Statement of Work.docx

V3352216

Statement of Work

Yard-Switcher Locomotive for Norfolk Naval Facility

Office of the Secretary, U.S. Department of Transportation Volpe National Transportation Systems Center Infrastructure Engineering and Deployment

Table of Contents

1. SCOPE

This Statement of Work (SOW) specifies the manufacture and delivery of one (1) new Yard Industrial Switching Locomotive including an option for a second locomotive and other options. A complete range of technical data, materials, and equipment necessary to ensure long-term compliance, operations, support, and maintenance for the locomotive. The locomotive required for this solicitation shall meet the range of requirements within this PWS. The delivery destination is Norfolk Naval Shipyard (NNSY) located in Portsmouth, Virginia.

2. APPLICABLE DOCUMENTS

2.1 Compliance Documents

The locomotive must satisfy the following:

a. Association of American Railroads (AAR) Manual of Standards and Recommended Practices Section-M, Locomotives and Locomotive Equipment

b. The Official Railway Equipment Register

c. Code of Federal Regulations (CFR) Title 49, Part 229 Railroad Locomotive Safety Standards

d. American Society of Mechanical Engineers, Boiler and Pressure Code Section IX, Welding Qualifications

e. American Welding Society D15.1 - Railroad Welding Specification

f. American Iron and Steel Institute Standards

3. LOCOMOTIVE REQUIREMENTS & SPECIFICATIONS

3.1 General Description and Configuration

3.1.1 Locomotive Type

New railway industrial/yard-switching diesel-electric locomotive. Locomotive shall be manufactured on a new frame and offer similar capabilities to a GE 80-ton unit it is replacing.

3.1.2 Dimensions

Overall length not to exceed 45 ft.

Width not to exceed 10 ft 6 inches.

Height not to exceed 15 ft.

3.1.3 Rail Gage

North American railway track gage, 56 ½ inches.

3.1.4 Weight

Locomotive weight shall be appropriate to provide the required tractive effort.

3.1.5 Curve negotiation

Locomotive shall be capable of maneuvering a 125-foot radius curve coupled to 40-foot railway flatcar.

3.1.6 Wheels

a. New steel wheels rated for railway use with flange and tread meeting AAR requirements

b. Wheel sets conform to 49CFR 229.73

c. Automatic wheel flange lubricators on all wheels

3.1.7 Tractive Effort

40,000 pounds minimum

3.1.8 Fuel Tank:

a. Fuel level sight glass and/or electronic gauges located on fuel tank.

b. Snyder (or equal) fuel fitting on filler pipe.

3.1.9 Couplers:

Coupler carrier system on both locomotive ends to allow the coupler to slide horizontally to accommodate curves while providing maximum pulling force coupled to 40-foot and 50-foot railway cars without the tendency to derail the locomotive or the railway cars. The couplers shall include an alignment assisting control feature operable from a safe location on both sides of the locomotive for both couplers. Figure-1 below is included to provide an example of the current design. The locomotive manufacturer shall advise on selection of the appropriate coupler system, including type, dimensions (including nominal 34½ inches (87.6 cm) height from top of rail to center of coupling), and features, to match the couplers used on Norfolk Naval Shipyard rail cars.

Figure 1, Coupler Alignment Control Assist Feature

3.1.10 Brakes:

a. AAR airbrake system compatible with 26L air brake schedule.

b. Basic duplex air end connection.

c. New brake rigging with single shoe design or double acting clasp design.

d. New composition brake shoes (if brake shoes are work more than 50% prior to delivery, a set of new brake shoes must be delivered and installed)

e. Emergency brake valve located in cab.

f. The locomotive shall have an Automatic Brake Application System. While locomotive is in operation, brakes are not applied, and there is no move command, the brakes shall be automatically applied within a preset time.

3.1.11 Emissions

Engine emissions shall meet or exceed current U.S. EPA Tier requirements for new built switcher locomotives at time of locomotive production.

3.1.12 Lighting/Illumination:

a. Dual headlights provided at both ends of the locomotive.

b. Hood/engine lights providing sufficient illumination for performing routine engine maintenance.

c. Step Lights

d. Roof mounted amber strobe light

e. Ditch lights

f. Cab lighting to provide sufficient illumination for all control instruments, meters, and gauges to enable the engine crew to make accurate readings from their normal positions in the cab.

g. The locomotive shall have a spotlight operable from the operator’s seat. The spotlight may be manual or electronic controlled.

