SOLICITATION_W58RGZ-16-R-0244_GENERATOR_TEST_STAND.pdf

SOLICITATION/CONTRACT/ORDER FOR COMMERCIAL ITEMS

Offeror To Complete Block 12, 17, 23, 24, & 30

1. Requisition Number Page Of

2. Contract No. 3. Award/Effective Date 4. Order Number 5. Solicitation Number 6. Solicitation Issue Date

7. For Solicitation Information Call:

A. Name B. Telephone Number (No Collect Calls) 8. Offer Due Date/Local Time

9. Issued By Code 10. This Acquisition is Unrestricted OR Set Aside: % For:

Small Business Women-Owned Small Business (WOSB) Eligible Under the Women-Owned Small Business Program

Hubzone Small Business EDWOSB

Service-Disabled Veteran-Owned Small Business NAICS:

Email: 8(A) Size Standard:

11. Delivery For FOB Destination Unless Block Is Marked

12. Discount Terms 13a. This Contract Is A Rated Order Under DPAS (15 CFR 700) 13b. Rating

See Schedule 14. Method Of Solicitation RFQ IFB RFP

15. Deliver To Code 16. Administered By Code

Telephone No.

17a. Contractor/Offeror Code Facility 18a. Payment Will Be Made By Code

Telephone No.

17b. Check If Remittance Is Different And Put Such Address In Offer

18b. Submit Invoices To Address Shown In Block 18a Unless Block Below Is Checked See Addendum

19.

Item No.

20.

Schedule Of Supplies/Services

21.

Quantity

22.

Unit

23.

Unit Price

24.

Amount

(Use Reverse and/or Attach Additional Sheets As Necessary)

25. Accounting And Appropriation Data 26. Total Award Amount (For Govt. Use Only)

27a.Solicitation Incorporates By Reference FAR 52.212-1, 52.212-4. FAR 52.212-3 And 52.212-5 Are Attached. Addenda Are Are Not Attached.

27b.Contract/Purchase Order Incorporates By Reference FAR 52.212-4. FAR 52.212-5 Is Attached. Addenda Are Are Not Attached.

28. Contractor Is Required To Sign This Document And Return _________ 29. Award Of Contract: Ref. Offer Copies to Issuing Office. Contractor Agrees To Furnish And Deliver All Items Set Forth Or Otherwise Identified Above And On Any Additional Sheets Subject To The Terms And Conditions Specified.

Dated . Your Offer On Solicitation (Block 5), Including Any Additions Or Changes Which Are Set Forth Herein, Is Accepted As To Items:

30a. Signature Of Offeror/Contractor 31a. United States Of America (Signature Of Contracting Officer)

30b. Name And Title Of Signer (Type Or Print) 30c. Date Signed 31b. Name Of Contracting Officer (Type Or Print) 31c. Date Signed

Authorized For Local Reproduction Previous Edition Is Not Usable

Standard Form 1449 (Rev. 2/2012) Prescribed By GSA-FAR (48 CFR) 53.212

W58RGZ-16-R-0244 2016JUL29

LUIS J. FERRER (256)842-1761

LUIS.J.FERRER.CIV@MAIL.MIL

2016AUG29 03:00pm

W58RGZ

ARMY CONTRACTING COMMAND-REDSTONE

REDSTONE ARSENAL AL 35898-5280

X

336412

X DOA1

X

SEE SCHEDULE

SEE SCHEDULE

X X

X 1

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19.

Item No.

20.

Schedule Of Supplies/Services

21.

Quantity

22.

Unit

23.

Unit Price

24.

Amount

32a. Quantity In Column 21 Has Been

Received Inspected Accepted, And Conforms To The Contract, Except As Noted: _________________________________________________

32b. Signature Of Authorized Government Representative 32c. Date 32d. Printed Name and Title of Authorized Government Representative

32e. Mailing Address of Authorized Government Representative 32f. Telephone Number of Authorized Government Representative

32g. E-Mail of Authorized Government Representative

33. Ship Number 34. Voucher Number 35. Amount Verified 36. Payment 37. Check Number Correct For Partial Final Complete Partial Final

38. S/R Account No. 39. S/R Voucher Number 40. Paid By

41a. I Certify This Account Is Correct And Proper For Payment 42a. Received By (Print) 41b. Signature And Title Of Certifying Officer 41c. Date 42b. Received At (Location)

42c. Date Rec’d (YY/MM/DD) 42d. Total Containers

Standard Form 1449 (Rev. 2/2012) Back

CONTINUATION SHEET

Reference No. of Document Being Continued Page of

Name of Offeror or Contractor:

