Statement_of_Work.pdf

Statement of Work/Specification for

Whirl Tower Motor

1.0 SCOPE: This specification defines the government’s requirements for the design, manufacture and installation of a new direct current motor system that will replace the existing 2350 horsepower direct current shunt-wound motor system located at the Helicopter Blade Test Facility, Fleet

Readiness Center East, Cherry Point, NC. The motor system shall consist of a direct current shunt-wound motor with personnel catwalk, armature bearing lubrication system, an external forced air ventilation system and a ground to motor base stairway.

2.0 APPLICABLE DOCUMENTS

2.1 General: The documents listed in this section are referenced in Sections 3 and 4 of this specification.

This section does not include documents cited in other sections of this specification or recommended for additional information or as examples. While every effort has been made to ensure the completeness of this list, document users are cautioned that they must meet all specified requirement documents cited in Sections 3 and 4 of this specification, whether or not they are listed.

2.2 Government Documents: The documents listed below form part of this specification and the contractor shall comply with all applicable sections. The documents are referred to in the text by basic designation only.

2.2.1 FLEET READINESS INSTRUCTION (FRCEASTINST)

FRCEASTINST 5090.1 – Environmental Compliance

FRC EAST 5090/20 - Maintenance Contractor Hazardous Material Inventory

FRC East Instruction 5000.1B, Enclosure 1 – Contract Performance Requirements

2.2.2 Code of Federal Regulations (CFR)

29 CFR 1910 Subpart S Occupational Safety and Health Standards

Electrical 29 CFR 1926 Safety and Health Regulations for Construction

29 CFR Part 1910.23 Subpart D Occupational Safety and Health Standards-

Walking and Working Surfaces

2.3 Non-Government Documents. The documents listed below form part of this specification and the contractor shall comply with all applicable sections. The documents are referred to in the text by basic designation only.

National Electrical Manufacturer’s Association (NEMA)

NEMA MG 1 (1993; Rev. 1 – 4) Motors and Generators

NEMA MG 2 (1989) Safety Standard for Construction and Guide for

Selection, Installation, and Use of Electric Motors and

Generators

National Fire Protection Association (NFPA)

NFPA 70 (1999) National Electrical Code

2.4 Order of Precedence: In the event of conflict between the text of this specification and the references cited herein, the text of this specification shall take precedence. Nothing in this specification, however, shall supersede applicable laws and regulations unless exemption has been obtained.

3.0 REQUIREMENTS

3.1 General Information.

3.1.1 Design and Construction

3.1.1.1 Dimensions: Many of the new motor’s physical dimensions must match those of the old motor to ensure the installation of the new motor will not require modifications to: (a) the motor foundation,

(b) the surrounding catwalk and platform, (c) the helicopter blade pitch control system, (d) the blade elevator, (e) the slip ring assembly attached to the bottom of the motor shaft and, (f) the extension shaft that bolts onto the top of the motor shaft. The General Electric Co., Sikorsky Aircraft Co., and

Naval Facilities Engineering Command drawings listed in section 2.3 of this specification depict the dimensional requirements that the new motor installation shall conform to.

3.1.1.2 Drive: The existing Rockwell Automation 12-pulse solid state drive system will power the new motor.

3.1.1.3 Motor Cabling: The existing armature and field cables from the Rockwell Automation. 12-pulse solid state drive to the motor shall be reused. The armature circuit has six, 750 kcmil, RHH, 90°C cables per pole (12 cables total). The field circuit has one, #4 AWG, THHN, 90°C cable per pole (2 cables total).

3.1.1.4 External Forces: During helicopter blade balancing, the blades exert an upward thrust of approximately 12 pounds per horsepower, therefore an upward force as high as 43,200 pounds is possible based on the 3600 horsepower one-minute rating of the motor. Lateral supports are attached to the motor feet in the event of the loss of a helicopter blade during balancing. These lateral supports are designed for 55,000 pounds of restraining force and the designed maximum tilting moment exerted on the base is 706,000 foot-pounds.

3.1.1.5 Current Production Material: The direct current shunt motor system shall be new and use the latest state of the art design. It shall be a current production design using proven design concepts and equipment that have performed satisfactorily under actual operating conditions by government or private industry. Products and materials such as prototypes, pre-production models or experimental units are not permissible. Modifications of existing (standard) designs are permissible as far as accessories or other minor features are concerned, provided the system, as modified meets all performance requirements.

3.2 Performance Requirements

3.2.1 Direct Current Shunt Motor Rating Requirements

3.2.2 Continuous Horsepower. The minimum accepted continuous horsepower rating is 2160, but preference will be given to horsepower ratings in excess of the minimum.

