Performance Work Statement Sources Sought.DOCX

Performance Work Statement (PWS) For Caterpillar 3456 Engine and SR4B Alternator Rebuild and Refurbishment September 17, 2020

Prepared by:

Albert Lyou – Mechanical Engineer Generator/ECO Special Operations Branch C5ISR Center, Product Realization Directorate (PRD) U.S. Army Combat Capabilities Development Command

1.0. Scope. This Performance Work Statement (PWS) defines the efforts required to render the services required by this solicitation in accordance with the documents listed below. The services being purchased are entitled “Caterpillar 3456 Engine and SR4B Alternator Rebuild and Refurbishment”. This is a requirement to provide: manufacturing-specific overhaul and rebuild of Caterpillar (CAT) 3456 diesel engines in all aspects to manufacturer warranty-level quality; the assembly and disassembly, physical and mechanical inspection, cleaning, maintenance, electrical load testing, and refurbishment of IPS Caterpillar SR4B alternators; the testing and validation of the complete power pack, packaging of the finished power pack; and shipment of the power pack. A “power pack” is the paired combination of a single CAT 3456 Engine and a single SR4B Alternator.

Engine & Alternator: Rebuilds and refurbishments will be completed in accordance with the manufacturer’s specification. Rebuilds will include engine/alternator decoupling and recoupling, engine disassembly, engine reassembly, cleaning of components, inspection of engines, disassembly and reassembly of alternators, physical and mechanical inspection of alternators, cleaning of alternators, maintenance of alternators, electrical testing of alternators, and refurbishment (dip and bake) of alternators.

Testing and Validation: (Insert engine break-in procedures paying particular attention to expected power levels required from the engine when considering the additional mechanical loads (hydraulic pump) so that the end result meets our requirements in the absence of a MEP-810 test bed). Engines do not have mounted radiators.

Packaging: The completed power packs will be packaged so that every component is secured and contained within a completely enclosed wooden crate capable of being reused and overseas shipment. All fasteners shall be of a thread type and capable of removal and reuse. All lumber/plywood used will be pressure treated (outdoor rated). All carriage bolts, screws, lag screws and associated nuts and washers will be outdoor rated. Screws (1 ¾” long) will be used to construct each component (i.e base, end, side, top). Lag screws (3/8” diameter, 4” long) with correct washers will be used to assembly the components together. All carriage bolts will have the appropriate nuts and washers included.

Shipping and Receiving: The contractor will pick up power packs identified for rebuild from Letterkenny Army Depot (LEAD), at 1 Overcash Avenue, Chambersburg, PA 17201, ATTN: DOCK 2, W90CGJ. Upon completion of the complete rebuild and overhaul, testing and validation, and packaging, the contractor will deliver overhauled power packs back to LEAD. All contractors must include transportation costs as part of the quote. Contractors must complete the overhaul of each power pack in 45 working days, not including shipping time. Overhauled power packs will be warrantied against failure for one year, or 1,000 operating hours, from the date of return to LEAD.

2.0. Applicable Documents. The following documents are applicable to the extent cited.

2.1. Reference Manuals

A. Service Manual SR4B SENR5359 01; ANSI/NETA MTS 2015 B. CAT Cleaning and Drying of Electric Set Generators SEHS 9124 C. Generator Service Manual – SENR5359

2.2. List of CDRL

B. Government Property Inventory Report C. Contract Government Furnished Material (GFM) Reporting of Government requisition and inventory report Inventory Held under Product Support Contractual Arrangements

3.0. Requirements. The items being serviced herein:

Generator & Alternator

Power Packs and Skids

The contractor shall provide all personnel, equipment, supplies, facilities, tools, materials, and other items necessary to rebuild and overhaul, validate, and ship CAT 3456 engines, IPS (CAT) SR4B Alternators, and a complete “turn-key” power pack as defined in this Work Statement. The Contractor shall perform to the standards in this contract.