3.1.12 Cold Weather Package:

The locomotive shall be equipped with a Cold Weather Package to ensure the locomotive will start and operate in freezing temperatures.

3.1.13 Cab:

3.2 Electrical/Electronics

a. The locomotive shall be equipped with a console mounted radio. The radio shall be programmable with trunking capability.

3.3 Sustainable Acquisition Requirement

To the maximum extent possible and consistent with the Federal Acquisition Regulations Part 23, the Government requires during the performance of the work under this Statement of Work (SOW) the Contractor to provide or use products that are: energy efficient (ENERGY STAR® or Federal Energy Management Program (FEMA)-designated); water-efficient; biobased; environmentally preferable (e.g., EPEATregistered, or non-toxic or less toxic alternatives); non-ozone depleting; or made with recovered materials. Unless otherwise identified in this SOW, each recovered materials or biobased product provided and delivered must meet, but may exceed, the minimum recovered materials or biobased content of an EPA- or USDA designated product. The sustainable acquisition requirements specified herein apply only to products that are required to be: (1) delivered to the Government during contract performance; (2) acquired by the contractor for use in performing services (including construction) at a Federally controlled facility; (3) furnished by the contractor for use by the Government; or (4) specified in the design of a building or work, or incorporated during its construction, renovation, or maintenance.

3.4 Paint

Contractor shall follow AAR Requirements for surfaces that are not to be painted. Ferrous metal surfaces to be painted shall be cleaned by sandblasting, commercial grade grit blasting, or mechanical or chemical means to remove all existing loose paint or other materials. Ferrous surfaces requiring finish painting shall be primed with rust inhibiting primer. Finish paint application shall be applied in accordance with paint manufacturers recommendations but no fewer than two complete finish coats of paint. Paint thickness of the combined primer and topcoat shall in accordance with the paint manufacturer's instructions. Paint specifications for locomotive, shall conform to AAR Standard M-1001 Section C, Part II, Section 5.2.

Black # 17038 Yellow # 13538 Red # 11105

3.4.1 Application to Locomotive:

a. Locomotive body: Yellow

b. Underframe: Black

c. Handrails and steps: Black

d. Trucks: Black

e. Cab interior: Manufacturer’s beige, gray or tan enamel

f. Stenciling: Black locomotive prefix (USN) and the road numbers located below USN stencil on cab. Black (United States Navy) to be located on both sides of low hood configuration (no smaller than 9-inch tall lettering equally spaced).

g. Locomotive number will be defined at a later date.

h. Chevron striping on front (angled 45-degree, downward toward the center) 6-inch (15 cm) black and yellow stripes equally spaced.

i. Locomotive Identification shall comply with 49 CFR section 229.11.

3.5 Training

The Contractor shall provide the training agenda no less than two (2) weeks prior to the start of any training for the government’s review and comment. The Contractor shall provide on-site operator training, hands-on maintenance training, service and troubleshooting training stressing the importance of system interactions and long-term preventative maintenance and operation. The Contractor shall provide training on site for eight (8) operators / maintenance technicians / engineers for three full normal workdays. Operations and systems training shall include equipment set up, systems explanations and features, routine maintenance, programming, and safety practices and procedures. An operator’s manual shall be provided for each student. Two sets of special tools required to perform all maintenance functions will be provided during training, technical manuals and other applicable documents used to identify parts and service manuals required to perform maintenance shall be utilized during the training activities. Training shall take place within 14 days following locomotive delivery and acceptance.

3.6 Documentation

The Contractor shall provide parts manuals, service manuals and operator’s manuals that meet the requirements described below as a minimum.

a. Parts/Service Manual. The locomotive parts/service manual shall be designed to provide quick access to information for the experienced and novice user. The parts/service manual will provide a description for all mechanical assemblies and all special tooling required for performing repairs if failure occurs. Safety will be announced in appropriate areas.

b. Operator’s Procedure Manual. The Contractor shall supply a stand-alone Operator’s Procedure Manual. The Yard Switcher locomotive operator’s Procedure Manual will contain a step-by-step process for starting and shutting down the locomotive. This shall include all safety warnings and safety related operations. Manuals and supporting documentation quantities are described in the following sections.

c. Documentation Package. Technical data descriptions used to describe parts, assemblies and equipment shall consist of data such as specifications, standards, drawings, photographs, sketches, and descriptions, and the necessary assembly and general arrangement drawings, etc. required to indicate the physical characteristics, location, and function of the item.

