LM2500_RFP_N6852022R0017_28JUL22.docx

N6852022R0017

Section A - Solicitation/Contract Form

GENERAL INFORMATION

1. This is a Small Business Set-Aside utilizing Lowest Price Technically Acceptable (LPTA) utilizing FAR Part 15.101-2.

2. The NAICS Code for this effort is 336412 – Aircraft Engine and Engine Parts Manufacturing

3. The contract will be awarded with a Period of Performance of 24 months with an estimated schedule of completion.

POINTS OF CONTACT

CONTRACT SPECIALIST:

Name: Samuel Stellwagon Email: samuel.d.stellwagon.civ@us.navy.mil

PROCURING CONTRACTING OFFICER:

Name: Tiffany L. Crayle Email: tiffany.l.crayle.civ@us.navy.mil

Section B - Supplies or Services and Prices

Test Cell #20 Labor

FFP

Labor in support of Section C: Statement of Work to support LM2500 Test Cell #20 FOB: Destination

PSC CD: H228

NET AMT

Test Cell #20 Material

Material Cost in support of Section C: Statement of Work for Test Cell #20

NET AMT

Test Cell #20 Software

Software Cost in Support of Section C: Statement of Work for Test Cell #20

NET AMT

Test Cell #20 Host Computer System

Cost for Test Cell #20 Host Computer System in support of Section C: Statement of Work. A minimum requirement Host Computer system consists of a Dell Precision Work Station configuration

NET AMT

Test Cell #20 Post Award Conference

Post Award Conference for Test Cell #20. Within seven (7) days from Contract award the Contractor shall conduct a post award conference with the Government to provide a Plan of Action and Milestones (POA&M) report, IAW Exhibit A CDRL A00A.

NET AMT

Test Cell #20 Warranty

Warranty for Test Cell #20. The Contractor shall provide warranty for a minimum of 12 months (e.g. 365 Days) that follows “start-up, system(s) testing, and acceptance/recognition of project completion,” by the Government and final payment acceptance by the Contractor.

NET AMT

Technical Data (CDRLS) - $NSP

CDRLS NSP

NET AMT

Test Cell #19 Labor

Labor in support of Section C: Statement of Work for Test Cell #19

NET AMT

Test Cell #19 Material

Material Cost in support of Section C: Statement of Work for Test Cell #19 *Test Cell 19 Includes Exhaust Cone

NET AMT

Test Cell #19 Software

Software Cost in support of Section C: Statement of Work for Test Cell #19

NET AMT

Test Cell #19 Host Computer System

A minimum requirement Host Computer system consists of a Dell Precision Work Station configuration in support of Section C: Statement of Work

NET AMT

Test Cell #19 Post Award Conference

Within seven (7) days from Contract award the Contractor shall conduct a post award conference with the Government to provide a Plan of Action and Milestones (POA&M) report, IAW Exhibit A CDRL A00A.

NET AMT

Test Cell #19 Warranty

The Contractor shall provide warranty for a minimum of 12 months (e.g. 365 Days) that follows “start-up, system(s) testing, and acceptance/recognition of project completion,” by the Government and final payment acceptance by the Contractor.

NET AMT

Section C - Descriptions and Specifications

STATEMENT OF WORK

STATEMENT OF WORK

OVERHAUL OF

LM2500 TEST CELLS #19 & #20

FRCSW, Building 397

Prepared by Michael Anderson / David Colson - Project Manager Dung Tina Phan / James Tran – Project Engineer Fleet Readiness Center Southwest (FRCSW) – North Island

1.0 SCOPE:

1.1 SYSTEM OVERVIEW:

The LM2500 Engine Test Cells #19 & #20 are used to perform depot-level functional and performance testing of General Electric LM2500 Gas Generator Assemblies (GGA), and the Power Turbine Assemblies (PTA) at FRCSW. The Data Acquisition Display and Control System (DADCS) provides the resources to control the engine and facility functions; acquire, display, and record physical engine and facility parameters; and calculate engine performance data. The LM2500 Engine Test Cell DADCS has the capability to operate in manual, semiautomatic, or full automatic modes of operations allowing predetermined engine test profiles to be executed with limited operator actions. The LM2500 Engine Test Cells are configured for testing LM2500 Engines in Hydro-Mechanical Fuel Control (MFC) or Digital Fuel Control (DFC) configurations. The proposed overhaul shall consist of all design, demolition, acquisition, integration, installation and testing tasks necessary to successfully complete the performance requirements of this document.

1.2 SOW DESCRIPTION:

a. This Statement of Work (SOW) describes the minimum specifications and requirements necessary to overhaul each of the current LM2500 Engine Test Cells (Test Cell #19, Test Cell #20) and support components as outlined in Section 3, as prescribed for each test cell within this SOW.

b. The purpose of this SOW is to provide details for a “Turn-Key” operation for a commercial vendor to provide parts, labor, installation, and materials delineated by contract scope and specified by SOW, to include: overhaul, start-up, commissioning, validation, calibration, documentation, 1 year warranty, and training of each LM2500 ENGINE TEST CELL located at Fleet Readiness Center Southwest (FRCSW), in Building 397.

c. The quality, size, and capacity for each respective test cell overhaul shall be no less than the minimum specification outlined in Section 3, of this SOW.

d. Work requirements specified in section 3 of the SOW for LM2500 TEST CELL 20 are required to commence upon the exercise of the first Option year for a total of 2 years under contract.

e. Work specifications and requirements in section 3 of the SOW for both Test Cells #19 and #20 are required to be completed as follows:

