRCEASTINST 5090.1 Environmental Compliance

(Copy available from Contracting Office upon request)

FRCEASTINST 5000.1A Visitor/ Contractor Site Specific Rules and Compliance

(Copy available from Contracting Office upon request)

2.6 Government Furnished Items

2.6.1 The following items may be furnished by the government as part of this contract. These items will be made available to the contractor upon request. The contractor shall provide the government notice / request of any GFI 6 weeks prior to the need date, at a minimum.

V22 Electronic Control Unit (ECU) 901-375-851-107

V22 BIT/BDU Module 901-375-857-101

2.7 Order of Precedence. In the event of conflict between the text of this specification and the references cited herein, the text of this document shall take precedence. However, nothing in this specification supersedes applicable laws and regulations unless a specific exemption has been obtained from the Government.

3.0 REQUIREMENTS

3.1 General Information and Coverage. The V-22 ETA shall be of the contractor's design except as otherwise specified and capable of performing its intended function in accordance with the operation and performance requirements within this document, and with no loss of capability of the current system. No loss of capability is intended to mean all measurements and data currently collected by the system will still be measured by the upgraded system. It is further intended that no shift of measured data shall occur as a result of this upgrade.

3.2 Definition. The contractor supplied ETA shall integrate with the existing computer, PLC, and DAQ to automatically, semi-automatically, and manually test all performance characteristics of the V-22 APU in accordance with the applicable technical manuals and references listed in Section 2.4 of this specification. The ETA shall integrate with the existing computer, PLC, and DAQ to successfully perform all data acquisition, processing, and control functions necessary to complete production overhaul tests. The existing system format and software functions shall be maintained throughout the project. The V-22 ETA shall utilize a contractor supplied CENCO brand or equivalent cradle and interface with the existing system with no loss of current capability. The ETA shall be designed for ease of maintenance, operation, and calibration.

3.3 Configuration and design. The V-22 ETA shall be designed for installation in the existing test cells 7, 8, 9, 10, 11, and 12 in the Test System of Building 137 at FRC East, MCAS, Cherry Point, NC. The system, as installed by the contractor, shall not be allowed any space outside the area of installation without prior Government approval.

NAVFAC Drawing No. 4253056 (Attachment 3) identifies the structural foundation plan of the existing test cell area. FRC East Drawing No. PE16208 2-2 (Attachment 2) identifies the layout of the existing test cells.

3.4 Permits. The contractor shall be responsible for obtaining all permits required for the scope of contractor supplied services. Examples of permits may include but are not limited to: hot work permits and North Carolina building permits. Permits requiring environmental consideration shall pass through the FRC East Environmental

Division office prior to application. The Government will direct the contractor in how to apply for and resolve any environmental items that arise. This direction shall not relieve the contractor of the financial responsibility of environmental permitting. Contractors shall comply with all federal, state, and local laws. The Government will supply Points of Contact (POCs) that can provide assistance in, obtaining the required permits. NOTE: all permits shall be the contractor’s responsibility. Permits for hot work shall be obtained by calling the fire department at (252)

466-2241.

3.5 Removal of Existing Equipment. The contractor shall be responsible for the removal of any equipment in test cells 7, 8, 9, 10, 11, and 12 required for the upgrade. The contractor shall be responsible for the safe and proper removal, disposal, and site restoration in the handling of hazardous materials. The contractor shall remove instrumentation and valves non-destructively. Construction debris shall be disposed of properly. The Government shall approve the disposal method of all equipment removed and reserves the right to retain any equipment or wiring for internal use.

3.6 V-22 APU ETA Characteristics. The V-22 ETA shall meet or exceed the following performance and physical characteristics. All technical wiring and existing system layout shall be the responsibility of the contractor.

Detailed drawings will not be provided by the Government as part of this solicitation unless specifically addressed in this specification.