PIIN/SIIN MOD/AMD

SUPPLEMENTAL INFORMATION

Buyer Name: LUIS J. FERRER

Buyer Office Symbol/Telephone Number: CCAM-AL-M/(256)842-1761

Type of Contract 1: Firm Fixed Price

Kind of Contract: Supply Contracts and Priced Orders

*** End of Narrative A0000 ***

W58RGZ-16-R-0244________________

A-1. PURSUANT TO FAR 6.1, THIS PROCUREMENT IS ISSUED AS FULL AND OPEN COMPETITION. THIS SOLICITATION IS FOR A QUANTITY OF 1 AUTOMATION

GENERATOR TEST STAND WITH THE CAPABILITY OF TESTING 8 DIFFERENT AIRCRAFT GENERATOR CONFIGURATIONS INCLUDING: UH-60 AUXILIARY POWER UNIT

(APU) GENERATOR, UH-60 GENERATOR, CH-47 APU GENERATOR, OH-58 GENERATOR, CH-47 AC GENERATOR, CH-47 GENERATOR AND UH-1N GENERATOR IAW THE

STATEMENT OF WORK (SOW) WITH DELIVERY TO CORPUS CHRISTI ARMY DEPOT (CCAD), TX.

A-2. THIS REQUIREMENT DOES NOT CONTAIN PRECIOUS METALS. ___

A-3. PROPOSALS SHALL BE SUBMITTED NO LATER THAN 10:00AM CST, 30 AUGUST 2016. CONTRACTOR MAY MAIL OFFER TO:

US ARMY CONTRACTING COMMAND-REDSTONE

ATTN: LUIS FERRER

5303 MARTIN ROAD

REDSTONE ARSENAL, AL 35898-5280

A-4. COMPLETE THE FOLLOWING CONTRACTOR POINT OF CONTACT INFORMATION:

NAME: __________________________________________________________

TELEPHONE NUMBER: ______________________________________________

FAX NUMBER: _____________________________________________________

E-MAIL ADDRESS: _________________________________________________

A-5. NOTICE: YOUR ATTENTION IS INVITED TO FEDERAL ACQUISITION REGULATION (FAR) 15.403-3 RELATIVE TO THE REQUIREMENTS FOR

OBTAINING OTHER THAN COST AND PRICING DATA. IF THIS IS NOT CONSIDERED TO BE AN INDEPENDENTLY COMPETITIVE REQUIREMENT, YOU ARE _____

REQUIRED TO SUBMIT OTHER THAN COST AND PRICING DATA IF REQUESTED. OFFEROR MAY USE THEIR OWN FORMAT TO PROVIDE AT A MINIMUM A ____________

BREAKDOWN OF ALL THE COST ELEMENTS TO INCLUDE PROFIT/FEE WHICH COMPRISE THE TOTAL PROPOSED PRICE OR SALES HISTORY.

A-6. PROPOSAL SHALL REMAIN VALID THROUGH 30 SEPTEMBER 2016.

*** END OF NARRATIVE A0001 ***

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W58RGZ-16-R-0244

PIIN/SIIN

Page of

Name of Offeror or Contractor:

ITEM NO SUPPLIES/SERVICES QUANTITY UNIT UNIT PRICE AMOUNT

Reference No. of Document Being Continued

MOD/AMD

SUPPLIES OR SERVICES AND PRICES/COSTS

0001 GENERATOR TEST STAND

0001AA AUTOMATION GENERATOR TEST STAND 1 EA $ $ _______________________________ ______________ __________________

COMMODITY NAME: GENERATOR TEST STAND

CLIN CONTRACT TYPE:

Firm Fixed Price

THE AUTOMATION GENERATOR TEST STAND SHALL BE IAW THE

STATEMENT OF WORK (SEE EXHIBIT C - SOW).

(End of narrative C001)

Packaging and Marking _____________________

PACKAGING/PACKING/SPECIFICATIONS:

IAW ASTM-D-3951

UNIT PACK: 000 INTERMEDIATE PACK: 001

LEVEL PRESERVATION: Commercial

LEVEL PACKING: Commercial

MARKING SHALL BE IAW MIL-STD-130

(End of narrative D001)

Inspection and Acceptance _________________________

INSPECTION: Destination ACCEPTANCE: Destination

Deliveries or Performance _________________________

FOB POINT: Destination

SHIP TO:

(W45N7V) SR W0MU USA DEP CORPUS CHRISTI

308 CRECY STREET

CORPUS CHRISTI,TX,78419-5260

THE GENERATOR TEST STAND AND ALL ASSOCIATED

COMPONENTS IAW THE SOW SHALL BE DELIVERED TO CCAD NO

LATER THAN (NLT) 15 AUGUST 2017. START-UP AND

TRAINING SHALL BE COMPLETE NLT 26 SEPTEMBER 2017.