These requirements listed may be expanded by mutual agreement between the Government and the Contractor by modification to the contract.

3.1 Receiving: Upon notification from ILSC PED, the contractor shall pick up the power packs identified for rebuild within seven business days from Letterkenny Army Depot (LEAD), at 1 Overcash Avenue, Chambersburg, PA 17201, ATTN: DOCK 2, W90CGJ. The contractor will identify their own logistic channel for delivery to and from LEAD (W90CGJ).

3.2 Power Pack Decoupling/Recoupling: The Contractor shall pick up the power pack from LEAD (W90CGJ), with the engine and alternator still connected to each other. The contractor is responsible for decoupling the alternator from the engine prior to the performance of the rebuilds and refurbishments. After completion of the services, the contractor will be responsible for recoupling the alternator to the engine prior to testing and crating.

3.3 Engine Disassembly/Reassembly: The Contractor shall be responsible for all assembly and disassembly inherent in performance of the cleaning, inspections, maintenance, and refurbishment of engines. The ECM will be reset for zero (0) hours.

3.4 Engine Component Replacement: The Contractor shall at the minimum, replace the following items during the rebuild using Original Equipment Manufacturer (OEM) components from the manufacturer or acceptable alternative approved by Caterpillar:

· Cylinder liners

· Piston skirts

· Piston crowns

· Piston rings

· Cylinder head

· Thermostats

· Main bearings

· Rod bearings

· All front gear bearings

· Thrust plates

· Fuel injectors

· Turbo charger

· Water pump

· Oil pump

· All seals and gaskets

· Oil and fuel filters

· Any other component deemed out of tolerance IAW CAT specifications.

3.5 Alternator Assembly/Disassembly: Contractor shall be responsible for all assembly and disassembly inherent in performance of the cleaning, inspections, electrical testing, maintenance, and refurbishment (dip and bake) of alternators. The IPS Enduraseal process must remain intact.

3.6 Physical and Mechanical Inspection: The Contractor shall inspect the physical and mechanical condition of alternator housing, bolting connections, anchorage, alignment, grounding, rectifiers, all components of the rotating field assembly (RFA), main armature, terminal leads, bearing, cables, and space heaters. (Reference: Service Manual SR4B SENR5359-01; ANSI/NETA MTS-2015)

3.7 Cleaning: The Contractor shall perform “as found” test(s) to determine the condition of insulation (see Electrical Testing). Cleaning will be performed to remove all contaminants such as dirt, grease, salt, or oil. Cleaning will be accomplished either by washing with an approved solvent IAW manufacturer’s directors or with steam cleaning when justified by dirty and greasy windings. Windings shall be oven dried after cleaning. After the windings and insulation have dried, the windings should be “dipped and baked” in a suitable varnish. (Reference: CAT Cleaning and Drying of Electric Set Generators SEHS 9124).

3.8 Maintenance: The Contractor shall be responsible for checking and balancing the rotor, replacing the main rotor bearing, installing and complete rectifier heat sink assemble, machine work to repair the ODE bearing housing, inspect PM exciter stator, identify any broken parts. Pain the alternator to match as closely as possible the original color (Caterpillar Yellow).

3.9 Repairs: If the equipment sent for refurbishment is found to be deficient and requires additional repairs outside the overhaul, a price estimate will be provided to the Government. The Government must approve all additional repairs and parts prior to installation. If the repair is not funded, the contractor will complete the refurbishment in accordance with this PWS and return shipment to LEAD (W90CGJ).