2.0 APPLICABLE DOCUMENTS AND REFERENCES:

2.1 GOVERNMENT DOCUMENTS:

SPECIFICATIONS, STANDARDS, AND HANDBOOKS

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

2.1.1 STANDARDS - FEDERAL

a. S9234-AB-MMD-030 Manual

b. US NAVY OPNAVINST 3960.16A: Navy Test, Measurement, and Diagnostic Equipment (TMDE), Automatic Test Systems (ATS), and Metrology and Calibration (METCAL) (2011)

c. MIL-STD-1472F - DOD Design Criteria Standard; Human Engineering military Systems. (2003 Edition)

d. ASTM D 3951 - Standard Practice for Commercial Packaging. (2004 edition)

(Copies of the above standards and specifications are available from ASTM International, 100 Barr Harbor Drive, PO Box C700, West Conshohocken, PA 19428-2959)

2.1.2 FED-STD-H28A - Screw Thread Standards for Federal Services (1994 edition)

a. MIL-STD-130N – Identification Marking of U.S. Military Property (2007 edition) (Copies of Federal and military specifications, standards, and handbooks are available from the Superintendent of Documents, U.S. Government Printing Office, Washington, DC 20402-0001)

2.1.3 FY20 NAVAIR METCAL scheduling letter

2.1.4 NAVAIR 17-35POP-01, Metrology and Calibration Program Operations and Processes (POP) Manual, 1 November 2000

2.1.5 NAVAIR 17-35QAC-01B, Navy and Marine Corps Calibration Laboratory Audit/Certification Manual, 1 December 2006

2.1.6 NAVAIR 17-35MTL-1, Metrology Requirements List (METRL), 1 December 2013

2.1.7 NAVAIR 17-35TR-04 and NAVAIR 17-35TR-50, REQUIREMENTS FOR THE PREPARATION OF NAVAIR 17–50 SERIES INSTRUMENT CALIBRATION PROCEDURES

2.1.8 NPSL-BP-01

2.1.9 Dept. of the Navy Local Population ID Card/Base Access Pass Registration SECNAV Form 5512/1

2.1.10 Local Documents:

a. FRCSWINST 11300.2F – Energy and Water Management Program (26 Aug 2008 Effective Date or latest)

b. FRCSW North Island Layout Drawings

2.1.11 REFERENCED PUBLICATIONS: The product offered shall comply with the following codes and specifications, where applicable. Unless a date or version is specified, the latest edition of the referenced publications in effect at the time of the bid shall govern. In case of a conflict between the requirements in this specification and those listed in the references, the supplier shall notify Technical Point of Contact (TPOC) for immediate resolution. The following other Government documents and publications form a part of this specification to the extent specified herein.

a. CODE OF FEDERAL REGULATIONS (CFR)

b. U.S. DEPARTMENT OF LABOR, OCCUPATIONAL SAFETY AND HEALTH ADMINISTRATION (OSHA)

c. 29 CFR PART 1910 - General, 2011 edition.

2.2 NON-GOVERNMENT DOCUMENTS:

The following documents form a part of this document to the extent specified herein. Unless otherwise specified, the issues of these documents are those cited in the solicitation or contract. The product offered shall comply with the following codes and specifications where applicable. Unless a date or version is specified, the latest edition of the referenced publications in effect at the time of the bid shall govern. In case of a conflict between the requirements in this specification and those listed in the references, the supplier shall notify the TPOC.

2.2.1 American Society of Mechanical Engineers (ASME):

a. ASME Y14.5 - Dimension and Tolerance (2009 edition). Application for copies should be addressed to the ASME International, Three Park Avenue, M/A 10 E, New York, NY 10016-5990.

2.2.2 International Organization for Standardization (ISO):

a. ISO 9000 (Applications for copies should be addressed to the International Organization for Standardization, Case Postale 56, Geneva, Switzerland CH-1211)

2.2.3 NATIONAL ELECTRICAL MANUFACTURERS ASSOCIATION (NEMA)

a. NEMA ICS 6 – Industrial Control and Systems Enclosures (1993 edition)Pg. 16 (13.16.3)

b. NEMA MG-1 – Industrial Control and Systems Enclosures (1993 edition) (Application for copies should be addressed to the National Electrical Manufacturers Association, 1300 N 17th Street, Suite 1847, Rosslyn, VA 22209)

2.2.3.1 SOFTWARE

· IEEE/EIA STANDARD 829 - 2008 - Standard for Software Test Documentation-IEEE Computer Society Document.

· IEEE/EIA STANDARD 1028 - 2002 - Standard for Software Reviews-IEEE Computer Society Document.

· IEC-604488-1 2004 - Higher performance protocol for the standard digital interface for programmable instrumentation part I: General first edition; identical to IEEE 488.1; replaces 60625-1:1993.

· IEEE/EIA STANDARD 1016-1998 - Standard for Software Test Documentation

· (Copies of the above standards may be obtained from The Institute of Electrical and Electronic Engineers Inc. 345 East 47th Street. New York, New York 10017)

· National Instruments - LabVIEW Development Guidelines, July 200, Chapter 6, LabVIEW Style Guild

(Copies of the above document can be obtained from National Instruments 115000 N. Mopac Expway Austin, Texas 78759-3504.)

2.2.4 NATIONAL FIRE PROTECTION ASSOCIATION (NFPA)

a. NFPA 70 - National Electrical Code, (2011 edition)

b. NFPA 79 - Electrical Standards for Industrial Machinery, (2012 edition)

(Application for copies should be addressed to the National Fire Protection Association, 1 Batterymarch Park, Quincy, MA 02269-9101)

2.2.5 NATIONAL INSTITUTE OF STANDARDS AND TECHNOLOGY (NIST), 2013 edition. Traceable Standard/Calibration

a. NIST 2013 edition can be found at: http://nvlpubs.nist.gov/nistpubs/ir/2013/NIST.IR.7298r2.pdf, and http://www.nist.gov/calibrations/sp250_series.cfm)

b. ANSI/ASME B89.4.1B - Methods for Performance Evaluation of LM2500 ENGINE TEST CELL #19/#20- American National Standards Institute / American Society of Mechanical Engineers

(Application for copies should be addressed to: https://www.asme.org/products/codes-standards/b894103602-2008-acceptance-test-reverification or http://www.ansi.org/ )

2.2.6 TELECOMMUNICATIONS INDUSTRY ASSOCIATION

a. TIA-232(F) - Interface Between Data Terminal Equipment and Data Circuit Terminating Equipment Employing Serial Binary Data Interchange. (1997 edition)

(Application for copies should be addressed to the Telecommunications Industry Association, 2500 Wilson Blvd, Arlington, VA 22201)

2.2.7 ORDER of PRECEDENCE:

In the event of a conflict between the specification and the references cited herein, nothing in this SOW, however, shall supersede applicable laws and regulations unless a specific exemption has been obtained. While every effort has been made to ensure the completeness of this list, the Contractor is cautioned that they shall meet all specified requirements cited in this SOW.