3.6.1 Data Acquisition Interface. New wiring shall be installed on all contractor supplied components. No new wiring to the DAS is required as the contractor’s supplied ETA shall utilize the wiring used by the government’s current ETA. All current capability for testing other model APU’s shall be maintained in the all test cells as part of the upgrade. All new wiring shall include but not be limited to, connections, cables, and harnesses as required on the

ETA. All wiring shall be clearly identified at origin and termination. All cables and connections shall be made of material that can tolerate oil (MIL-L-23699), temperatures up to 130 degrees Fahrenheit, and fuel Jet Propellant

(JP5) exposure that is common to jet engine test cells. Wiring and cables shall be routed in a manner that allows maintenance and accessibility. All connections shall be made of corrosion inhibitive anti-electrolysis material.

3.6.2 Test Cell Instrumentation. No new instrumentation is required as part of this procurement. The contractor shall interface with existing instrumentation as required to meet the requirements of this specification.

3.6.3 Cradle. The contractor shall provide an engine cradle (Cenco brand or equivalent) with hoists and trolley. The engine cradle shall be complete assemblies with all hardware, connectors, connection plates, wiring etc.

required for ‘plug and play’ functional operation of the testing process for the V-22 APU. Interface wiring and associated diagnostics shall be the responsibility of the contractor. The cradles shall be ‘plug and play’ compatible with the current test cell configuration. Drawings of the current cradle configuration will be provided by the government to the successful vendor. The vendor shall modify the configuration to accommodate testing of the V22.

A drawing providing the specific touch points for handling the V-22 APU shall be provided by the government at award. A drawing providing required salient characteristics for cradle compatibility is provided as Attachment 1 for illustration purposes.

3.6.4 Hoist and Trolley Specifications. The hoist and trolley system provided as part of this contract shall comply with the following criteria:

3.6.4.1 Hoist configuration.

a. Each new hoist shall have a lift capacity of at least 2000 pounds.

b. Each new hoist shall have a duty cycle of H3 per ASME HST-1.

c. The hoist frames shall be made of cast, welded and/or machined steel.

d. Each new hoist shall be designed to withstand test loads of 131.25 percent of nameplate capacity for initial certification and annual re-certification per NAVFAC P-307.

e. Each new hoist shall utilize welded link load chain as the lifting medium.

f. Each new hoist shall be provided with an integral chain container.

g. Each new hoist shall be configured for at least 10 feet of lift.

h. Each new hoist shall have two (2) speeds and cannot be Variable Frequency Drive (VFD) controlled.

The low speed setting shall be configured for lifting and lowering at or below three (3) feet per minute.

The high speed setting shall be configured for lifting and lowering at or below eight (8) feet per minute.

i. Each new hoist shall have a mechanical load brake capable of stopping and holding the rated test load.

j. Each new hoist shall have a load limiting device.

k. Each new hoist shall have travel limit switches with adjustable chain stops for up and down travel.

l. Each new hoist shall have an adjustable hoist motor brake capable of stopping and holding the load.

m. Each new hoist shall be delivered with the following hoist brake information as applicable:

(1) Minimum and maximum spring length/torque setting

(2) Minimum and maximum air gap/plunger stroke

(3) Minimum brake lining thickness.

n. The motor brake shall be mounted so as to provide easy access for disassembly and adjustment. The brake assembly shall not be mounted between the motor and gear case.

o. The hoist hooks shall be made of un-plated forged alloy steel and equipped with a safety latch.

p. The hoist hooks shall be easily removable (welding prohibited) for periodic Non Destructive Inspection

(NDI) test performed by the Government.

q. The removable hoist hook(s) and retaining nut or eye pin (and swivel eye bar as applicable) shall pass

NDI by the Government in accordance with ASTM A275 prior to acceptance.

r. Each hoist pair shall have a common control pendent with a selector switch that allows hoists to be operated in tandem or individually.

s. The control pendent shall be fitted with functional emergency stop or on/off buttons that control a mainline contactor capable of stopping all power to the hoist and trolley units.

t. The pendant buttons shall be clearly labeled: UP, DOWN, FORWARD, REVERSE. The hoists and trolley units shall have corresponding labels.

u. Pendant length shall be such that the bottom of the control pendant is 30 to 42 inches above the finished floor when the engine carrier test bed is attached. The tread line is approximately 14 feet zero (0) inches above the finished floor.

v. The pendant cable shall have an integral strain relief.