3.2.3 Overload Capability. The one-minute horsepower rating of the motor shall be at least 150% of the continuous horsepower rating of the motor.

3.2.4 Speed. The base speed rating of the motor shall be 150 revolutions per minute. The top (field weakened) speed rating of the motor shall be 380 revolutions per minute minimum.

3.2.5 Armature Voltage. The armature voltage rating of the motor shall be 600 Vdc.

3.2.6 Armature Current. The existing Rockwell Automation 12-pulse solid state drive can supply 3200 amps continuous and 4100 amps for one minute.

3.2.7 Shunt Field Voltage. The shunt field voltage rating of the motor shall be 200 Vdc maximum.

3.2.8 Shunt Field Current. The shunt field current rating of the motor shall not exceed 60 Adc.

3.2.9 Rotation. The motor rotation shall be reversible.

3.2.10 Temperature Rise. The observable temperature rise under rated load conditions of each of the various parts of the motor, above the temperature of the cooling air, shall not exceed the values given in paragraph 23.40 of NEMA MG 1 for General Industrial Service, Semi-enclosed, Insulation Class F motors.

3.2.11 Vibration Limits. The maximum allowable vibration during pre-shipment testing shall be in accordance with NEMA MG 1-1993, Revision 1, Part 7 General Standards Applying to All

Machines, Mechanical Vibration- Measurement, Evaluation and Limits.

3.2.12 Reliability. A mean time between failure (MTBF) of 30,000 hours is required. Preference shall be given to those with a higher MTBF. MTBF data provided shall include, but not be limited to, information for the armature brushes and bearings. A life expectancy of 30 years without failure is required with routine maintenance. Preference shall be given to those with higher life expectancies.

3.2.13 Critical Speeds: The natural frequency of the motor armature shall be outside a 20% margin from the normal operating speed range of 150 to 380 revolutions per minute. In addition, the natural frequency of the armature, motor casing and other supporting structures shall be outside a 20% margin from the 3x, 6x and 9x rotating speed to ensure there is no excitation resulting from the aerodynamic blade pass forcing function and its lower multiples. During blade testing on the current GE motor, motor bearing vibration predominately occurs at the blade pass frequency and its lower multiples due to the large amounts of aerodynamic energy occurring at these frequencies. Where these natural frequencies are unavoidable, damping shall be sufficient to limit spectral vibration levels to within acceptable limits. During the design stages of this project, the contractor shall demonstrate to the government, the design strategy regarding operating speeds and resonant frequencies that may exist.

3.2.14 Efficiency: The motor efficiency shall not be less than 90% as defined by NEMA MG1, Part 2.

3.2.15 Speed Limit Switch: The motor shall contain a double acting speed limiting switch that will activate at a preset motor speed in either the forward or reverse direction. This signal is monitored by the Rockwell Automation 12-pulse solid state drive system.

3.2.16 Winding Temperature Measurements: Temperature measurement devices, such as thermocouples, shall be provided for measuring the internal temperature of the motor during operation. The contractor shall identify acceptable temperature operating limits for these measurements.

3.2.17 Brush Rigging Access: Openings shall be provided to allow adequate access to the brushes, brush rigging, and commutator to perform regularly scheduled maintenance and inspections.

These openings shall be provided with covers that seal to prevent moisture from entering the motor through the access openings.

3.2.18 DC Motor Physical Characteristics: Referring to General Electric drawing 757E386, the new motor shall match the following critical physical characteristics of the existing motor:

a. Distance from bottom of lower pads to flange on top of shaft: 10’9 3/4”.

b. Location and size of lower pad lateral support and vertical support holes.

c. Motor shaft top flange inside radius, outside radius, bolt holes’ size and locations.

d. Vertical dimension from lower pad, radial dimension from motor centerline, quantity and size of hole in upper end bracket for mounting of upper deck plate.

e. Four-inch diameter hole through shaft.

f. Bottom flange of shaft where slip ring assembly attaches.

g. Diameter of stator extending below lower pads must be a maximum of 7’.

h. 180 tooth, 10 pitch gear for driving shaft speed encoder and associated mounting brackets.

i. Vertical and angular location of terminals for field and armature conductor connections.

3.2.19 Motor Base Seal: The contractor shall install airtight and watertight sealing between the motor base and motor foundation.

3.2.20 DC Motor Enclosure: The motor shall be furnished with a weather-protected enclosure. The motor shall be ventilated by an external forced air ventilation system. The air inlet shall be via the existing duct in the motor foundation and up through openings in the bottom (foundation end) of the motor. The upper shaft and the upper end bracket shall be sealed to prevent water from draining into the top of the motor.