3.0 REQUIREMENTS:

3.1 OVERALL REQUIREMENTS:

These below describe the overall requirements for the overhaul, upgrade, design, on-site installation, integration, and testing of each LM2500 Engine Test Cell at FRCSW North Island, Building 397:

Hardware Materials:

a. Host Computer System

b. Woodward/Data acquisition system

c. Vibration System

d. Facility/Engine Control system

e. Pressure Measurement System

f. Equipment Racks/Consoles

g. Engine Lube Oil Cart system

h. DFC Interface Cart system

i. Thrust Stand

j. Piping and Turning Valves repair

k. Power system and Conditioning

l. Fuel system

m. Test Cell electrical system

n. Test Cell lighting system

o. Test Cell intranet system (Connections between PC, Woodward, PXI, CEC 8000, PLC, Woodward IEC Controller)

p. Intercom system

q. Closed-Circuit Television (CCTV) system

r. Exhaust Cone (Only to be included with Test Cell #20)

s. Miscellaneous Materials

Software:

a. Graphical User Interface (GUI) Software Update

b. Debugging system that is more transparent than current version to identify and resolve failures.

c. Test Report shall allow user to filter out the data by provide more filter criteria.

d. All data entry into the system used for calibration shall be recorded.

e. All test reports shall be automatically saved in the system for one year.

f. Any test data that are out of acceptance criteria shall print out in red color

g. Ability to select, filter, save, export and print test reports in formats such as Excel and Word respectively.

The Contractor shall overhaul each test cell console, thrust stand wiring and connectors, piping, interlocks, and other components to restore the latest system and to fully operation condition.

The Contractor shall integrate all new system components as required to perform LM2500 DFC and MFC testing

The Contractor shall make all adjustments, replacements, modifications, upgrades, and pass all environmental, safety, and fire regulations according to the technical requirements included in this SOW in paragraphs 2.0 and subsequent.

Operator manual, bill-of-materials, drawings, calibration procedures, training, acceptance testing, and a turn-key upgrade for each test cell shall be provided by the Contractor.

Contractor shall provide training for Calibration, Operation, Maintaining, and debugging the system for each test cell.

3.2 TEST CELL CONTROL ROOM:

The control room area of the Building 397 facility contains the majority of the Test Cell DADCS components. The system components are mounted in the Operator Control Console, Instrument Cabinets, Woodward Control System Cabinet, or the Auxiliary Cabinets.

3.2.1 Host Computer System

The computer for each test cell console shall be of a rack mountable type utilizing a 19” wide mounting rack and consist of internal hardware and peripherals.

3.2.1.1 A minimum requirement Host Computer system consists of a Dell Precision Work Station configuration. See section 3.14.7 for detailed requirements/specifications.

3.2.1.2 The Contractor shall upgrade the software to the latest version. The Software list below shall reside on the Host Computer Subsystem:

· Window 10 Professional Operating System

· LabView Professional Control Edition Developer Suite, or equivalent

· SYTRONIC’s Professional Turbine Engine and Component Software (ProTECS) latest version, or equivalent

· SYTRONIC’s ProTECS Configuration Files, or equivalent

· Rockwell RSLogix 500 Ladder Logic Programming Package, or equivalent

· Rockwell Factory Talk Studio Machine Edition Programming Package, or equivalent

· Rockwell RSLinx OEM, or equivalent

· MySQL Database Server 5.7 or latest version, or equivalent

· Symantec Norton Ghost 10.0 Drive Imaging Package, or equivalent

· Acronis True Image 2018 Driver Imaging Package or latest version, or equivalent

· Adobe Acrobat Reader 7.0 Software or latest version

· Excel 2020

· Word 2020

· Snipping Tool

3.2.1.3 Software Features. At a minimum, the Contractor shall provide the following software features with the computer system

a. Menu driven, self-teaching/programming software, utilizing function oriented pictures (icons) and bold graphics type directions

b. Conversational programming

c. Modes of operation; learn, edit, execute, digitizing

d. Graphical User Interface

e. Windows control PC based (open architecture)

f. Reverse engineering software Scan (digitizing) software with graphical display with capabilities to import or export to a CAD/CAM system via IGES, DXF or STEP format

g. Microsoft Windows 10, Office Suite programs to include Note, Winmerge, Word, Paint, Media Player to be used in conjunction with the Contractor’s program

h. ADOBE Acrobat Reader Professional to be used in conjunction with the Contractor’s program

i. Government to receive a full copy of all programming and software licenses and data rights used in the system/equipment.

j. Vendor to provide 24 months of any and all available upgrades to the software/programming/logic of the system from the time of acceptance at no additional cost to the Government.

3.2.2 19-inch Flat Panel Monitors:

The Contractor shall provide at least five (5) Computer monitors that are at minimum equivalent to Dell Ultrasharp U2415 19.0-Inch Screen LED, Black for Operator Control Console. The monitors shall be connected to the Host Computer System providing the interface for engine testing configuration, control, monitoring, and analysis. One (1) monitor shall be specifically used for monitoring any Woodward event log.