3.6.4.2 The Trolley: (RJ Mack or equivalent)

a. Shall be compatible with the existing 3 ¼ inch patented track and end stops.

b. Shall have wheels made from machined steel (forged, rolled, or cast). Stamped steel or cast iron is prohibited.

c. Shall have safety lugs (drop stops) or a functionally equivalent feature on the trolley frame to prevent derailment in the event of wheel or axle failure.

d. Shall have bumpers to contact end stops.

e. Shall have dual collectors which match the existing Cleveland Tramrail SAFPWRBAR conductor bars.

f. Shall have an adjustable trolley brake that is easily accessible (not between the motor and gear case) for inspection and periodic disassembly.

g. Shall have a powered trolley with a maximum travel speed of 30 feet per minute. Trolled drive should be

Variable Frequency Drive (VFD) controlled, two (2) speed infinitely variable.

h. Shall be designed to carry two (2) 2000 pound or greater capacity hoists with their hooks centers located

24” apart.

i. Shall be a single trolley unit, linking two (2) separate trolley units to accomplish this purpose is prohibited.

3.6.4.3 The Assembled Hoist and Trolley Units:

a. Shall be equipped with a NEMA 1 control cabinet that includes a main line contactor.

b. Shall have a minimum 4 inches clearance from any permanently attached surrounding conduit, test cell doors or building structure when traveling.

c. Shall comply with requirements of NFPA 70, National Electric Code (2008 Edition).

d. Shall be installed and tested on FRC East’s monorail system prior to acceptance.

e. Shall include a welded master link (Crosby A-1343 or equivalent) between the eyebolt on the carrier and the hoist hooks.

3.6.5 Engine Test Cart. A contractor designed and supplied test cart shall be included as part of the upgrade.

The test cart shall be configured to contain all of the driveline components (APU, flywheel, water brake, etc) necessary for successfully testing the V-22 APU IAW the manuals listed in Section 2.4 of this specification.

Although the contractor will supply a CENCO or equivalent cradle, the test cart shall have the capability to interface into all of the existing like kind CENCO cradles in the structural system and interface with the current test cell coupling plate for instrumentation and parameter measurement. The contractor shall provide all of the necessary hardware, hoses, cables, and wiring required for the test carts. The contractor shall design the test cart so that all structural and transportation devices are integrated into the Test System. The contractor shall develop the test cart to allow access to parts commonly replaced during UUT testing (i.e. Clutch Cooling Valve, Oil Cooler, etc.), and for easy filling and draining of engine oil (MIL-L-23699). The contractor shall develop and provide wiring and instrumentation diagrams for the carrier coupling plates as part of the engineering documentation in Section 3.21 of this specification. The test cart shall be designed such that the assembly, with APU installed, shall not be susceptible to damage from resonance. The natural frequencies of the test cart, in ready-to-test form with APU installed, shall be below 50% of maximum APU rotor speed, and not within 25% of APU output shaft speed.

3.6.6 Electronic Control Unit (ECU) Interface. The government shall provide, as Government Furnished

Equipment (GFE), a V22 ECU for use with the contractor supplied V22 ETA. The provided ECU shall be interfaced with the ETA and existing test system to allow for UUT testing. The ECU interface shall allow UUT testing IAW the V22 Engine Manual called out in section 2.4 of this specification. The ECU interface shall also include a Built-In-Test (BIT) Display Unit (BDU). The BDU will be provided as GFE and shall be visible to the test cell operator so that they may view ECU fault codes. The ECU interface wiring shall be labeled at both ends as well as provide test points for troubleshooting.

3.6.7 Inertial and Static Loading System. The contractor will supply a loading system to meet the requirements of the manuals listed in Section 2.4 of this specification. In order to maintain parts interchangeability with the existing V-22 cart, the Flywheel, Flywheel Housing, and Friction Brake shall be Kahn Model 505-001-063 or equivalent. The Hydraulic Dynamometer (AKA Water Brake) shall be Kahn Model 101-080-022 or equivalent.