3.2.20.1 DC Motor Cooling System Requirements. An external filtered forced air ventilation system shall be provided for the motor. Air filters shall be replaceable. The ventilation system characteristics shall be determined by the contractor and subject to government approval. The government will provide a point of connection of 480 V, 60 hertz, three phase, to power the blower motor for the ventilation system. The inlet shall be sized to fit the existing air duct opening in the motor foundation. Naval Facilities Engineering Command drawing numbers 1107412 and 1107414 show the dimensions and orientation of the air duct. The ventilation system shall be provided with an airflow switch that will be routed to the Rockwell Automation 12-pulse solid state drive system for permissive control and warning indication.

3.2.21 DC Motor Bearing Lubrication Requirements Bearing lubrication systems shall be provided that supply oil flow to the upper and lower armature bearings at the required temperature and pressure. These systems shall contain all necessary heating elements, temperature sensors, and control elements to maintain the oil supply within the required operating envelope. The bearing lubrication systems shall also provide low/high pressure signals, low/high temperature signals, and low oil reservoir level signals that will be routed to the Rockwell Automation 12- pulse solid state drive system for permissive control and warning indications. The oil supplies shall be located either in the motor pit or outside provided their components are suitable for outdoor applications. The contractor shall determine the location of these systems subject to government approval at the design review.

3.2.22 DC Motor Bearing Vibration Requirements. The motor shall be equipped with a minimum of three each ICP accelerometers for monitoring bearing vibration levels. Two of the accelerometers shall be mounted near the lower bearing for monitoring levels in the radial and axial directions while the third transducer shall be mounted in the radial direction on the upper bearing. The transducers and associated cabling shall terminate in a NEMA 4X junction box with BNC type connectors for interface to Government Furnished Equipment (GFE) vibration analyzers. The junction box shall be provided with minimum of three additional BNC connectors for future use. Component locations shall be subject to government approval during the design review.

3.2.23 Magnetic Pickup Bolt. The contractor shall drill and tap in the mounting flange to accommodate the magnetic pickup bolt. The size and location of the holes (2) shall conform to the size and location of the holes in the existing motor flange. Locations subject to government approval during design review.

3.2.24 Workplace Safety Provisions. The contractor shall provide a metal stairway from ground level to the top of the concrete motor base, and a catwalk, guard rail, and stairway that is attached to the motor for maintenance personnel to stand on to periodically inspect the motor brushes and perform preventative maintenance procedures. The ground level to motor base stairway shall be attached to the concrete ground level surface and the motor base. These provisions shall be in accordance with 29 CFR Part 1910.23 Subpart D, Occupational Safety and Health Standards- Walking and Working Surfaces.

3.3 Nameplate. The motor shall be provided with an attached nameplate. The nameplate information shall be marked per part 23.60 of NEMA MG 1. The nameplate shall also include the manufacturer’s name and serial number.

3.4 Lifting Means. The motor shall have provisions for lifting the motor as per paragraph 2.3 of

NEMA MG 2 and be able to be lifted from overhead by large truck crane.

3.5 Installation.

3.5.1 Government Removal and Installation of Ancillary Equipment. Naval Aviation

Depot personnel will remove the rotor head assembly, the pitch control mechanism, deck and baffle assembly prior to contractor arrival. The contractor shall remove the old motor and ventilation system and protect this equipment from rain damage for the duration of the contract.

The contractor shall perform the initial installation of the new motor and coordinate with

Reliance Electric Co. personnel for the setup of the Rockwell Automation 12-pulse solid state drive system and successful performance of a no-load test. After the completion of a no-load test, NADEP personnel will require ten (10) working days to reinstall and align the deck and baffle assembly, pitch control system, and the rotor head assembly. Contractor shall commence final acceptance test within two days of notification that the government reinstallation is complete.

3.5.2 Equipment Installation. The contractor shall disconnect the existing motor's electrical connections and mechanical supports and then shall remove the existing motor and ancillary equipment. The contractor shall be responsible for installation of the new motor system and ancillary equipment making all the required mechanical and electrical connections. After successfully installing the new motor and initial setup of the Rockwell Automation 12-pulse solid state drive system, a no-load test will be performed to confirm proper operation. The contractor shall be responsible for obtaining the services of Rockwell Automation on-site field service representatives to adjust, modify, and set up the various drive parameters necessary to adapt the existing Rockwell Automation 12-pulse solid state drive system to the new motor.

These services shall include entering a new field weakening curve schedule for motor speeds above base speed and ensuring all motor sensors are integrated into the Rockwell Automation

12-pulse solid state drive system permissive, interlock, and monitoring functions. The contractor shall prepare an installation plan (CDRL A003) that shall be submitted and approved by the government during the design review.