3.2.3 Panel View Plus Touchscreen Monitor:

The Contractor shall provide a monitor at minimum equivalent to a 19-inch mount-on Allen-Bradley Panel View Plus 1500 Touchscreen Monitor that shall be integrated into the Operator Control Console and serves as a control and actuator panel for engine and facility function.

(Facility is considered fuel room, or test cell engine room, control room, and equipment room.)

3.2.4 Facility Control Panel:

The Contractor shall upgrade the Facility Control Panel. The Facility Control Panel shall include a panel-mounted digital display of the T5.4 engine temperature parameter. The fire system SPURT and FLOOD control buttons shall be equipped with a hard covers to prevent switch action due to inadvertent touching.

3.2.5 Intercom System:

The Contractor shall upgrade the intercom system to the most current model for clear-com digital matrix intercom system to allow multi-point communication between Control room, Engine Test Cell, and Fuel Room areas of the facility.

3.2.6 Cameras and Video Display system:

The Contractor shall upgrade the Camera and Video Display system to the most current model for a new vision surveillance system in the engine test cell to allow visual inspection of the engine under test. The video surveillance system shall include six (6) surveillance Cameras to monitor the engine in test, zoom in/out functions, and the 24” flat panel monitor on the operator Control Console.

3.2.7 Color Laser Printer:

The Contractor shall upgrade the color printer, with the minimum equivalence to Hewlett-Packard (HP) Color Model M180nw or latest version. Wireless Laser Printer for provide hardcopies of test reports, plots, and related documents. The HP can print in color and black/white.

3.2.8 PXI\SCXI\RTDAS Cabinets:

The Contractor shall upgrade the PXI cabinet to the most current model in order to house the National Instruments PXI/SCXI RTDAS, Allen-Bradley PLC System, CEC Vibration Tracking System, PLC Servo Amplifier, NPT Signal amplitude Measurement System, Ethernet Switch, and Pressure Transducer System.

3.2.9 National Instruments PXI/SCXI RTDAS

The Contractor shall upgrade the National Instrument PXI/SCXI RTDAS to the latest model and with the real-time operating system. The PXI/SCXI RTDAS collects and processes data from the engine and facility sensors and sends the data over an Ethernet connection to the Host Computer system.

3.2.10 Allen-Bradley PLC System

The Contractor shall upgrade The Allen-Bradley to the latest model. The PLC minimum requires:

· 10-slot Chassis

· 1747-L553 SLC 5/05 Processor or Latest version

· 1746-OB16E or latest version which has 16-Channel Digital DC Outputs Module

· 1746-OW16 or latest version which has 16-Channel Relay Outputs Module

· (2) 1746-IB 16 Digital DC Inputs Module

· (2) 1746-NI8 8-Channel Analog inputs Module

· 1746-NO8V Analog Output Module

3.2.11 CEC Vibration Tracking system:

The Contractor shall upgrade the CEC C-CATS 8000 computer Controlled Amplifier/Tracking System to the latest model. This Vibration Tracking system shall be configured with four amplifiers/tracking modules. The amplifiers shall be able to condition the raw vibration signals from the engine transducers, provide outputs to the RTDAS and monitor for vibration and analysis.

3.2.12 PLA Servo Amplifier

The Contractor shall upgrade the Cenco PLA Servo amplifier to the latest model. The Allen-Bradley PLC provides the required PLA command signal to the PLA Servo Amplifier, which in turn drives the PLA motor attached to the LM2500 throttle spindle.

3.2.13 NPT Signal Amplitude Measurement System:

The Contractor shall upgrade two (2) Daytronic Model 2168-200C AC voltage Meters to the latest model to provide a measurement of the AC amplitude level of the LM2500 Engine NPT RPM signal. The AC Voltage Meter shall have a high-accuracy 4-1/2 digit display of true RMS voltage and provide a corresponding DC output representing the measured AC amplitude.

3.2.14 Ethernet Switch:

The Contractor shall upgrade a D-link Model DGS-1016D Switch to the latest model. This D-link shall provide the Ethernet communication path between the DADCS components.

3.2.15 Pressure Transducer:

The Contractor shall upgrade a series of Honeywell Model FP2000 Sensotec discrete pressure transducers as installed in the PXI Cabinets for the measurement of the following pressure parameters:

· Stored Air Pressure (STORAIR): 0 – 500psig

· Starter Air Pressure: (SAP): 0 – 100 psig

· Left Recoup Pressure (LRECOUP): 0 – 500 psia

· Right Recoup Pressure (RRECOUP): 0 – 500 psia

· Front Cell Pressure (FRONTCP): 16 to 32 inHG

· Rear Cell Pressure (REARCP): 16 to 32 inHg

· Barometer pressure (BAROP): 16 to 32 inHg

· Compressor Inlet Pressure (PT2_MFC): 16 to 32 inHgA

· Power Turbine Inlet Pressure (PT5_4_MFC): 0 to 100 psi

· Compressor Discharge Pressure (PS3_MFC): 0 to 300 psig

3.2.16 Woodward Control System Cabinet:

The Contractor shall upgrade the Woodward system to the latest model. The Woodward is providing the engine control required for DFC LM2500 Engines. Minimum requirements for Woodward system consists of the following:

· Woodward Micronet Test Cell Control system and associated signal conditioning and control components.

The Contractor shall supply Data Acquisition logging, which shall record digital, analog signals, data from engine, test cell, fuel rate, sensors, vibration analysis, and record data every 10 seconds.

· The Data Acquisition Central Unit (DACU) shall provide the capability to check the status of each functional cards in the system.

· The DACU shall provide the capability to debug and troubleshoot the software, or the hardware in the test cell system

· The DACU system shall have the storage space for 72 hours of testing.

· The DACU system chassis shall have expansion capability (room for additional circuit cards).