3.10 Electrical testing: Each alternator shall be tested in its “as found” and “as left” (after refurbishment conditions. Test values will be adjusted for temperature and humidity IAW ANSI/NETA 2015 MTS standards. Testing results shall be submitted IAW CDRL A001. The contractor is also responsible for maintaining testing records. These records shall be tracked by alternator serial number. The following components of each alternator will be tested (Reference SR4B Generator Service Manual – SENR5359):

· (CR1-CR6) Rectifier

· (CR7) Varistor

· (L1) Exciter field (Stator)

· (L2) Exciter armature (Rotor)

· (L3) Main field (Rotor)

· (L4) Main armature (Stator)

· (L5) Pilot exciter armature

· (PM) Permanent magnet Alternators will be tested IAW ANSI/NETA 2015 MTS standards to include:

· Insulation resistance test (PI/DAR)

· Surge test

· Winding resistance test

· Hi-Pot tests

· Step voltage tests

3.11 Enduraseal Coils: The SR4B alternators each must have fully functioning Enduraseal Coils. Should the contractor receive an alternator with either faulty or lacks Enduraseal coils, the contractor shall apply Enduraseal Coils for a pre-negotiated cost to the government.

3.12 Power Pack Break-in Load Test: The Contractor shall perform a power pack break-in and load test on the complete power pack as a complete system on JP8 fuel. The break-in and load test procedure shall include a 110% of 420kW output step. If the power pack break-in and load test is not performed on a MEP-810 chassis with all of its’ parasitic load present, then the procedure MUST include the 46 bhp consumed by the hydraulic pump at ALL points during the test.

3.13 Documentation: Documentation shall be provided to ILSC PED and attached to the power pack when crated listing all components replaced and measurements taken to include the power pack break-in load test as part of the rebuild and services performed.

3.14 Power Pack Crating: The completed power packs shall be packaged so that every component is secured and contained within a completely enclosed wooden crate capable of being reused for repeated shipment. All fasteners shall be of a thread type and capable of removal and reuse. All lumber/plywood used will be pressure treated (outdoor rated). All carriage bolts, screws lag screws and associated nuts and washers will be outdoor rated. Screws (1 ¾” long) will be used to construct each component (i.e base, end, side, top). Lag screws (3/8” diameter 4” long) with correct washes will be used to assemble the components together. All carrier bolts will have the appropriate nuts and washers included.

3.15 Warranty: Overhauled engines shall be warrantied against failure for one year, or 1000 operating hours. Alternators will be warrantied for 5 years.

3.16 Shipping: The contractor shall pick up power packs identified for rebuild from LEAD (W90CGJ). Upon completion of the complete rebuild and overhaul, testing, validation, and packaging, the contractor will deliver completed power packs back to LEAD. Contractors must complete the overhaul of two power packs in 15 working days, not including shipping time to and from LEAD (W90CGJ). Overhauled power packs will be warrantied against failure for one year, or 1000 operating hours, from the date of return to ILSC PED.

3.17 Storage: The Contractor shall be able to store the power packs in various modes of operation between three to six months. The contractor shall submit quarterly inventory reports IAW CDRL B001.

3.18 Inventory: The Contractor shall submit annual reports IAW CDRL B002.

4.0. Government Furnished Equipment.

4.1 Introduction

A. Army Materiel Command (AMC) and its units use Total Asset Visibility – Contractor (TAV-C) capability in its Logistics Management Program (LMP) to account for Government Furnished Equipment, Materiel, or Property (GFE/M/P) placed in the possession of contractors to support contracts for: 1) repair, modification, or upgrade work; 2) materials held for Stock, Store and Issue (SSI), or 3) New Production. Accounting records within LMP for this inventory are subject to verifying physical inventories and audits by the Army to ensure accuracy. This section addresses contractor requirements for repair, modification and/or upgrade contracts.

4.2 System Overview and Portal Access Requirements

A. To use TAV-C, Contractors shall request one of two TAV-C access methods below to exchange required inventory data with LMP: 1) Defense Logistics Management Standards (DLMS) interface or 2) the Army TAV-C Portal. Approval of the contractor’s access method will be based first on the type of work being performed, second, the sufficiency of the contractor’s existing property accountability and connectivity to LMP, and third, request by the to use the portal based on economic factors.