3.6 Equipment Disposal. The contractor shall be responsible for disposing of all material disconnected or removed from the Whirl tower work site. Equipment shall be retained and weather protected at the work site until final acceptance of the new motor acceptance. Contractor shall dispose of material outside of the Marine Corps Air Station Cherry Point and no later than upon completion of installation. Equipment disposal shall be in accordance with all environmental and hazardous waste disposal regulations. The lubricant oil in the existing motor is Mobil DTE 26. The Material Safety

Data Bulletin for this product is provided as Attachment 12 to Section J.

3.7 Standard Commercial Warranty The contractor shall provide the government with their standard commercial warranty for the new motor. A copy of the standard commercial warranty shall be provided with the offeror’s proposal for evaluation. The desired services to be provided by the standard commercial warranty is that a qualified factory maintenance representative be on-site within

24 hours of the contractor being notified of a warranty problem by the Naval Aviation Depot and an one year warranty on all parts and labor. In addition, it is desired that the warranty service include rapid factory response in obtaining spare parts that may be required for corrective warranty. Also, the contractor shall be able to provide all corrective maintenance parts not covered by the warranty agreement to the government. The corrective maintenance parts not covered by the standard commercial warranty will be procured under a separate purchase action.

3.8 Castings and Forging: All castings shall be new, free from blowholes, porosity, hard spots, shrinkage defects, cracks, and other defects. Forging shall be free from scale, inclusions, cold shuts, mismatching, and other defects. Strength and other essential properties of the castings, forging shall be adequate to meet the performance requirements specified herein.

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

3.10 Measurement systems: The U.S. Customary System of Units (US) or the International System of Units

(SI) shall be used in the design and construction of the test stand. In this specification, all measurements, dimensions, sizes and capacities are given in the U.S. System.

3.10.1 Electromagnetic Radiation: Conducted and radiated electromagnetic interference shall be suppressed so normal operation of the machine and other adjacent electrical equipment shall not be affected. Non-magnetic materials shall be employed where necessary to assure no interference with facility or equipment operations.

3.10.2 Nameplates and Product Markings: All words on instruction, indicating and name plates shall be in the English language. Characters shall be permanently applied, in boldface, on a contrasting background. The plates shall be made of corrosion resistant metal.

3.10.2.1 Identification Marking of Military Property: The motor shall be identified as per DFAR 252.211-

7003, MIL-STD-130, and all applicable documents within the standard, with Machine Readable

Information (MRI) for item identification marking and automatic data capture. The application of

Human Readable Information (HRI) shall be used in combination with MRI and free text.

3.10.3 Safety: Covers, guards, and other safety devices shall be provided for all components of the test stand that present potential safety hazards. The safety devices shall not interfere with operation of the test stand. The safety devices shall prevent unintentional contact with the guarded component and shall be removable to facilitate inspection, maintenance and repair. The contractor shall follow all applicable safety and health guidelines described in US Army Corps of Engineers Safety and

Health Requirements Manual (EM 385-1-1).

3.10.3.1 Fail-Safe Operation: All energy sources shall be designed for fail-safe operation and shall be appropriately guarded, insulated, isolated, shielded, or grounded for safe operation.

3.10.3.2 Human Engineering: All operating controls shall be located convenient to the operator at their normal workstation. The test stand shall be designed and manufactured to minimize the possibility of human error and injury (i.e. back injury) and to ensure human/machine compatibility.

3.10.3.3 Lockout/Tagout: A disconnect for lockout/tagout shall be provided for all energy sources on the motor. The lockout/tagout points shall isolate all energy sources in the machine. Any residual energy shall be able to be bled off. The contractor shall provide a written Lockout/Tagout procedure as described in Section 3.11.13.

3.10.3.4 Noise Restriction: Noise transmitted from the equipment furnished shall not exceed 84 db at the source in accordance with OPNAVINST 5100.23G.

3.10.3.5 Asbestos Restriction: Asbestos and materials containing asbestos shall not be used on or in the test stand.

3.10.3.6 PCB Restriction: Equipment or materials containing polychlorinated biphenyl (PCB) shall not be used in the test stand.

3.10.3.7 ODS Restriction: Equipment or material containing Class 1 Ozone Depleting Substances (ODS) shall not be used except when approved by the Navy Senior Acquisition Executive, Assistant

Secretary of the Navy For Research, Development, and Acquisition.

3.11 Documentation Deliverables: Appropriate technical documentation shall be provided by the contractor to support the motor. The contractor shall deliver documentation in accordance with the requirements listed below. All documentation shall be delivered with three (3) hard copies and one

(1) copy on CD/DVD. Digital copies of documentation shall be delivered as an editable MS Word document and as an editable Portable Document Format (.pdf).