EARLY DELIVERY IS ACCEPTABLE WITH A MINIMUM OF 60

DAYS PRIOR APPROVAL BY THE CONTRACTING OFFICER.

(End of narrative F001)

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PIIN/SIIN

Page of

Name of Offeror or Contractor:

ITEM NO SUPPLIES/SERVICES QUANTITY UNIT UNIT PRICE AMOUNT

Reference No. of Document Being Continued

MOD/AMD

0002 CDRL ____

A001 CONTRACT DATA REQUIREMENTS LIST (CDRL) 1 LO $ ** NSP ** ______________________________________ __________________

SERVICE REQUESTED: DD FORM 1423

SEE EXHIBIT A FOR THE DETAILS OF THE CDRLS

REQUIREMENTS AND THE REQUIRED DELIVERY DATE FOR

CDRLS A001-A012.

(End of narrative C001)

Inspection and Acceptance _________________________

INSPECTION: Destination ACCEPTANCE: Destination

DLVR SCH PERF COMPL

REL CD QUANTITY DATE ________ ______________ __________

001 1 SEE DD FORM 1423

DELIVERIES FOR THE CDRLS SHALL BE IAW EACH DD 1423.

(End of narrative F001)

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PIIN/SIIN MOD/AMD

DESCRIPTION/SPECIFICATIONS/WORK STATEMENT

STATEMENT OF WORK

AUTOMATED GENERATOR TEST STAND

PART 1

GENERAL INFORMATION

C.1. GENERAL:

This is the Corpus Christi Army Depot (CCAD) Statement of Work for the following task(s) utilizing the Capital Improvements Program

Fiscal Year 16 contract:

C.1.1. Description/Introduction:

The Contractor shall provide a fully functional automated Aircraft Generator Test Stand to maintain existing and future Aircraft

Generator programs. The Contractor shall perform the work and tasks required to design, manufacture, ship and perform acceptance testing the Aircraft Generator Test Stand (CCAD will receive and physically install the test stand under contractor oversight). The

Generator Test Stand shall consist with the following major components:

1) Control Console Location for the operator to control the Generator Test Stand and monitor testing progress.

2) Drive Stand Rotates and monitors the Unit Under Test (UUT).

3) AC Drive Assembly Provides precise speed control of the AC motor.

4) System Assembly Provides for electrical interface to the UUT, system data acquisition, system control and power distribution.

5) Hydraulic Oil Supply Provides temperature controlled and filtered cooling oil to the UUT.

6) A Load Bank to provide resistive and reactive loading.

7) Universal Adapter Interface to provide connectivity to the UUT and eliminate the existing Generator Control Unit

(GCU).

8) Universal Generator Control to support testing the eight different generator configurations listed in Appendix B.

9) Electrical Adapters to reduce adapter changeover time when switching from one type of generator to a different type.

C.1.2. Background:

The current test stand has been the go-to generator test stand for CCAD. Since its purchase in 1996, the stand has performed in manual modes alone. Currently only a handful of generators are tested on the test stand due to adapter availability and the time required to change dissimilar generators.

The average time per test is approximately 6 hours. This time includes the time it takes to manually move through the test procedure and in some cases, manually connect other test sets, such as a scope to the stand, and perform other tests. The time required to change generators is relatively short, usually 15-30 minutes, if the UUT is the same part number generator. The time significantly increases when changing from one part number to another.

The steps involved with this change are complicated, time consuming, and waste resources. An adapter must be changed at the drive stand to accommodate the new Generators unique electrical signals. A GCU must be taken from active flying service and used to control the generator through the console. At times, due to multiple changes, the GCUs actually cause errors during the testing of the generators.

Finally, another adapter must be changed at the test console to translate the signals from/to the GCU.

In order to reduce costs to the government, it is imperative that as many pre-existing electrical and mechanical adapters, wiring harnesses, and equipment be reused with the purchase of a new Generator Test Stand. The list of currently owned CCAD adapters is included in Appendix G. Contractor will not only include a universal electrical adapter but also a mechanical adapter to allow previously acquired mechanical adapters to be reused. Finally, the user interface needs to remain standardized for all generators tested. By purchasing a more universal Generator Test Stand, the possibility for negative transference in operation will be significantly reduced.

Typically most Depots will assign a certain type of generator per test stand in order to reduce Turn around Time (TAT) and streamline internal processes. They also restrict themselves to utilize limited Adapters and GCUs. This typically creates a single point of failure within a shop.