B. Contractors can choose between the two methods for accounting for government property as further described below:

1. Defense Logistics Management Standards (DLMS) interfaces: Contractors that have accounting systems capable of using a DLMS interface (see: DLM 4000.25, Defense Logistics Management Standards (DLMS) on the Defense Logistics Agency (DLA) website) shall request to use their accounting system and interface to account for Government Furnished Equipment/Materiel/Property (GFE/M/P) using DLMS transactions.

NOTE: If a contractor does not currently have an established DLMS interchange with Defense Logistics Agency (DLA) Defense Automated Addressing System (DAAS), it will be the contractor’s responsibility to contact DAAS to establish access to DAAS messaging system to support the exchange of DLMS transactions with the Army. DAAS provides a value added service for standard Military Standards (MILS) transactions providing the ability to receive, edit and route logistics transactions for the Military Services and Federal Agencies. Information on DAAS can be found at https://www.dla.mil/HQ/InformationOperations/DAAS/

2. Army TAV-C Portal: Contractors who, during negotiation with the government, are determined to be allowed to use the TAV-C Portal, will comply with prescribed processes to provide qualified workers to access the system to exchange data with LMP.

C. Portal Access Requirements. Contractor personnel who input data into the TAV-C Portal, must meet qualification requirements specified in the TAV-C Portal Guide Detailed Procedures and requirements are detailed in the TAV-C Portal Guide. These requirements include:

1. Contractor provided computer system: The contractor shall provide a computer system and internet connectivity that meets acceptable standards as identified in the TAV-C Portal Guide.

2. Security Requirements.

(a) The government requires contractor personnel accessing the LMP system to possess either a United States Government Common Access Card (CAC) or a Department of the Defense approved External Certification Authority (EAC). To apply for these credentials, contractor personnel must possess a soft certification from a security credentialing firm.

NOTE: At the time of this writing, the government has successfully used IdenTrust and WidePoint (formerly ORC) for satisfactory credentials. It is the contractors’ responsibility ensure operators accessing the portal have and maintain current credential and to comply with the selected vendors’ service contract requirements. These firms are provided as a courtesy and are not an endorsement for any firm by the U.S. Government.

(b) Contractors will coordinate with the Contracting Officer’s Representative or designated government re presentative to complete required forms to obtain the CAC/EAC. This will require the above certification, forms of identification, etc.

3. User Training Requirements: TAV-C Portal user training is government provided and varies by the function performed. The training is online and completion of the training by each operator is required before accessing and using TAV-C.

4. The on-line training site will be provided by the government after award and access to the system has been granted. Functional training required to begin work should take no more than 15 hours to complete.

D. Problem Resolution: LMP is a government owned and maintained system. The contractor shall notify the COR or designated government point of contact for system related issues and government resolution.

4.3 DLMS Transactions / Portal Data Requirements

A. For DLMS Transactions for repair, modification and/or upgrade contracts, the inventory management transactions to be provided to the government by DLMS interface are:

1. DLMS 527R Materiel Receipt Acknowledgement (MRA) Transactions (for GFM expected to be consumed).

A. For DLMS Transactions for repair, modification, and/or upgrade contracts, the material receipt transactions to be provided to the contractor by the government via the DLMS interface are:

1. DLMS 527D Pre-positioned Material Receipt Document for stock in-transit to vendor.

B. Army TAV-C Portal: Contractors who, during negotiation with the government, are allowed to use the TAV-C Portal to exchange required data directly with LMP, will provide the following information via data inputs to LMP.

1. TAV-C Portal Requirements: Details on entry of the input into the LMP Portal will be provided as part of the government provided training.

2. The required data will be based upon the business process being performed. Inputs and input formats will be driven by the role performed for this work as directed in the contract.

3. The LMP Portal will provide to the contractor reports which will serve to inform the contractor and aid in work performance. Details on the various reports and how they can be used will be covered as part of the government provided LMP Portal training.

C. Consumption Reporting: Quarterly reports on the consumption of repair parts, disposition of equipment, and adjustments to inventories will be provided to the government as specified.