3.11.1 Acceptance Test Plan: The contractor shall provide plans for performance of acceptance testing as described in Section 4.2. Pre-shipment Acceptance test to be conducted at the contractor’s facility, and a Final Acceptance Test Plan to be conducted at FRC East. The Acceptance Test Plan shall be submitted within thirty (30) calendar days prior to the start of Final Acceptance Testing

(FAT). The plan will be reviewed, revised by the contractor as necessary, and approved by the

Government prior to acceptance testing.

3.11.2 Plan of Action & Milestones: The Contractor shall provide a Plan of Action & Milestones

(POA&M) report to identify Contractor performance dates of all major events from contract award to completion of contract requirements. The report will be reviewed by the Government. The milestones shall be prepared using Microsoft Project. The initial report shall be submitted with the contractor’s proposal. A final report shall be submitted within thirty (30) calendar days after date of contract award. The Government and the Contractor shall review the report periodically on an as-needed basis until Final Acceptance has been accomplished. Any changes to the final approved

POA&M must be approved in advance by the Government to ensure adherence to contractual milestones. The POA&M shall detail such items as system design concept, software design concept, software development, engineering, procurement of major hardware, assembly, operational debug, factory acceptance, shipment, installation, and site acceptance test.

3.11.3 Data and Manuals: The Contractor shall provide technical manuals and schematics describing all the components of the specified equipment delivered to the Government no less than thirty (30) days prior to delivery of the motor. All technical data furnished shall be written in the English language. Documentation shall include at a minimum, Operations, Installation, Maintenance, Calibration Procedure, Preventive Maintenance, Lockout/Tag out Procedures, Illustrated Parts

Break Down, Recommended Spare Parts List, Vendors Literature, Mechanical Design Drawings, Pneumatic Schematics, and Electrical/Electronic Schematics.

3.11.4 Operators Manual (OM): The contractor shall provide an Operators Manual that describes Step-by- Step everything needed to load and test a Whirl tower motor on the contractor provided motor.

The OM shall identify all controls and indications required to operate the system. The OM shall provide in detail how to set-up, install, and test all starter models. Contractor format is acceptable upon review by the government. The preliminary OM shall be delivered thirty (30) calendar days prior to (JDR). The (OM) must be approved prior to the start of FAT and be in final format. The government may request minor change to this manual for areas that are discovered during FAT.

3.11.5 Calibration Procedure: The contractor shall provide specific instructions describing full calibration of the test stand. Calibration procedures for each component requiring calibration or verification shall be included in the manuals. The contractor shall work in conjunction with FRC

East, Navy Primary Standards Laboratory (NPSL) San Diego, Naval Science Department (Corona

Division), or other appropriate Government activity to produce an Instrument Calibration

Procedure (ICP) for the test stand, written in standard NAVAIR 17-20 format as specified in

NAVAIR 17-35TR-04 (available from FRC East upon request). All calibrated systems shall have certificate of calibration traceable to the National Institute of Standards and Technology (NIST).

Preliminary calibration procedure is due at JDR. Final version due thirty (30) days prior to start in installation.

3.11.6 Engineering Documentation: The contractor shall provide complete drawings/schematics of the

Whirl tower motor, including a Block Diagram, Signal Flow Diagram, Pneumatic Flow Diagram, Physical System layout, Hydraulic Schematics, Pneumatic Schematics, Electrical/Electronic

Schematics, and Mechanical Schematics. 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 drawings shall provide detailed materials and design specifications used in the manufacture and installation of the Whirl tower motor. All manufactured components required for testing, shall have a set of complete specifications and must contain all detailed information required to manufacture the components. Within each drawing there shall be the Drawing Number, Part

Number, and Bill of Materials (BOM). All views required to manufacture the component, material, current revision of the drawing, and finish requirements (if none required, state “No finish required”). The contractor shall apply ASME Y14.100-2013 “Engineering Drawing Practices” drawing standards. Engineering Documentation shall be delivered thirty (30) calendar days prior to JDR.

3.11.7 Provisioning Technical Documentation: The contractor shall provide Provisioning Technical

Documentation for the Upgrade. This document shall show all replaceable parts in the systems, their location, and part number or vendor for part replacement. It shall also list frequently consumed and long lead-time parts that should be maintained for un-interrupted system use. All parts and components shall be identified and referenced back to Engineering Documentation for location and signal flow. The first submission shall be fifteen (15) days prior to the joint design review. The contractor shall provide a listing of separately priced critical spare parts (i.e. those parts which would adversely affect the capability to test electric starters). The final submission shall be approved by the government no later than ten (10) calendar days before final acceptance testing.