The complete documentation package consists of the following:

(1) Locomotive dimensions and capacities

(2) Component (part) identification

(3) Maintenance Manual (including troubleshooting guide)

(4) Operator’s Procedure Manual (described above)

(5) Parts/Service Manual (described above)

(6) Lubrication Orders

(7) Electrical schematics and wiring diagrams

(8) Diagrams of all water, fuel, air, and lube systems

(9) All certifications, tests, repairs and inspections

(10) Manufacturer’s Parts catalog (with pricing index if available)

Note: all electronically formatted documentation shall be compatible with Adobe Acrobat Reader and have the ability to be electronically reproduced for Government use.

3.7 Spare Parts/Maintenance Items

The Contractor shall submit a recommended spare parts list with the proposal, which shall be incorporated as part of the contract. Spare parts are those items recommended by the manufacturer to be kept on hand for quick and immediate maintenance access. This list shall identify the parts required to support the locomotive for one year of service. A one-year supply of spare parts as identified in the spare parts list shall be delivered with the locomotive and shall be inspected for completeness before acceptance. This does not include fuel and lube oil.

3.8 Tools

Any special and unique tools necessary to perform preventative and corrective maintenance to be provided.

3.9 Prior to Locomotive Delivery

After contract award but not less than one (1) week prior to delivery of locomotive to destinations the Contractor shall provide complete Documentation Packages (as described above) for the locomotive by road number per locomotive. Documentation Package quantities and locations are described below:

a. One (1) CD or DVD copy to the Volpe Center, Cambridge, MA

b. One (1) CD or DVD copy and three (3) hard copies in binder form to the U.S. Navy (to be determined)

NOTE: The Contractor shall also provide to the Volpe Center and the U.S. Navy the authority to copy and distribute for their use, the documentation described herein.

4. LOCOMOTIVE DELIVERY

At no less than 30 days prior to delivery, the Contractor shall notify the Government representatives of a proposed arrival date at NNSY. The Government representatives will initiate and inform the Contractor of the entry requirements to get Contractor personnel into the shipyard. Upon request, the Contractor shall supply all required information and/or documentation for personnel entry. Contractor personnel shall include all truck driver(s) and all manufacturer personnel who assist with delivery and assembly. Normal Shipyard business hours are 7:30am to 4:00pm Monday through Friday excluding federal holidays

4.1 Final Destination

The Contractor shall deliver the locomotive to the following address:

Portsmouth, VA 23709

The locomotive may be delivered by rail or over the road. Locomotive delivery method shall be specified with proposal.

4.2 General Test and Inspection Information

4.13

4.2.1 Test at Origin

a. Operational Test – Locomotive will be operationally tested meeting all specifications. To be tested at no load for proper operation of all manual controls, electronics, mechanisms and accessories. After initial warm-up, locomotive to be fully cycle tested.

b. Performance Test – Locomotive to be tested using the manufacturers testing plan.

4.2.2 Test at Destination

Acceptance Testing to be conducted prior to Acceptance.

a. Locomotives with flatcar in tow must be able to remain in control with no tendency to de-rail maneuvering a 125-foot radius curve.

b. Operate successfully as designed, pulling full load, and on encapsulated rail throughout Norfolk Naval Shipyard, Portsmouth Virginia.

4.2.3 General Inspection

All manufacturing, inspection and tests shall be conducted and documented by a shop which has AAR M-1003 certification, uses AAR approved practices and procedures and is recognized by the railroad industry. If the shop does not have AAR M-1003 certification, an alternate quality assurance certification shall be deemed acceptable if the Contractor can prove equivalency and provide cross-reference to the AAR M-1003 requirements.

If transportation to destination is by rail, the Contractor’s facilities must be serviced by a railhead and be serviced by a recognized railroad. The facilities must recognize and adhere to OSHA and EPA requirements and standards. Each locomotive shall be certified in writing that each locomotive meets the specifications and minimum requirements of the specifications contained herein. The Government reserves the right to inspect the locomotive prior to any re-work/repair work proposed. Inspections may occur at the location of manufacture. Final acceptance will take place at the destined U.S. Navy installation facilities. The Government shall verify specification compliance at the point of final acceptance. The following check list shall apply:

a. Exterior

(1) General overall appearance is clean and structurally correct as originally designed