3.2.17 Auxiliary Cabinets:

The Contractor shall upgrade the Auxiliary Cabinets to the latest model, which include many of the support components for operation of the test cell systems. The support components include control relays, power supplies, circuit breaker panels, and other ancillary devices. The Auxiliary Cabinets also include the primary breakout point (terminal strip TS4) for all signal and control wiring between the Control Room and all other tests cell facility systems.

3.3 TEST CELL and ENGINE ROOM:

3.3.1 Thrust Stand System:

The Contractor shall refurbish the existing thrust stand system with new wiring and connectors, fuel lines, interlocks, and other components necessary to restore the thrust stand with the latest model components to its fully operation condition.

3.3.2 “Wet” Pressure Transducers:

The Contractor shall upgrade a series of Honeywell Model FP2000 Sensotec discrete pressure transducers with the latest model that are in the Thrust Stand J-Box for the measurement of the following pressure parameters:

3.3.2.1 Fuel Inlet Pressure (FUELIP) is from 0 to 100 pounds per square inch gauge (psig)

3.3.2.2 Fuel Supply Pressure (FUELSP) is from 0 to 100 psig

3.3.2.3 Fuel Manifold Pressure (FUELMP) is from 0 to 1000 psig

3.3.2.4 Lube Oil Pressure (LOP) is from 0 to 250 pounds per square inch absolute (psia)

3.3.2.5 Spare Pressure is from 0 to 30 psid

3.3.3 New Exhaust Cone (Test Cell 19 only):

The Contractor shall supply a new set of the Exhaust Cone for test cell #19 that is specified by FRCSW that will fit on the LM2500 engine. Reference to existing exhaust cone in the Test Cell #20.

3.3.4 Woodward FMV/A or Digital Fuel Control cart:

The Contractor shall provide a Woodward Model 3055 FMV/A DFC cart or the latest model. The DFC cart shall be capable of testing either the DFC or MFC variant of the LM2500 Engine. The FMV/A cart is required to contain the Woodward Model 3055 Liquid FMV/A Assembly, Pressure Transducers, and the Engine Hydraulic system accumulator. The DFC should also include a series of discrete pressure transducers on the cart for the following pressure measurement parameters:

a. Compressor Inlet Pressure (P2): 0 to 30 psia

b. Power Turbine Inlet Pressure (P5.4): 0 to 100 psia

c. Compressor Discharge Pressure (A) (PS3(a)): 0 to 500 psia

d. Compressor Discharge Pressure (B) (PS3(B)): 0 to 500 psia

3.3.5 Lube Oil Cart:

The Contractor shall provide a new Lube Oil Cart with new components. The Lube Oil Pressure (LOP) shall measure a range from 0 to 200 psia.

3.3.6 Inlet Turning Valve Control and Instrumentation:

The Contractor shall upgrade the instrumentation and controls necessary to restore the Turning Vanes to an operational condition.

3.3.7 Exhaust System in the Test Cell:

The Contractor shall provide a new augmentor tube as part of the new test equipment system and to reattach panels which have been dislodged.

3.3.8 Test Cell Camera System:

See requirements listed in 3.2.6.

3.3.9 Sliding Doors

The Contractor shall restore the sliding doors to their original operational condition and location in accordance with all safety and LM2500 engine testing requirements.

3.3.10 Engine Oil Heater

The Contractor shall provide a new Engine Oil Heater. Engine oil shall be preheated before injecting into the engine during any test which utilizes an LM2500 engine. Engine oil shall be heated to 130° F within 30 minutes.

3.3.11 Weather Station

The Contractor shall evaluate and verify if the existing weather station sensor is operational.

3.4 FUEL ROOM:

The Contractor shall provide and install two (2) new Coriolis Flow Sensors and new pressure-regulating valves in the Fuel Room.

3.5 EQUIPMENT ROOM:

The Contractor shall upgrade the Equipment Room, which houses supporting equipment for the control of the engine fuel supply pressure and starter air pressure regulation and associated air valve and air tank equipment, Compressor Inlet Temperature Resistive Temperature Devices, and terminal breakouts (Terminal strip TS5) for signal lines for many of the test cell control systems.

3.6 Environmental Protection and Safety Requirements: The Contractor shall complete the installation meeting all applicable Environmental Protection Agency (EPA) and Occupational Safety Health Association (OSHA) restrictions for materials classified as hazardous to the environment in effect on the date of contract. During the operation of the equipment at their final location, all equipment shall comply with all applicable EPA and OSHA regulations in effect on the date of contract regulating the emission of material hazardous to the environment. For additional information, the Contractor is instructed to contact the TPOC.

Waste Disposal. Disposal of non-hazardous solid waste disposal shall be the responsibility of the Contractor. FRCSW shall assume all responsibility and associated liability for disposal of hazardous waste as defined in California Code of Regulations Title 22.

Disposal of Old Equipment: Unless stated otherwise, the Government is responsible for the disposal of any old equipment. The Contractor shall disassemble, cut if necessary, and stage at a pre-arranged location for the Government to clean and dispose of the equipment. The Contractor shall stage and secure old equipment on pallets, which shall be provided by the Government. The Contractor shall contact the TPOC and obtain specific instructions in regards to location and latest regulation from the Government for disposal of old equipment/parts/machinery.