3.11.8 Maintenance Manuals: The contractor shall provide maintenance manuals. The maintenance manuals shall include information on diagnostic, periodic, and preventive maintenance of the test facility. This shall include pre-operational checks, critical voltage checks for the data acquisition system power supplies, data base checks, and hard drive storage space. Supplemental manuals or copies of this manual shall be provided during training on the materials presented to demonstrate how to use the manual to perform maintenance on the system. The preliminary Manual shall be due at the JDR. The final manual shall be due at FAT.

3.11.9 Detail Design Description: The contractor shall include a Detail Design Description (DDD) as part of the system hardware design documentation. The DDD shall summarize and then describe in detail the design, function, and operation of the system starting from the system, major subsystems, assemblies and components work individually and interface together to accomplish the requirements of the system. The DDD shall include the inputs requirements for each component or subsystem such electrical power or pneumatic conditions and their limits. It shall also list the outputs of each component and subsystem and the conditions and limits of an acceptable output.

The DDD shall describe the conditions, descriptions, and requirements for all indicators, switches, controls, relays, and alarms in the System. The DDD description shall identify all components with system-wide designation traceable to the Engineering Documentation. Contractor suggested format is acceptable upon government approval. The DDD shall be supplied to the Government as part of the data submission for the JDR, at least thirty (30) calendar days prior to the JDR. Final delivery of the DDD shall be approved prior to the start of FAT.

3.11.10 Version Description Documentation (VDD): The Contractor shall record, list, describe all software changes made, software defect or symptoms, and the files changed, starting from the day of installation of the system at FRC-E Cherry Point. The version of each software application shall be controlled and clearly identified on the system. Revisions of the software shall be updated for each change in the VDD and on the system. The VDD shall be made available to the government monthly, starting from the installation of the Upgrade. The final delivery will be at the end of

Acceptance testing.

3.11.11 Software Application Manual: The contractor shall provide complete documentation of the test application software. The documentation shall include instructional background information on the software(s), how to use it, troubleshoot it, operate it, and install it as well as installation media

(CD). Reference information including command manual, error messages, program calls, quick reference guide, software tools manual, and utilities shall also be provided. This document covers all software, firmware, and configurable items, components, or devices in the system. It shall provide all configurations as delivered, including version, or default values. It shall describe how to test all software configurable items for as delivered. It shall describe how to add new UUTs to the test application, modify test parameters, delete test parameters, and add test parameters. It shall describe how to modify Alarm parameters. The document shall have a description on how to back up the system totally or selectively listed critical files required for system operation. It shall describe how to perform administrative functions, User passwords, configuration control, etc. It shall describe how to add, modify, or delete Input / Output channels. It shall describe how the software communicates with other system components, drives, transducers, databases, reports, LAN, serial, parallel, USB, etc. The document shall have a list of all known developed errors messages and alarms and what it took to create them. It shall provide details on all software installed on the computer and its purpose. The documentation shall include system startup, login, operation, shutdown, and error recovery procedures. All configurable items outside of the LabVIEW shall be described as to how to program. The document shall describe all limitations of the software or configurable items. The first submission shall be delivered sixty (60) calendar days before final acceptance testing. The final submission must be approved by the government prior to final acceptance testing.

3.11.12 Site Preparation and Installation Plan. The contractor shall provide a clear and concise site preparation and installation plan. Facilities preparation instructions shall be provided to the government 60 days prior to preliminary acceptance testing and shall be approved by the government prior to preliminary acceptance. The plan shall include a detailed description of all installation work, a detailed site layout, general equipment specification (i.e. size, weight, etc.), any required structural modification or additions, utility requirements and location, pertinent electrical details, and any other details required for site preparation and layout. As part of the site preparation and installation plan the contractor shall include facilities preparation instructions. The preliminary draft of the plan shall be delivered to the Government at the Joint Design Review. The final site preparation plan shall be submitted at least 60 days prior to installation. Contractor format is acceptable upon Government approval. The contractor shall provide, with the Site Preparation and

Installation Plan, detailed information concerning any equipment that applies a load to a facility structure, wall or roof. If use of a crane or rigging is part of the contractor's Installation Plan, the contractor shall have the Installation Plan reviewed and certified / stamped by a Professional

Engineer (PE). Prior to submission to the government, if the use of crane or rigging is part of the

Installation Plan, the contractor shall contact the Fleet Readiness Center - East Weight Handling

Certifying Official providing the PE certified Installation Plan to the Weight Handling Certifying

Official in order to ensure that the plan is accurate, complete, and approved. The contractor shall submit information for approval to the Government in accordance with the contractor submitted and Government approved POA&M (Paragraph 3.5.2).

