SOW_Test Cell 19 20_60C1EL027SE_3_02_21.docx

CIP# 60C1EL027SE

CIP# 60C1EL027SE

STATEMENT OF WORK

OVERHAUL OF LM2500 ENGINE TEST CELL #19 and #20 in Bldg.397

STATEMENT OF WORK

OVERHAUL OF

LM2500 TEST CELLS #19 & #20

FRC-SW, Building 379

Prepared by Michael Anderson / David Colson - Project Manager Dung Tina Phan - Electrical Engineer Fleet Readiness Center Southwest (FRC-SW) – North Island

1.0 SCOPE:

1.1 SYSTEM OVERVIEW:

The LM 2500 Engine Test Cells #19 & #20 are used to perform depot-level functional and performance testing of General electric LM 2500 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 LM 2500 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 LM 2500 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 structures 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 (FRC-SW), in Building 379.

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:

Note: Options are unilateral rights of the Government and will be exercised, if required, by the Government. The inclusion of options in a contract does not constitute any guarantee to the contractor that the option will be exercised.

2.0 APPLICABLE DOCUMENTS AND REFERENCES:

2.1 GOVERNMNET 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 (DoDISS) 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)

b. OEM calibration certificates/letters (CDRL B003)

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

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. Add any other necessary documents per engineering

c. 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 Designated Government Representative (DGR) 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 DGR.

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, contractors are cautioned that they must meet all specified requirements cited in this SOW.

3.0 REQUIREMENTS:

3.1 OVERAL 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 FRC-SW 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. Plumping and Tuning 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

p. Intercom system

q. CCTV system

r. Exhaust Cone (Test Cell #20 only)

s. Miscellaneous Materials

Software:

a. Graphical User Interface (GUI) Software Update

b. Debugging system is more transparent to identify the 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, plumbing, interlocks, and other components to restore the system to the latest state of arts 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, documentations, 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 with a minimum of 19” and consist of internal hardware and peripherals.

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

3.1.1.2 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

· SYTRONIC’ Professional Turbine Engine and Component Software (ProTECS) latest version

· SYTRONIC’s ProTECS Configuration Files

· Rockwell RSLogix 500 Ladder Logic Programming Package

· Rockwell Factory Talk Studio Machine Edition Programming Package

· Rockwell RSLinx OEM

· MySQL Database Server 5.7 or latest version

· Symantec Norton Ghost 10.0 Drive Imaging Package

· Acronis True Image 2018 Driver Imaging Package or latest version

· Adobe Acrobat Reader 7.0 Software or latest version

· Excel 2020

· Word 2020

· Snipping Tool

3.2.2 19-inch Flat Panel Monitors:

At least five 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 monitor shall be specifically used for monitoring any Woodward event log.

3.2.3 Panel View Plus Touchscreen Monitor:

Monitor shall be at minimum equivalent to a 19-inch mount-on Allen-Bradley Panel View Plus 1500 Touchscreen Monitor is integrated in the Operator Control Console and serves as a control and annunciator panel for engine and facility function.

(Facility is consider of fuel room, or test cell engine, or other functions)

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 state-of-the art 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 and state-of-the art 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 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 and state-of-the-art 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 State-Of-The-Art 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 State-Of-The-Art. 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 state-of-the-art. This Vibration Tracking system must configure 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 state-of-the-art. 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 Daytronic Model 2168-200C AC voltage Meters to the latest State-Of-The-Art to provide a measurement of the AC amplitude level of the LM 2500 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 State-Of-The-Art. This Dlink shall provide the Ethernet communication path between the DADCS components.

3.2.15 Pressure Transducer:

The Contractor shall upgrade a series of Honey-well 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 state-of-the-art. The Woodward is providing the engine control required for DFC LM 2500 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 state-of-the-art, 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, plumbing, interlocks, and other components necessary to restore the thrust stand with the latest state-of-the art 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 state-of-the-art that are in the Thrust Stand J-Box for the measurement of the following pressure parameters:

3.1.1.1 Fuel Inlet Pressure (FUELIP) is from 0 to 100 psg

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

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

3.1.1.4 Lube Oil Pressure (LOP) is from 0 to 250 psia

3.1.1.5 Spare Pressure is from 0 to 30 psid

3.3.3 New Exhaust Cone (Test Cell 20 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 LM 2500 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 Digital Fuel Control (DFC) cart or the latest state-of-the-art model. The DFC cart shall be capable of testing either the Digital Fuel Control or Manual Fuel Control (MFC) variant of the LM 2500 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 and to reattach panels which have been dislodged.

3.3.8 Test Cell lighting system:

The contractor shall provide an LED lighting system to replace existing lighting system.