3.6.1 Safety and Health Requirements: The Contractor shall ensure all machine parts, components, mechanisms, and assemblies furnished for the LM2500 ENGINE TEST CELL #19 and #20, whether or not specifically required herein, comply with all of the requirements of OSHA 29 CFR 1910 and OPNAVINST 5100.23G.

a. Mercury Restriction: The LM2500 ENGINE TEST CELL #19 and #20 shall not contain mercury or mercury compounds nor be exposed to free mercury during manufacture.

b. Asbestos Restriction: Asbestos and materials containing asbestos shall not be used on or in the LM2500 ENGINE TEST CELL #19 and #20.

c. Lead: Lead and materials containing lead shall not be used on or in the LM2500 ENGINE TEST CELL #19 and #20 unless otherwise stated.

d. Use of Polychlorinated Biphenyl (PCB): The use of polychlorinated biphenyl (PCB) on or in the equipment is prohibited.

e. Audible Noise Level: Audible noise emitted by the equipment shall not exceed 84 decibels (dB), measured on the “A” weighted scale of a standard Type II sound level meter, at the operator's work position or any point at a distance of three (3) feet from the equipment. Noise generated by the work piece, shall be excluded in determining compliance of the equipment with the 84 dB requirements.

f. Lubrication: Means shall be provided to ensure adequate lubrication for all moving parts. Recirculating lubrication systems shall include a filter that is cleanable or replaceable. Each lubricant reservoir shall have at least a 24-hour capacity. Means shall be provided to indicate a low oil condition. Should a low oil condition occur, the test equipment shall enter an emergency stop condition upon completion of the current operation. All oil holes, grease fittings, and filler caps shall be accessible.

g. Interchangeability: All parts subject to replacement shall be manufactured to definite dimensions and tolerances. Replacement parts shall be interchangeable without requiring modification. Replacement parts are those that are subject to wear or failure such as gears, bearings, shafts, feed screws, drive belts, pumps, and seals. Electrical replacement parts shall include but not be limited to, motors, relays, fuses, switches, magnetics, pushbuttons, light bulbs, braking mechanisms, and solid-state devices. Tooling and accessories normally supplied as standard items shall also be considered replacement parts. Foreign-sourced replacement parts shall be interchangeable with domestically supplied components or be readily available from a domestic source.

3.7 Detail Tasks: The Contractor shall construct test equipment with parts that are new, without defects, and free of repairs. The structure shall withstand all forces encountered during operation of the test equipment to its maximum rating and capacity without distortion.

3.7.1 Surfaces: All surfaces shall be clean and free of harmful or extraneous materials. All edges shall be either rounded or beveled unless sharpness is required to perform a necessary function. The condition and finish of all surfaces shall be in accordance with the manufacturer's commercial practice.

3.7.2 Painting: The test equipment shall be painted in accordance with the manufacturer’s commercial practice. All paint shall be of the lead free type.

3.7.3 Workmanship: Workmanship of the test equipment shall meet all requirements specified herein and shall be of a quality equal to that prevailing among manufacturers producing equipment of the type covered by this purchase description.

3.7.4 Solid-State Components: The use of selenium in solid-state components shall be restricted to those devices that protect other solid-state components from voltage surge.

3.7.5 Marking on Instruments, Control Panels, and Plates: (see 3.17 for specifications).

3.7.6 Castings and Forgings: All castings and forgings shall be free of defects, scale, and mismatching. No processes such as welding, peening, plugging, or filling with solder or paste shall be used for reclaiming any defective part.

3.7.7 Fastening Devices: All screws, pins, bolts, and other fasteners shall be installed to prevent unintentional loosening. Fastening devices subject to removal or adjustment shall not be permanently installed.

3.7.8 Threads: All threaded parts, either US or SI, used on the test equipment and its related attachments and accessories shall conform to FED-STD-H28 and the applicable "Detailed Standard" section referenced therein.

3.7.9 Welding, Brazing, or Soldering: Welding, brazing, or soldering shall be employed only where specified in the original design. None of these operations shall be employed as a repair measure for any defective part.

3.7.10 Maintainability: The equipment shall be designed and constructed to permit maintenance personnel to easily service the equipment using a minimal number of tools. All parts subject to wear, breakage, or distortion shall be accessible for adjustment, replacement or repair. Consistent with required maintenance and design of the equipment, the Contractor shall provide any special tools required to service the Unit. The equipment shall be equipped with access covers to facilitate inspection, cleaning, and repair, or replacement of parts.

3.7.11 Epoxy floors: The Contractor shall install new epoxy on the Test Engine room floor. After removal of old equipment, Contractor shall clean the area and prepare for industrial epoxy. Epoxy shall not exceed 5’ over the equipment footprint. The TPOC is to sign off on the class, consistency, color, and type of Epoxy.

3.8 Acceptance Test: The Contractor shall deliver a draft acceptance plan (CDRL A001). FRCSW reserves the right to comment on the draft plan and require revisions incorporating such comments at no change in contract price. A final acceptance test plan incorporating FRCSW comments shall then be delivered to the FRCSW TPOC for approval.

3.8.1 Test Plan: Contractor shall give a 90-day notice before anticipated completion of the project. Any tests shall be coordinated through the FRCSW TPOC.

3.8.2 The Contractor shall perform a fit check of the system. Any deficiencies discovered during this verification shall be corrected by the Contractor via an Engineering Change Order (ECO) received from the US Government and/or its designated engineering representatives. Acceptance will be provided by FRCSW’s TPOC.

3.8.3 The Contractor shall perform an inspection of the system and document the inspection to verify its compliance. Additionally, a 2nd inspection shall be performed and documented to demonstrate the performance of the system. The Contractor shall prepare for a review to be conducted at FRCSW – NAS North Island should a major performance issue arises. The Contactor shall repair and/or fortify the system via an ECO should a performance issue arises during this validation. Acceptance will be provided by FRCSW’s TPOC and signed off by TPOC, FRCSW engineer, and Contracting Officer Representative.

3.8.4 The Contractor shall conduct the final inspection for acceptance in the presence of FRCSW’s Engineers, Contracting Officer (KO), and TPOC.

3.8.5 Final Inspection/Acceptance Test (Destination): Final Inspection and acceptance test shall be performed on the LM2500 ENGINE TEST CELL #19 and #20, and at the customer’s site to ensure conformance with this SOW. The acceptance test shall be performed only after the work and installation has been completed. The LM2500 ENGINE TEST CELL #19 and #20 shall pass the examination, inspections, Correlation tests, and certification by a third party to be accepted.