The Inertial loading, friction brake, and water brake assemblies shall be of the same manufacture, produced and delivered as an assembly to ensure correct fitment. The loading system shall be configured to mount to the APU using the APU gimbal and expansion pins, as it is installed in the aircraft. It shall also include all shafts, adaptors, and accessory equipment to accomplish installation and testing of the APU per its manuals. A spare set of shafts and adaptors (if required) connecting the APU to the ETA shall be provided.

3.6.8 Equipment and Special Parts for Test Measurements. Unless specifically identified as GFE the contractor shall be responsible for the design and production of all special parts, brackets, and equipment necessary to accomplish testing of the APU per its manuals listed in Section 2.4 of this specification. This includes, but is not limited to: APU output shaft, exhaust gas tailpipe and temperature sensor ring, and inlet temperature sensor brackets.

3.6.9 Water Brake Facility Services. In general each test cell is capable of water flow to two (2) independently controlled water brakes, but only one brake shall be used for testing of the V-22 APU. The water header system is capable of supplying ambient temperature water up to 22 gpm at 85 +/- 10 psig, per test cell. Control air pressure is approximately 90 +/- 10psig. If the contractor requires water, air, or any other facility services outside the range of the existing services available, he shall be responsible for providing said service.

3.6.10 Documentation of Existing System. Unless specifically addressed in this specification details of existing design configuration and system drawings will not be provided by the Government. The contractor shall determine all system wiring and documentation necessary to perform the contract. Drawings and Documents formed as a part of this procurement shall have government purpose rights.

3.7 Computer. The contractor shall use the existing test cell computer system to provide the upgrade. The contractor shall utilize the existing software for testing of the V22 APU. Existing operation, reporting, calibration, and data capabilities shall be maintained.

3.8 Computer System Software Characteristics. The V22 APU test systems shall use the existing computer system(s) to perform data acquisition, control, operation, display, and reporting of all the V22 UUTs. The existing system is LabVIEW based. The V22 testing shall be integrated with no loss of capability with the existing APUs.

All of the existing reporting structure and data capture capability shall be maintained with the upgraded systems.

3.8.1 Software. The contractor shall utilize the existing EngineTest software and V22 TPS for testing of the

V22 UUT. All of the current software capabilities shall be maintained with the upgraded system.

3.8.2 Calibration Software. The ETA shall not contain any hardware requiring calibration aside from the load cell required for UUT loading via the water brake. The new ETA shall utilize existing transducers, thermocouples, etc as required for UUT testing.

3.8.3 Engine Vibration Analysis System (EVAS). The Contractor shall provide engine vibration analysis capability in all 6 test cells. Vibration analysis capability shall include the use of Yanos Aerospace EngineTest

Vibration Analyzer software. The acquiring of vibration and sound data shall be accomplished through the use of a

National Instruments cDAQ based data acquisition allowing for use of up to 8 vibration or microphone channels with up to 2 speed channels. A microphone signal conditioner and microphone shall be included for all six (6) test cells.

The microphone shall have a frequency response of greater than 30 kHz and be capable of operating in an engine test environment with ambient temperatures up to 130 degrees Fahrenheit. The EVAS shall interface with the existing

CEC charge amplifiers as well as include any additional charge amplifiers needed for use of 8 vibration channels simultaneously. All necessary hardware and cabling required for the measurement, analysis, and recording or engine vibration and sound shall be included. All connections for vibration transducers and microphone shall run through the Cell Connection Panel (“Squash Plate”) and Engine Connection Panel. The Engine Test Vibration Software at a minimum shall include configuration profiles for the following UUTs

GTCP36-150

GTCP36-200

GTCP36-201

GTCP36-201C

GTCP95-2

GTCP95-3

GTCP95-10

T-62T-11

T-62T-27

T-62T-2B

T-62T-40-1

T-62T-40-7

T-62T-40-LC2

T-62T-46-2

MK IV APU (Part Number CR00305)

The Engine Test Vibration Software package shall exist as a stand-alone component, no loss of current capabilities shall occur. The contractor shall provide provisions to store large amounts of vibration data. This data shall include broadband vibrations, narrowband tracked vibrations, peak-hold data, etc. along with all time and frequency data.