(2) Structural damage is nonexistent

(3) No evidence of locomotive body sag or twist

(4) Must be free from any corrosion or oxidation

(5) Must be properly stenciled

(6) Hood, doors and end arrangements conform to standards and operate properly

b. Underframe The underframe shall be damage-free and structurally intact and have legible manufacturer’s builder plates

c. Couplers

(1) Check coupler castings and coupler pockets for repairs or cracks

(2) Check for proper height of coupler

(3) Check and measure coupler knuckle for operation and condition

(4) Check coupler alignment control and operation

d. Brakes

(1) Check air brake cylinders and valves

(2) Check reservoirs

(3) Check all brake rigging

(4) Check hand brake for operation and correct application

(5) Check all safety hangers

(6) Check for correct AAR/DOT pneumatic piston travel

(7) Air brakes shall be tested and adjusted until satisfactory performance is obtained

e. Safety Appliances

(1) Check for proper clearances and applications

(2) Check to ensure handholds and sill steps installed are secured properly

(3) Check Strobe light visibility

f. Trucks

(1) Springs

(2) Wheels and tire defects per 49CFR 229.75

g. Miscellaneous

(1) Electrical circuits tested for continuity and load capacity

(2) Speed recorder

(3) Bell and horn

(4) Safety devices and markings including reflective tape

(5) Cooling system

(6) Protective devices

(7) Low voltage circuits and equipment

(8) Water tightness (including window seals)

4.3 Locomotive Offload, Assembly and Set-up

4.5 The Shipyard can provide a crane and rigging service for the offload and assembly of equipment. Except for the crane and rigging services associated with the offload and assembly, the Contractor will provide all personnel, tools, and equipment necessary to make operational. The Contractor is responsible to provide any specialized rigging gear, written instructions for assembly, and key personnel to instruct/guide Navy personnel with the assembly process.

4.3.1 Offload

The Contractor shall provide supervision and personnel necessary to perform the offload at the destination work site. The Contractor shall instruct the carrier that the equipment shall be offloaded only under the supervision of a representative of the Contractor.

4.3.2 Material Handling Requirements

The Original Equipment Manufacturers (OEM) recommended lifting plan shall be provided. OEM designed specific purpose rigging gear, as opposed to general purpose rigging gear such as standard wire rope slings, rings, and shackles shall be provided with the equipment. Any specialized rigging gear provided by the Contractor will become property of the government. The Government will provide general purpose rigging gear. The Government will inspect and certify the readily commercially available general purpose rigging gear. The Contractor’s specialized rigging gear shall be marked to show its capacity or specific product to be lifted and the gear shall be inspected by the Government in accordance with NAVFAC P-307 paragraph 14.4.2 and 14.4.3. Any lifting operation in support of a Contractor shall require prior approval of the Shipyard Point of Contact. The Contractor shall provide any additional equipment, (such as forklifts, Bobcats, manlifts, etc.) necessary for continuous support of the assembly and shall provide qualified operators. The Contractor shall provide a lifting sketch, as described below, 90 days prior to arrival of equipment. Lifting sketches, as a minimum, shall identify the following:

a. The weight of the load.

b. The location of the center of gravity.

c. The minimum capacity/length of slings.

d. The minimum capacity of other standard rigging gear.

e. The attachment (lifting) points for the load.

(1) The attachment point for multiple leg lifts shall be sized such that each attachment point can support half the load's weight at the anticipated lift angle.

(2) The attachment point for single leg lifts shall be sized such that the attachment point can support the entire load's weight.

f. Limitations on allowable orientations for any parts making up the lifting assembly.

g. For single vertical lifts using twisted rope (wire or synthetic), two parallel ropes each capable of supporting the entire load alone shall be required unless a method is used to prevent unlaying the rope.

h. A minimum D/d ratio of 1 (one) shall be required where wire rope slings pass over any object, or in the eyes of wire rope slings. A minimum D/d ratio of 1 (one) shall be required where synthetic rope slings pass over any object, or in the eyes of synthetic rope slings.

(1) "D" represents the diameter of the object the sling passes over.

(2) "d" represents the diameter of the sling.

(3) Table 14-3 of NAVFAC P-307 lists efficiency factors at the various D/d ratios.

i. Components in each handling assembly shall be sized based on the worst-case distribution of loads. NOTE: When making a two-, three-, or four-point lift, the handling gear shall be sized so that two legs can support the load without exceeding the working load limit (WLL) at the lift angle expected, unless equalizing method is used.

j. When the Contractor requires non-standard gear (i.e., round stock lifting bars) be provided, written instructions shall be provided to the designated shipyard official to ensure:

(1) The proper material is being used.

(2) The item is certified.