3.8.6 Verification: The meaning of verification for the purpose of this contract is to assure that the items installed and/or connected by Government personnel are correct.

3.8.7 Validation: Contractor shall perform a validation test of the equipment as part of the final inspection, provide all reports and all the tools necessary for the validation. All tools and/or fixtures for validation of the equipment shall be part of the overall LM2500 ENGINE TEST CELL #19 and #20, and provided to the Government at no additional cost.

3.8.8 Calibration: Contractor shall provide a certificate of calibration (CDRL A003) from the manufacturer and all the relevant documentation. A list of all parts (CDRL A004) that require calibration is requested to be provided to the TPOC no later than end of contract period of performance.

3.8.9 Acceptance Test: Contractor shall schedule and coordinate acceptance test with the FRCSW TPOC. This acceptance is intended to be a verification of the performance of this system. An Acceptance sign-off shall be completed as two separate acceptance criteria:

3.8.9.1 Operational test (new equipment). The Contractor shall operate the test cell in accordance with the manufacturer's standard operating test procedure.

3.8.9.1.1 Reference to chapter 13 of the S9234-AB-MMD-030 Technical Manual for LM2500 Propulsion Gas Turbine and Accessories, the Contractor shall ensure that the Acceptance Test Procedure (ATP) shall follow the instrumentation requirements (Paragraph 13-4) and operating limits (Para. 13-22) for testing of the following LM2500 Gas Generator Assemblies (GGA) if available:

a. Single Shank Turbine - Manual Fuel Control

b. Single Shank Turbine - Digital Fuel Control

c. Twin Shank Turbine - Manual Fuel Control

d. Twin Shank Turbine - Digital Fuel Control

3.8.9.1.2 Reference to chapter 22 of the S9234-AB-MMD-040 Technical Manual Power Turbine Overhaul and Repair Instructions Depot Level Maintenance LM2500 Propulsion Gas Turbine and Accessories, the Contractor shall ensure that the ATP shall follow the instrumentation requirements (Para. 22-4) and operating limits (Para. 22-11) for testing the Power Turbine Assemblies (PTA) if available:

a. Low Pressure Turbine - Manual Fuel Control

b. Low Pressure Turbine - Digital Fuel Control

3.8.9.1.3 The Contractor shall ensure that the ATP defines the normal operating conditions for the test cells #19 and #20, and chapters 13 and 22 also provide acceptance criteria for the GGA and PTA. Passing the acceptance criteria for the GGA and PTA shall be the acceptance criteria for the test cells #19 and #20.

3.8.9.1.4 The Contractor shall submit two (2) copies of the manufacturer's standard performance, operational, alignment, accuracy, and repeatability test procedures (CDRL A005) with the Contractors’ proposal for Government review. The Government will inform the Contractor of the acceptance or the rejection of test procedures.

3.8.9.2 Performance tests (new equipment). After installation at FRCSW NAS North Island, the Contractor shall perform the final acceptance tests:

3.8.9.2.1 Conduct of Test Program

a. At FRCSW, a specific LM2500 engine, Serial Number GG2024, will be used for correlation test, and verify the new LM2500 test system.

b. The Contractor shall not make adjustments to, or replace engine hardware on LM2500 Engine Serial Number GG2024 between engine runs.

3.8.9.2.2 Success Criteria

a. The Contractor will ensure that the Isentropic Gas Horse Power calculated in the test cell is within +1% of baseline data.

b. The Contractor will ensure that the Turbine exit temperature in the test cell is within +5° F of baseline data.

c. The Contractor will complete the final acceptance test, which includes the engine installation, instrumentation calibration and engine test, within 10 working days.

d. The Contractor will certify that the test cell is satisfactory for the depot level performance testing of LM2500 turbo shaft engines

e. The Contractor shall issue preliminary letter on the results of the testing upon the completion of the test.

3.8.9.2.3 Facility Installation Requirements

a. The Contractor shall install the engine in the test system as described in S9234-AB-MMD-030/LM2500, Gas Turbine Overhaul and Repair Instructions, Part 2, Revision 4, 15 Mar 2012.

b. The Contractor shall measure the engine exhaust nozzle area.

c. The Contractor shall use JP-5 or JP-8 fuel.

d. The Contractor shall use MIL-L-23699 oil as the engine lubricant.

3.8.9.2.4 Instrumentation Requirements

a. The Contractor shall measure and record the primary performance of the parameters of the items on the Instrumentation List, enclosure (1), is a list of the primary performance of parameters that will be measured and recorded.

b. To ensure accurate data acquisition when comparing engine performance, The Contractor shall perform the instrumentation calibrations prior to engine testing. Using the procedures in LM2500 Engine Test Cell Calibration Procedure, 1 Mar 04, the Contractor shall perform calibration on the instrumentation and over the associated range and with the tolerances listed in enclosure (1).

c. The Contractor shall perform instrumentation endtoend system checks from as close as possible to the sensor to the test cell control cab indicator. This to include heat gun checks of all thermocouple connectors.

3.8.9.2.5 Test Requirements

a. The Contractor shall record following engine life parameters:

1. Number of engine starts

2. Engine run time

b. If necessary, the Contractor shall perform a water wash of the engine prior to the start of each performance run.