3.11.13 The Control of Hazardous Energy (Lockout/Tagout): A written procedure for locking out all energy sources as per Section 3.10.3.3 shall be provided in accordance with 29 CFR 1910.147. The written procedure shall be included in the equipment manuals. Preliminary version due at JDR.

Final version due fourteen (14) days prior to start of installation.

3.11.14 Data Rights: 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.

3.11.14.1 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.

3.12 Warranty: The contractor shall warrant all equipment, systems, components, etc. to be provided hereunder for a minimum period of one (1) year to begin upon the government’s final acceptance of the product. The warranty shall cover all parts, labor, and travel expenses related to the warranty repair/support.

3.12.1 The contractor shall contact the Government at least 30 calendar days prior to delivery of the equipment to confirm the training schedule, which shall be included in the contractor’s POA&M.

3.13 Installation and Delivery: Installation and Final Acceptance Testing (FAT) of the Whirl Tower

Motor shall be completed within 30 calendar days from delivery of the system hardware (56 weeks after contract award). Installation shall be conducted during the FRC East’s normal working hours of 7:00 am to 3:30 pm (EST), Monday thru Friday unless authorization to work outside of normal working hours is requested by the contractor and approved in advance by the Government. Downtime as a result of the work to be performed shall be approved by the Government. Downtime shall be kept to a minimum. Contractor shall complete all contract requirements within 60 weeks after receipt of award.

3.13.1 Government Responsibilities: Government will provide the following utilities with 100 feet of the installation site: 120/208 and 277/480 VAC; three (3) phase 60 Hz; compressed air of 85 psi.

Contractor shall provide new disconnects on all energy sources used for the test stand. Contractor shall be responsible for hookup of all utilities to test stand.

3.13.2 Contractor Responsibilities: The contractor shall be responsible for installation of the Whirl tower motor. The contractor shall also clean up and dispose of any and all waste generated during the installation of the test stand at the FRC East. The contractor shall also be responsible for the following:

a. Criminal Records Check: Working contractors shall have all their employees obtain and provide a two-year Criminal Records Check (CRC). This also includes sub-contractors; the sub-contractor shall be required to provide the CRC on all their employee's that expect to work onboard this facility, or gain access. The contractor (employee) upon arrival at the MCAS front gate will provide their CRC on the spot per existing rules, regulations and policy.

b. Ensuring that all personnel directly or indirectly employed by the contractor and requiring entrance to this facility shall be English speaking. Appropriate documentation shall be submitted to the security pass office prior to entrance to this facility.

c. Obtaining all passes required for entry for manufacturers personnel entering FRC East, Cherry

Point. In addition, the contractor shall be responsible for the conduct of all representative personnel while they are on station.

d. Giving advance notification of visits to the Government's facility. At least five (5) days notification is required for visits by US citizens and at least 60 days notification is required for visits by foreign nationals. This rule applies to all visits.

e. The installation shall be accomplished using materials and wiring methods required by NFPA 70

(NEC). All unloading, handling, and moving shall be performed to preclude damage to materials, equipment, and building facilities.

f. Equipment shall not be dragged on facility floors. Metal skid plates or wooden skids are acceptable for unfinished floors; however, in areas with finished floors, equipment shall be moved by means of load spreading rollers, dollies, or shall be trucked clear of the floor.

g. The contractor shall be responsible for the installation of equipment covered by this specification and the connection of that equipment to Government furnished utilities provided at or near the installation site. The contractor shall locate the equipment within the boundary areas in a fashion that will provide a minimum working clearance of three (3) feet around the equipment, and the immediate work area. Sufficient space between the equipment and the boundaries shall be provided as required for performance of normal maintenance functions. All electrical control and power panels shall be located so as to provide a minimum safe working clearance immediately in front of the panel that is in compliance with Section 110-16 of the National Electrical Code.

3.14 Design Reviews:

3.14.1 Post Award Conference: A Post Award Conference shall take place at FRC East within thirty (30) calendar days after contract award. The purpose of the conference is to ensure the Contractor fully understands the Government requirements. Discussion shall include but is not limited to specification requirements, technical documentation and deliverables, schedules, administrative procedures, space needs for equipment storage, access to the facility, points of contact and a training schedule. In addition to these guidelines, the contractor shall present and submit a Plan of Action and Milestones (POA&M) including appropriate milestone and deliverables data.

3.14.2 Preliminary Design Review (PDR): A Preliminary Design Review (PDR) shall be conducted at the Government facility at the time specified in the Government approved Plan of Action and

Milestones (POA&M). This review shall allow the contractor to propose their design and shall be considered a 25 percent completion design review. Long lead time items shall be identified for procurement at this time. Environmental impact issues shall be identified at this time and known impacts will be reviewed by the Government.