(3) Any special requirements or dimensions are followed to ensure that engineering assumptions are met (i.e., eccentricity of the bearing points).

Ensure Lifting Sketch and details are included in the technical manuals.

4.3.3 Assembly and Set-Up

The Contractor shall provide all tools, labor, materials, and field supervision necessary to assemble, connect, equip, and make operational the equipment, program, and test the system as discussed herein. Special equipment, including measuring equipment, required by the Contractor to make the equipment operational and perform the tests specified herein shall be furnished by the Contractor and shall remain the property of the Contractor. The Government shall furnish no tools or equipment. Services required to make the system operational include, but are not limited to:

a. Remove subassemblies and components from packaging

b. Assemble components and subassemblies

c. Perform mechanical and structural alignments as required and specified by the OEM.

d. Connect hoses, pipes, cables, couplings, and fasteners

e. Provide and charge lubrication and operational fluids, and purge undesirable gasses

f. Route and connect conduit and wiring for power and controls

g. Make ready and operational all requisite electrical equipment

h. Load required software

i. Set and adjust operating parameters

j. Perform pre-operational inspections

k. Perform operational inspections and tests.

Upon completion of assembly, the Contractor is responsible to provide all necessary operating fluids for start-up and initial operation. The Contractor shall provide training to key personnel to instruct/guide NNSY personnel (operators, engineers, technicians, and mechanics) on the locomotive operating characteristics, operating functions, safety devices, error codes, error code reporting, etc., as specified in Section 3.4.

4.3.4 Field Supervisor

The Contractor shall provide a full-time (start of assembly to final acceptance) field supervisor to direct assembly integration and testing of the equipment. He or she shall be capable of reading, writing, and conversing fluently in the English language. The field supervisor shall have full authority to implement field decisions expeditiously. No work shall be accomplished when the field supervisor is not in the immediate work area. The field supervisor shall be identified to the receiving activity prior to start of offload. The field supervisor shall be responsible for coordinating with the receiving activity for any security clearances for all Contractor personnel expected to perform on-site work. The Government Point of Contact will be notified of any change in personnel performing this duty.

4.3.5 Receiving Activity Point of Contact

The Government’s receiving activity will designate a Point of Contact who will be responsible for appropriate surveillance and coordination of all services to be performed under this contract. The Point of Contact shall serve as the Contractor’s primary contact for all interaction with other Shipyard and Government activities. The Contractor’s Field Supervisor will be notified of any change in personnel performing this duty.

4.3.6 Touch-Up Painting

The Contractor shall provide all labor, equipment, and materials to properly touch-up paint equipment surfaces disturbed by the execution of this specification. Disturbed surfaces shall be returned to original condition unless such condition is required for the equipment or system being supplied. Operations at NNSY shall be performed in a manner consistent with air pollution control practices for minimizing emissions. If any Volatile Organic Hazardous Air Pollutant (VOHAP) containing materials are being used, containers shall be free of all defects and remain closed unless materials are being added to or removed from them.

4.3.7 Facility Regulations

The assembly site will be occupied. The Contractor shall comply with all regulations, including safety practices, environmental directives and security restrictions governing the operation on the premises. Assembly, integration, test, and acceptance shall be performed in a manner not to unreasonably interrupt or interfere with the Norfolk Naval Shipyard’s normal business processes. Work performed outside the normal working hours of Norfolk Naval Shipyard shall be done only with written approval of Norfolk Naval Shipyard at no additional cost to the Government. The Contractor shall be responsible for security of their property.

5. Warranty The warranty shall start on the same day the locomotive is accepted by the Volpe Center at the final destination. Standard commercial warranty shall apply. A copy of the warranty shall be included as an attachment to the contract.

6. OPTIONS

6.1 OPTION– CAMERA SYSTEM

The locomotive shall have a camera system. At minimum, the system shall include four (4) cameras with split screen monitor: two (2) cameras in the front and two (2) cameras in the rear to monitor coupling and track path. Cameras and monitor shall be hard-wired and not utilize wireless transmission and not have the ability to record.

6.2 OPTION – Second locomotive

This option locomotive shall have the same requirements as the base item locomotive.

6.3 OPTION– CAMERA SYSTEM for Option Second Locomotive

The optional second locomotive shall have a camera system with the same requirement listed in section 6.1

7. REQUIRED DELIVERY

Delivery of the locomotive is within 12 months of award of the purchase order. The option items shall be delivered within 12 months of the exercise of the applicable option.

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