This data shall be exportable to an Excel spreadsheet and sortable by date, work order number, engine serial number, engine type, etc. Within Excel there shall exist the capability to plot data. This capability shall include Time

Domain Plots, Frequency Domain Plots, Waterfall Plots, etc. This data shall not be stored on the primary hard disk of the Engine Test computer system. The addition of engine vibration analysis capabilities shall be turnkey and include all software, hardware, and cabling required in all 6 test cells.

3.9 Control Functions. The existing control functions shall be maintained as part of the upgraded system. No loss of current control capability shall occur.

3.10 Electrical. The upgraded system shall be furnished complete with all accessories such as, controls, relays, and switches pre-wired for operation upon connection to the main power source. To facilitate tracing of circuits, all control circuit wiring shall be identified by sequential alphanumeric markings that correspond to the schematic diagram. Labels shall be of a permanent design and shall be stamped or printed on a base material or covered with a clear shrink wrap material to facilitate durability within the test cell environment. Graphic symbols for logic diagrams shall be IAW applicable requirements of NEMA ICS-l. All electrical components shall conform to the requirements of NFPA No. 79, 423, or 70 as required.

3.10.1 System Voltage. The system upgrades shall be designed to operate from the local power source provided to each system of 225 Amp, 208/120 volt three (3) phase four (4) wire 60 hertz. All other voltages shall be derived from the system voltage.

3.10.2 Control Voltage. All system controls shall not exceed 120 volts.

3.10.3 Variations in System Voltage. The system shall be designed to fully operate within a plus or minus 10 percent variation in system voltage. The computer and PLC shall be connected to an Un-interruptible Power

Supply(s) (UPS), to allow for at least 15 minutes of safe operation and an orderly shutdown in case of primary power loss, with a minimum of 500 VA rating.

3.10.4 Line Conditioning/Voltage Transients. The system control package including all electronic devices and computers shall be capable of maintaining normal operations during voltage drops to 40 percent of rated value lasting up to 0.25 seconds (15 cycles) in duration.

3.10.5 Orderly Shutdown. An orderly shutdown of the system is required during periods where voltage conditions do not permit normal system operation. System and personnel protection shall be provided when an orderly shutdown occurs. After assuming a fail-safe mode, the system shall not re-start without operator action.

3.10.6 Main Electrical Disconnects. The contractor shall maintain the existing manually operated fusible disconnect switch or circuit breaker sized to carry the entire electrical load of the system. The main disconnect device is located inside Building 137 between the test cell doors and the control room doors, and meets the

Lockout/Tagout requirements of OSHA 29 CFR 1910.147, Control of Hazardous Energy.

3.10.7 Disconnect Switches. Automatically operated circuit-breaker-type disconnect switches shall be provided for any items upgraded by the contractor. Existing circuit breakers may be reused if appropriate for the size of the service required. All disconnect switches shall be lockable for tag-out OFF condition. The switches shall be heavy duty quick-make, quick-break, as applicable and meet the applicable requirements of NEMA KS-1.

Switches serving as motor-disconnect means shall be horsepower rated.

3.10.8 Emergency Stop Control. An emergency stop button which conforms to 29 CFR 1910 shall be maintained on the console and in existing locations. This button shall initiate an emergency cell shutdown when pressed by the operator. All power sources shall be removed from the UUT and test stand upon initiation of an emergency stop command in a controlled and safe manner. A second mushroom head emergency stop switch currently exists in series with the first switch and is located near the front of the test bed. A third mushroom head emergency stop switch is wired in series with other two and located at rear exit door of each test cell. All emergency stop switches shall perform the same functions and shall be maintained in their existing location.