3.3.9 Test Cell camera system:

The current camera controller in the test cell is old and obsoleted. The camera system in the test engine room have three cameras and they do not function correctly and not cover all angles that needed to check while running the engine test. The contractor shall add more cameras and upgrade the system to a latest state-of-the art.

3.3.10 Sliding Doors

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

3.4 FUEL ROOM:

The contractor shall provide and install two 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, Compressor Inlet Temperature Resistive Temperature Devices (RTD), 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 completed installation shall meet all applicable Environmental Protection Agency (EPA) and Occupational Safety Health Association (OSHA) restriction 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. The contractor shall coordinate with FRC-SW and Naval Air Station, North Island (NAS) regarding construction site approvals and environmental permits required by Federal, State, Country, and Local Laws. For additional information, the contractor is instructed to contact the Designated Government Representative (DGR). Within 30 days from contract award, contractor shall provide in writing the make, model, capacity, footprint, mechanical, and electrical requirements of the equipment to the DGR.

Permitting. FRCSW is responsible for obtaining the required Authority to Construct and Permit to Operate from the San Diego County Air Pollution Control District (SDCAPCD) for this equipment. Construction shall not commence until the Authority to Construct is received by FRCSW. The contractor shall ensure that the equipment meets all SDCAPD requirements in accordance with the latest version of their rules and regulations. Final acceptance will be contingent upon the installed equipment meeting all conditions listed on the SDCAPCD Authority to Construct and Permit to Operate issued to FRCSW.

Waste Disposal. Disposal of non-hazardous solid waste disposal shall be the responsibility of the contractor. FRC-SW 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 shall be 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 DGR and obtain specific instructions in regards to location and latest regulation from the government for disposal of old equipment/parts/machinery.

3.2.1 Safety and Health Requirements: All machine parts, components, mechanisms, and assemblies furnished for the LM2500 ENGINE TEST CELL #19 and #20, whether or not specifically required herein, shall 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 machine 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 machine shall be constructed of parts that are new, without defects, and free of repairs. The structure shall withstand all forces encountered during operation of the machine 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 machine 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 machine 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 machine 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 Secondary Containment: Contractor to verify with DGR if equipment will require a secondary containment. The Secondary (if needed) Containment shall be built around the equipment to ensure no leakage, spillage, or contamination extends to the floor or rest of the equipment. This secondary containment shall meet all OSHA and EPA guidelines. A design/drawing for secondary containment shall be delivered to the DGR at the time of the design/award/notice to precede meeting.

a. The secondary containment system shall hold 100% all liquids within the equipment in the event of a spill, leakage, release, or malfunction of the equipment where liquids are released on to the floor. The industrial lining shall be strong enough to contain all liquids and prevent any spillage onto the ground and shall meet all EPA and OSHA guidelines and requirements.

3.7.12 Epoxy floors: The Contractor shall verify with the DGR if epoxy floors are needed. 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 DGR is to sign off on the class, consistency, color, and type of Epoxy.

3.7.13 Foundation: The Contractor shall verify with DGR the depth of the present foundation. If it is determined that the new equipment requires a different depth (e.g. present 11” needs 14”), then the contractor shall include all foundation work as part of the project and ensure the foundation will be strong enough to withstand the equipment and its workload. All foundation unless otherwise stated in this SOW shall be at the same level than the rest of the foundation/floor in the building.

3.8 Acceptance Test: A draft acceptance plan shall be delivered 90 (Ninety) days prior to installation of the equipment. FRC-SW 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 FRC-SW comments shall then be delivered to the FRC-SW DGR for approval.

3.8.1 Test Plan: Contractor should give a 90-day (ninety) notice before anticipated completion of the project. Any tests shall be coordinated through the FRC-SW DGR.

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 FRC-SW’s DGR.

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 FRC-SW – North Island should a major performance issue arises. The contactor shall repair and/or stiffen the system via an ECO should a performance issue arises during this validation. Acceptance will be provided by FRC-SW’s DGR and signed off by DGR, FRC-SW engineer, and Army Corps of Engineering representative.

3.8.4 The contractor shall conduct the final inspection for acceptance in the presence of FRC-SW’s Engineers, KO, and DGR.

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 Mechanical drawing, circuit schematic, troubleshooting documentation, and related software: Contractor shall provide three sets of hard copy, and three sets of soft copy for storages and records.

3.8.7 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.

3.8.8 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 or included on the original bid.

3.8.9 Calibration: Contractor shall provide a certificate of calibration from the manufacturer and all the relevant documentation. A list of all parts that require calibration shall be provided to the DGR 90 days after award of contract.

3.8.10 Acceptance Test: Contractor shall schedule and coordinate acceptance test with the FRC-SW DGR.

3.8.11 An Acceptance sign-off shall be completed as two separate acceptance criteria. This acceptance is intended to be a verification of the performance of this system.