3.8.9.2.6 Test Plan (CDRL A001)

a. The following test plan, with the exception of step c is applicable for the test. The Contractor shall use step c below for exhaust nozzle validation.

b. The Contractor shall perform a minimum of three performance runs as described below. The Contractor shall provide documented nozzle area.

c. For each performance run, the Contractor shall record test results at the following power settings:

1. Pre-test Zero data (prior to engine start)

2. Idle

3. NGGK = 9500 rpm

4. NGGK = 9400 rpm

5. NGGK = 9300 rpm

6. NGGK = 9200 rpm

7. NGGK = 9100 rpm

8. NGGK = 9000 rpm

9. NGGK = 8900 rpm

10. NGGK = 8800 rpm

11. NGGK = 8700 rpm

12. NGGK = 8600 rpm

13. NGGK = 8500 rpm

14. NGGK = 8400 rpm

15. NGGK = 7750 rpm

16. Idle

17. Post-test zero (following engine shutdown)

d. The Contractor shall stabilize the engine for a minimum of 10 minutes at the max power point and 5 minutes for all other power setting before recording the test results. The Contractor shall record three datum points after the 5 or 10 minute stabilization at each of the power settings.

e. The Contractor shall shut down the engine for a minimum of one hour between performance runs.

f. Before and after each calibration, the Contractor shall record the weather conditions (wind direction, velocity, relative humidity) in the vicinity of the engine.

g. The Contractor shall conduct the test program to minimize the amount of engine run time.

3.8.9.2.7 Data Analysis Requirements

a. The Contractor shall use the LM2500 Performance Reduction program to calculate the engine performance.

3.8.9.2.8 Test Article Maintenance Requirements

a. The Contractor shall take oil samples as necessary and are to be subjected to analysis consistent with the standard Spectrometric Oil Analysis Program (SOAP) requirements.

b. The Contractor shall take fuel and oil samples to measure the temperature, density (specific gravity) and viscosity. Lower Heating Value (LHV) will also be determined from the sample

c. The Contractor shall perform an inspection of the engine upon receipt of the engine. The Contractor shall perform additional inspections as necessary during the test program.

d. Following completion of testing at a facility, the Contractor shall preserve the engine as per the procedures in S9234-AB-MMD-030/LM2500, Gas Turbine Overhaul and Repair Instructions, Part 2, Revision 4, 15 Mar 2012.

3.9 Installation:

3.9.1 No lead time for manufacturing: Installation to start no later than 90 days after contract award date with a working schedule of Monday through Friday 0600 to 1430 PST hours, respecting federal holidays, furloughs, base closures, and other dates that the base might not be operational.

3.9.2 Lead time for manufacturing: If equipment has a lead time for manufacturing, Contractor to provide the lead time at the time of award to TPOC and KO for approval. Equipment shall arrive on site no later than 30 days after manufacturing, initial inspection, and acceptance at manufacturer’s location has taken place.

3.9.3 Site Preparation: The Contractor is required to remove all existing electrical, mechanical, and pneumatic, components associated with the overhaul/replacement of the test equipment listed in 3.1 – 3.5. This shall be completed no later than seven (7) days before equipment is scheduled to arrive on site. Work shall have a minimum impact on the Government, all work shall be scheduled as to not have more than seven (7) days in between all work completed and the arrival of the equipment.

3.9.4 Utilities: The Government will provide all utilities within 20’ from equipment. Contractor shall be responsible of all utilities and connections from that point to the equipment.

3.9.5 Access to the base: The Contractor shall coordinate with FRCSW TPOC the base access requirements at the time of contract award.

3.10 DELIVERABLES:

3.10.1 Installation & Integration: Contractor shall install and integrate new hardware/software as specified in this SOW. System level functional tests will be performed after installation and integration.

3.10.2 Calibration Procedure (CDRL A006): Contractor shall provide the calibration documents for the LM2500 equipment, for the whole system, and the list of equipment that is used to perform calibration if applicable.

3.10.3 Prints and/or Drawings Documentation and Manuals: The Contractor shall provide all prints, drawings, schematics, specifications, Bill-Of-Materials and documentation (CDRL A002) to complete this project in the form of two (2) electronic sets in CD/DVD format and two (2) hard copy sets to FRCSW TPOC before the final completion date and not later than five (5) working days after completion of all work. Contract shall be signed off by FRCSW TPOC and representatives after all manuals, documentation, and training requirements have been satisfied.

3.10.4 Training Manuals: All training manuals (CDRL A007) are required to cover in detail all phases and cycles of operation such as start-up, maintenance, idle, shut down, trouble shooting, programming, running programs, printing, re-starting systems, etc. Manuals shall include the Vendor’s contact information, parts list, preventive maintenance cycles, any/all information and documentation necessary to properly service, operate, maintain, adjust, and perform all functions within the equipment.

3.10.5 Maintenance Manuals: All maintenance manuals (CDRL A008) shall properly identify in detail the extent of preventive maintenance, materials, liquids, substances, parts, and chemicals used during preventive maintenance, repair, and/or troubleshooting of equipment. A complete list (CDRL A004) of all materials, chemicals, substances, and parts used for the maintenance and operation of the equipment shall be provided to the Government.

3.10.6 Calibration Manuals: All calibration manuals (CDRL A006) are required to properly identify in detail the extent of calibration, part numbers, model numbers, and manufacturer used.

a. A complete list (CDRL A004) of all materials, chemicals, substances, and parts used for the calibration, or that need to be calibrated within the equipment shall be provided to the Government 90 days prior to installation of equipment, but no later than end of contract period of performance. Manuals shall be provided at the time of delivery and/or before acceptance of equipment.

3.11 CALIBRATION: The Contractor shall comply with all Calibration Requirements listed under 2.0 “Applicable Documents,” NPSL-BP-01.

3.12 INSPECTIONS:

3.12.1 Safety: FRCSW Safety to inspect, clear, and certify all work at the time of completion. All work performed shall pass all of the tests and inspections required by OSHA 29 CFR 1910, Government/Federal Regulations, and FRCSW Safety before closeout of project.

3.12.2 Fire and Safety: A final inspection and certification is required by the fire department and safety department at the time of completion.

3.12.3 Environmental: Industrial Hygienist and Environmental at FRCSW will inspect, clear and certify all work at the time of completion according to the applicable documents and requirements cited in this SOW.

3.13 QUALITY ASSURANCE:

3.13.1 Responsibility for Inspection: The Government reserves the right to perform any inspections set forth in the SOW where such inspections are deemed necessary to assure supplies and services conform to prescribed requirements.