3.10.9 Test Cell Warning Lights. The primary test cell computer currently controls the operation of test cell warning lights located above the front and rear test cell doors. This control shall be maintained during the upgrade of the V-22 test system. The lights shall operate to warn if an APU has been selected for testing and shall be off if no UUT has been selected.

3.11 Maintainability. System configuration and adjustment features shall be designed for easy access.

Instructions for disassembly, repairs, adjustment, and reassembly shall be concise and clearly defined. All wiring, plumbing, and functional components installed as part of the upgrade shall be located for maximum accessibility.

Modifications as part of this upgrade shall comply with current ergonomic and OSHA standards.

3.12 Environmental Conditions.

3.12.1 Noise Levels. Any new equipment shall not emit noise levels above 84 decibels as required by

OPNAVINST 5100.23.

3.12.2 Operating Environment. New equipment shall be capable of continuous, convenient, efficient, and safe operation in a normal factory environment, defined as ambient conditions of 50 to 140 degrees Fahrenheit, and 10 to

95 percent relative humidity, non-condensing.

3.13 Design and Construction. The upgraded components shall be new parts, free from defects. All upgraded components shall allow testing of the V22 APU to its maximum operating conditions without permanent damage to the upgraded system. Any components installed as part of the upgrade shall not result in any loss of capability of the existing system.

3.13.1 Workmanship. Workmanship shall be in accordance with standard commercial practices to ensure safety, proper and dependable operation, and service life. New components shall be constructed to produce a system free from all defects, which would adversely affect functioning of the equipment. Particular attention shall be given to thoroughness of assembly, alignment of parts, tightness of screws and bolts, marking of parts, protective finish, and removal of all burrs and sharp edges.

3.13.2 Welding, Brazing, or Soldering. Welding, brazing, and soldering shall be performed in accordance with standard commercial practice and employed where these operations are required in the design. Permits are required for hot work. Permits for hot work should be obtained by calling the fire department at (252) 466-2241.

3.13.3 Fastening Devices. All screws, pins, bolts, and other fasteners shall be installed in a manner to prevent change of tightness. Fastening devices subject to removal or adjustment shall not be swaged, peened, staked, or otherwise permanently installed.

3.13.4 Threads. All threaded parts used on the machine and its related attachments, and accessories shall conform to FED-STD-H28.

3.13.5 Painting. The equipment shall be painted. Painting shall be in accordance with the manufacturer's standard commercial practice. Painting shall result in a highly wear-resistant finish designed to provide continued protection in the test cell and shop environment under all service conditions. Color shall replicate existing equipment colors in the work area.

3.14 Mercury Restriction. The use of mercury, mercury compounds, or mercury bearing instruments on or in the system is prohibited.

3.15 Asbestos Restriction. Asbestos and materials containing asbestos shall not be used on or in the system.

3.16 Poly Chlorinated Biphenyls (PCB) Restriction. Components or materials containing PCB shall not be used in the construction of the system.

3.17 Electromagnetic Radiation. Controllers and other electronic control components including wiring assemblies, shall comply with Federal Communications Commission (FCC) Regulations, Part 18, and Subparts A through C. Conducted and radiated electromagnetic interference shall be suppressed so as to not affect the normal operation of other adjacent items of electrical equipment. Non-magnetic materials shall be employed where necessary to assure no interference with facility or equipment operations.

3.18 Measurement Systems. The US Customary System of Units (US) shall be used in the design and construction of the system. In this specification, all measurements, dimensions, sizes, and capacities are given in the

US system. All measuring and indicating devices on the system shall be graduated to display the units referenced in the technical documentation for the V22 APU.

3.19 Safety. The equipment shall be equipped with safety devices such as covers and guards for hazardous mechanical and electrical components, safety interlocks, and safety warning devices. Safety devices shall be designed to protect personnel and equipment in accordance with OSHA standards 29 CFR 1910 and 29 CFR 1926, construction, and electrical standards specified herein. The equipment shall comply with OSHA standards 29 CFR

1910. Other safety devices shall be provided as specified in other paragraphs of this specification.

3.20 RESERVED

3.21 Documentation and Deliverables. Documentation and deliverables shall be provided by the contractor as part of the installation. All updated drawings, or new drawings, shall be in the format of STEP/IGES for 3 dimensional and DWG and DXF for 2 dimensional drawings. The contractor shall be responsible for generating new documents associated with the test upgrade, or to create an update to existing documentation that complies with the requirements of this section. All documentation created as a part of this contract shall have government purpose rights. All text documents shall be in an editable MS Word format and an editable Portable Document Format (.pdf).