3.8.12 Operational test (new equipment). The machine shall be operated in accordance with the manufacturer's standard operating test procedure (see section 3.19.2).

3.8.13 Performance tests (new equipment). After installation at the end user's facility, the list of final acceptance tests shall be provided and shall be performed per section 3.19.3. The contractor-supplied component(s) shall have certification as to the dimensions and demonstrate the LM 2500 Thrust Stand adherence to this SOW include what documentation it shall comply to.

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 DGR and KO for approval. Equipment shall arrive on site no later than 30 days after manufacturing, initial inspection, and acceptance at manufacturer’s has taken place.

3.9.3 Construction: Any electrical, mechanical, pneumatic, foundation, equipment removal, and work that is deemed necessary for this project, shall be completed no later than 7 (seven) 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 7 (seven) days in between all construction work completed and the arrival of the equipment. Site is not to be left empty waiting for equipment to arrive for no more than 7 (seven) days.

3.9.4 Utilities: The Government shall 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: shall be coordinated with FRC-SW DGR 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: Contractor shall provide the calibration documents for Woodward machine, for the whole system, and the list of equipment that use to perform calibration if applicable

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

3.10.4 Training manuals: All training manuals 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 must 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 must 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 of all materials, chemicals, substances, and parts used for the maintenance and operation of the equipment must be provided to the Government.

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

a. A complete list of all materials, chemicals, substances, and parts used for the calibration, or that need to be calibrated within the equipment must be provided to the Government 90 (ninety) days prior to installation of equipment. Manuals must be provided at the time of delivery and/or before acceptance of equipment.

Title Deliverable.

Engineering Documentation Software Media Software Operating System Documentation and Media Software Application Program Documentation and Media System Documentation Validation Plan and Procedure Validation Report System User’s Manual Calibration Procedures Maintenance Manuals Provisioning Technical Documentation Plan of Action and Milestone (POA&M)

3.11 CALIBRATION:

3.11.1 STE Test Set Calibration Requirements:

The Contractor shall provide the capability/information for the FRCSW to calibrate STE, Test Adapter Fixtures and Specialized Repair Equipment (SRE). Calibration is defined as the comparison of a measurement system or device of unverified accuracy (unit under test) to a measurement system or device of known or greater accuracy (reference Calibration Standard (CALSTD)) to obtain a measurement result. The CALSTD is a measuring instrument or artifact used as a reference to establish and maintain the accuracy of other measuring instruments or artifacts. CALSTD may be used to calibrate other standards of lesser accuracy or to calibrate Test, Measurement, Diagnostic Equipment (TMDE) directly. Calibration should not be confused with "adjustment" or "alignment" of a measuring system. Calibration of TMDE and Support Equipment (SE) confirms an acceptable level of measurement reliability. TMDE/SE performance is compared against CALSTDS for a higher level of accuracy. This often occurs in upper level calibration laboratories with traceability to national standards maintained by the National Institute of Standards and Technology (NIST) and the United States Naval Observatory (USNO) using natural physical constants or ratio type calibrations. Any performance parameter of TMDE/SE used to make quantitative measurements or to provide a reference quantity of known value must be calibrated.

The Naval Surface Warfare Center (NSWC) Corona serves as the scientific and technical agent for the Navy Metrology and Calibration (METCAL) Program. NAVAIR METCAL Program office maintains their technical authority to the Navy’s acquisition and logistics managers while NSWC Corona ensures that the Navy’s measurement capability and calibration standards are properly planned, implemented, and supported per OPNAV Instruction 3960.16

3.11.1.1 Instrument Calibration Procedures (ICPs) Source Data:

The Contractor shall provide ICP source data for all instruments requiring calibration including all embedded COTS equipment: system/subsystem specifications, functional specifications, manufacturer’s catalogs or data sheets, user’s manuals, maintenance manual, Acceptance Test Procedure (ATP), engineering drawings and associated technical data including all versions of relevant software (which impact calibration) for TMDE and calibration equipment/standards that do not have US Navy-approved ICPs. The Contractor shall submit specific recommendations and data using any Contractor’s Technical Report process. The Contractor shall provide drafts of the ICP source data 60 days prior to the Test Readiness Review (TRR).

3.11.1.2 Calibration Manual:

The Contractor shall provide a calibration manual that properly identify in detail the extent of calibration, methodology, part numbers, model numbers, and manufacturer used for the calibration equipment. All TMDE and Support Equipment (SE) shall follow Navy standard, and allow authorized Navy personnel to access.

The calibration manual should outline the calibration coefficient update process, and provide update calibration coefficient or any embedded equations related to calibration for the system;

A complete list of all materials, chemicals, gas purity, substances, and parts used for the calibration, or that need to be calibrated within the equipment shall be provided to the Government one hundred and twenty (120) days prior to installation of equipment.