3.10.3 Joint Design Review: A Joint Design Review (JDR) shall be conducted at the Government facility at the time specified in the Government approved POA&M. At the JDR the contractor shall present their design at an 80 percent completion level. This design review shall occur prior to system procurement, and include development plans, software coding, and equipment assembly IAW

IEEE 12207. The contractor shall have, at this review, a final version of the site preparation and equipment installation plan, engineering documentation, environmental impact and concern.

3.10.4 Pre-Shipment Review: A pre-shipment review may be conducted at the contractor’s facility prior to shipment of the upgraded system to the Government. The contractor shall provide a pre-shipment plan to the Government at least thirty (30) days prior to the date scheduled for government personnel to travel to the contractor’s facility. The government may perform a Physical Configuration Audit during the pre-shipment review. The PCA is the formal examination of the "as-built" configuration of a configuration item (hardware and software) against its technical documentation. The PCA normally includes a detailed audit of engineering drawings, specifications, and technical data (including COTS documentation). Draft copies of maintenance manuals, installation manuals, and the engineering drawing package shall also be provided for review three (3) weeks prior to the pre-shipment review. As part of the pre-shipment review the government shall perform pre-shipment testing. The system will be examined for design, construction, material, components, and workmanship to determine compliance with the requirements of the specifications. Limited testing and operation of the assemblies and components of the system shall be demonstrated by the contractor IAW a pre-shipment test plan.

4.0 VERIFICATION

4.1 Responsibility for Inspection: Unless otherwise specified in the contract or purchase order, the

Contractor is responsible for the performance of all inspection requirements (examinations and tests) as specified herein. The government reserves the right to perform any of the inspections set forth in this specification where such inspections are deemed necessary to ensure supplies and services conform to prescribed requirements.

4.1.1 Responsibility for Compliance: All items shall meet all requirements of Section 3 of this specification. The absence of any inspection requirements in the specification shall not relieve the contractor of the responsibility of ensuring that all products or supplies submitted to the government for acceptance comply with all requirements of the contract.

4.1.2 Reliability Validation: Deleted

4.2 Acceptance Test

4.2.1 Preliminary Acceptance: Pre-shipment testing shall be performed by the Contractor in accordance with their standard procedures. The Contractor shall give the government thirty (30) days’ notice that the test stand is ready for pre-shipment testing to begin. FRC East reserves the right to witness pre-shipment testing if deemed necessary. All testing documentation shall be turned over to the government.

4.2.2 Final Acceptance Test: Upon completion of the installation, final acceptance tests shall be conducted in accordance with the approved ATP. These tests shall include confirmation of the correct functioning of all the motor system’s features and load tests of the complete system. The government shall provide sets of helicopter blades that will be mounted on the Whirl tower by government personnel. A minimum of four sets of blades (H-46 FWD, H-46 AFT, H-3 and H-53E

NAVY) shall be provided. The load test shall consist of performing a complete blade production test procedure for each set of blades. This will ensure that the dc motor system is operating correctly over its entire specified operating range. Final tests are to include verifying the correct operation of all permissive signals originating from the motor system. The contractor shall provide instrumentation to measure critical motor system parameters, such as armature and field voltage, armature and field current, speed, and temperature rise. A Test /Inspection Report (CDRLA006) shall be provided within ten (10) days after the completion of the final acceptance tests.

4.2.2.1 Examination of Product: The motor and all of its components shall be visually examined to determine compliance with each paragraph of this specification. Additionally, all pieces of equipment shall be of good quality and not physically damaged during or subsequent to their manufacture/assembly. Nonconformance of any component shall be cause for rejection of this part.

4.2.2.2 Operational Test: Operation of the motor shall be demonstrated to show conformance with section

3.0 of this specification. Proper operation of all Whirl tower motor functions shall be demonstrated.

4.2.2.3 Performance Test: The Whirl tower motor shall be functionally tested to verify that it performs in accordance with section 3.0. The performance period for acceptance testing shall be conducted during normal working hours (Monday thru Friday, 6:30 am to 3:00 pm). Should the motor fail to meet performance test requirements within five (5) consecutive calendar days, all testing shall be terminated until a written request for additional testing is submitted by the contractor and is acknowledged by the contracting officer. Should the motor fail to meet requirements during subsequent performance tests, the Government shall have the authority to initiate termination procedures against the Contractor.

5.0 CONTRACTOR’S UNAUTHORIZED WORK PERFORMANCE. The Contractor shall not perform work that deviates from contract requirements and specification.