Drawings shall be delivered in (.dwg and .dxf) format as well as in Portable Document Format (.pdf) . All documentation shall be delivered with three (3) hard copies and one (1) copy on CD/ DVD.

3.21.1 Data Rights.

3.21.1.1 The Government specific purpose rights shall be provided to technical data, software, and drawings. The

Government requires rights to the technical data, software, and drawings that allow it to maintain and upgrade the items throughout the planned lifecycle. In addition, the Government’s license to the technical data rights, license, and drawings will allow future competitive procurement of replacements and upgrades. When an upgrade or re-procurement is contemplated, the Government will have the right to provide drawings, software code and technical data to vendors who have signed a non-disclosure agreement allowing use of the data, code, and drawings only to create a competitive procurement package. The technical data, software, and drawings will not be used to award a sole source contract to a competitor. These data rights shall pertain to all documentation and drawings pertaining to the system to be acquired through this procurement.

3.21.1.2 No data, materials, information or other items (hereinafter singularly or collectively "Items") created or provided expressly for this purchase description/specification shall be used by the Contractor for any purpose other than those that are in support of, or for performance under, this purchase description/specification without the prior written permission of the Contracting Officer. The Contractor is obligated to protect from unauthorized use or disclosure all Government confidential or classified material and/or Government-owned proprietary, and/or

Personally Identifiable Information or Personal Privacy, Items obtained in the course of performance under the

Government contract, as long as such Items remain proprietary, confidential, sensitive or classified. Any information obtained in the course of duties, or the performance of services, under this contract including, but not limited to, information that may be made available for use that relates to the technical data, trade secrets, processes, operations, style of work, or apparatus, or to the technical data, statistical data, amount or source of any income, profits, losses, or expenditures of any person, firm, partnership, corporation, or association is included in this clause (and with

Items). Contract personnel shall not publish, divulge, disclose, or make known Items in any manner, or to any extent not authorized by the Contract without first receiving the written permission of the Contracting Officer. When the

Contractor's need for such Items ends (including all database or GFI/GFE/GFM items), the Items shall be returned promptly (within 10 business days) to the appropriate Government program personnel. However, the obligation not to discuss, disclose, release, reproduce or otherwise provide or make available such Items, or any portion thereof, shall continue, even after completion of this contract/order. Any actual or suspected unauthorized use, disclosure, release, or reproduction of any Items or violation of this agreement, of which the company or any employee is or may become aware, will be reported promptly (within one business day) to the Contractor's program manager, who will inform the Contracting Officer within 5 business days of receiving such report.

3.21.2 Engineering Documentation. The contractor shall provide complete drawings of the ETA and EVAS, including a Block Diagram, Signal Flow Diagram, Pneumatic Flow Diagram, Physical System layout, Hydraulic

Schematics, Pneumatic Schematics, Electrical/Electronic Schematics, and Mechanical Drawings. All diagrams shall be cross-referenced to each other, and include component, identity, locations, and I/O channels entry points. The document shall further break down the system diagrams into component schematics, I/O channel signals, power distribution, and wiring connections. Wiring tables shall be provided for all plugs, jacks, and terminal boards with their associated signal designation. The document shall provide a list of all switches, relays, indicators, valves, and controls and how it relates to the above diagrams and their locations. Supplemental manuals or copies shall be provided during training on the materials presented to demonstrate how to use the manual to perform signal tracing on the system. The contractor shall provide one (1) electronic copy of all drawings and three (3) hard copies. The drawings shall provide detailed materials and design specifications used in the manufacture of the ETA and installation of the EVAS.