Any required environmental conditions (e.g. temperature, humidity, pressure) and facility requirement (e.g. compressed air-line, ventilation system) that must be adhered to during calibration process to meet specification must be clearly stated in the calibration manual. The calibration manual shall also contain information on recommended calibration interval of all individual subcomponents that need to be calibrated.

The vendor prepared ICP(s), as part of the calibration manual, must have NAVAIR METCAL approval before use. The Contractor shall provide drafts of the ICP 60 days prior to the Test Readiness Review (TRR). The Contractor shall provide the final versions of the ICP and ICP source data at the conclusion of Acceptance Testing and after incorporation/correction of all discrepancies found in accordance with CDRL B001 and through the outcome of the review/inspection process by the Metrology Engineering FST team at FRCSW.

The ICP(s) shall be written following the guidelines of NAVAIR 17-35TR-50. This document, which must be used in conjunction with the current NAVAIR 17–35TR–04 document (Requirements for Preparation of Instrument Calibration Procedures), provides directions covering all elements of all new calibration procedure development process, including style, format, and technical content. This allows NAVAIR to better manage the calibration parameters of standards and workload; streamlining the calibration procedure to promote the consistency, efficiency, and success of calibration process; and the inclusion of functional features that enhance the technicians’ ability to perform the calibration. NAVAIR 17-35TR-50 and NAVAIR 17–35TR–04 is included as attachments to this Statement of Work (SOW).

3.11.1.3 Calibration and Measurement Requirements Summary (CMRS):

A CMRS Guidance Conference shall be conducted prior to the System Function Review (SFR) and occur between the Contractor and Metrology Engineering FST team to discuss the functions and required information on the CMRS.

It is the intent of the CMRS to document and outline the traceability from actual system and equipment level measurements to the National Institute of Standards and Technology (NIST) through an unbroken chain of comparisons. These measurements are traced through properly selected and calibrated Test, Measurement, and Diagnostic Equipment (TMDE). Traceability of all system, subsystem, and equipment parameters will ensure system and equipment operational integrity and accuracy. The Contractor shall prepare a CMRS, which shall be developed using MIL-STD-1839(Series), and DI-QCIC-80278(Series) as guidance.

The CMRS shall identify:

(1) Calibration support requirements for a weapon system/platform or major subsystem.

(2) Technical summary of calibration and measurement requirements of weapon systems, SE, TMDE and calibration reference standards.

(3) Documents traceability of platform measurement requirements to NIST

The Operational/System and Subsystem Device should be reflected under Category I of the CMRS; the Test, Measurement, and Diagnostic Equipment (TMDE) and/or Support Equipment (SE) under Category II and the Calibration Equipment /Standards under Category III. (CDRL B002).

The initial Review of contractor CMRS draft is conducted 90 days prior to Preliminary Design Review (PDR). Second CMRS Review is conducted 30 days prior to Critical Design Review (CDR). The final CMRS Review is conducted in unison with CDR and is followed with submission to Metrology Engineering FST Team for final review and approval. The CMRS approval will includes, but not limited to, a review of Contractor identified measurement parameters, accuracy of CMRS information (e.g. Test Uncertainty Ratio (TUR), Probability of False Acceptance (PFA), Test methodology), traceability, completeness and consistency of CMRS data, correlation between Contractor recommendations with standard Navy practices.

3.11.1.4 Risk Level of Calibration Process:

It shall be clearly documented in the CMRS the required tolerance of the Category 1 and Category 2 equipment and the measurement uncertainty of the contractor recommended CALSTD(s) and any ancillary equipment that contribute to the uncertainty budget for Category III equipment. Contractor shall ensure all measurement processes utilizing TMDE and CALSTD(s) are capable of limiting the risk of wrong measurement decisions at each level in the traceability chain for any supported measurement parameter. The risk level for measurement processes must be documented to include the probability of false acceptance and probability of false rejection. Probability of false acceptance must be limited to 2 percent or less. Probability of false rejection impact on total cost and readiness must be considered and must not exceed 15 percent. The aforementioned documentation must be submitted to Metrology Engineering FST team for review and approval.

(1) Measurement processes with a documented minimum test uncertainty ratio (TUR) of 4:1 or greater for each measurement parameter will be deemed to meet this requirement.

(2) If a probability of false acceptance of 2 percent or less and a probability of false rejection of 15 percent or less cannot be achieved, the contractor must provide, prior to implementation, a documented justification or mitigation strategy for the deviation to Metrology Engineering FST Team for resolution and approval.

In the event that the contractor recommended CALSTD equipment is not listed in the Calibration Standards and Equipment List (CALSEL) which contains a complete and current inventory of NAVAIR CALSTDs, the Contractor must provide…