C.1.3. Objectives:

The objective of this effort is to increase equipment reliability and longevity, reduce TAT and work hours required to test aircraft generators, retire the current K838 Manual Avtron Test Stand (S/N 33) and replace it with a fully automatic Generator Test Stand, and return valuable Generator Control units back to flight service. The new Generator Test Stand will decrease TAT & work hours by utilizing

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a Universal Adapter System, which reduces adapter changeover by 45 minutes per UUT. Contractor shall use a Universal GCU, which means that aircraft Generator Control Units are no longer required for Generator test and can be returned to service. Finally, the Generator

Test Stand shall have low voltage waveform capture capability which will significantly reduce test time, provide high fidelity on the low voltage side and provide the ability to capture the test results electronically.

C.1.4. Scope:

The purpose of this effort is to provide an automation solution, modernization and sustainment of CCADs Generator production capability for the following configurations: UH-60 Auxiliary Power Unit (APU), UH-60 GEN, CH-47 APU GEN, OH-58 GEN, CH-47 AC GEN, CH-47 GEN and UH-

1N GEN. The results are improved efficiency and effectiveness, reduced maintenance cost, production schedules met, increase revenues, and enhance customer relationships.

This SOW is designed and engineered to support and integrate multiple weapon system configurations into one automated Generator Test

Stand and provide capability for future weapon systems.

C.1.5. General Information:

C.1.5.1. Type of Contract:

The Government will award a firm fixed price contract.

C.1.5.2. Physical Security:

The Contractor shall be responsible for safeguarding all Government equipment, information and property provided for Contractor use.

Contractor shall adhere to all security requirements, Security Requirements for All Contracts Performed at CCAD, Attachment 1.

C.1.5.3. Post Award Conference/Periodic Progress Meetings:

The Contractor agrees to attend any post award conference convened by the contracting activity or contract administration office in accordance with Federal Acquisition Regulation Subpart 42.5. The Contracting Officer (KO), COR, and other Government personnel, as appropriate, may meet periodically with the Contractor to review the Contractor's performance. At these meetings the KO will apprise the Contractor of how the Government views the Contractor's performance and the Contractor shall apprise the Government of problems, if any, being experienced. Appropriate action shall be taken to resolve outstanding issues. These meetings shall be at no additional cost to the Government.

C.1.5.4. Contracting Officer Representative (COR):

The COR will be identified by separate letter. The COR monitors all technical aspects of the contract and assists in contract administration. The COR is authorized to perform the following functions: assure that the Contractor performs the technical requirements of the contract: perform inspections necessary in connection with contract performance: maintain written and oral communications with the Contractor concerning technical aspects of the contract: issue written interpretations of technical requirements, including

Government drawings, designs, specifications: monitor Contractor's performance and notifies both the KO and Contractor of any deficiencies; coordinate availability of Government furnished property, and provide site entry of Contractor personnel. A letter of designation issued to the COR, a copy of which is sent to the Contractor, states the responsibilities and limitations of the COR, especially with regard to changes in cost or price, estimates or changes in delivery dates. The COR is not authorized to change any of the terms and conditions of the resulting order.

C.1.5.5 Warranty:

Contractor warrants that all Products and Services delivered or performed under this Order shall conform to the requirements of this

Order (including all applicable descriptions, performance criteria, specifications and drawings), shall be free from defects in material and workmanship and shall, to the extent not manufactured pursuant to detailed designs furnished by Buyer, be free from defects in design and fit for the intended purposes as set forth under this Order. These warranties will remain in effect for a period of twelve

(12) months after Final Acceptance of each unit. The contractor shall submit warranty information with Operation & Maintenance Manual

(O&M), IAW DI-TMSS-817000, Job Manual, CDRL A006.

PART 2

DEFINITIONS & ACRONYMS

C.2. DEFINITIONS AND ACRONYMS:

C.2.1. Definitions:

C.2.1.1. CONTRACTOR. A supplier or vendor having a contract to provide specific supplies or service to the Government. The term used in this contract refers to the prime.

C.2.1.2. CONTRACTING OFFICER (KO). A person with authority to enter into, administer, and or terminate contracts, and make related

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determinations and findings on behalf of the Government. Note: The only individual who can legally bind the Government.

C.2.1.3. CONTRACTING OFFICER'S REPRESENTATIVE (COR). An employee of the U.S. Government appointed by the KO to administer the contract. Such appointment shall be in writing and shall state the scope of authority and limitations. This individual has authority to provide technical direction to the Contractor as long as that direction is within the scope of the contract, does not constitute a change, and has no funding implications. This individual does NOT have authority to change the terms and conditions of the contract.

C.2.1.4. DELIVERABLE. Anything that can be physically delivered but may include non-physical things such as meeting minutes.

C.2.1.5. PHYSICAL SECURITY. Actions that prevent the loss or damage of Government property.

C.2.1.6. QUALITY CONTROL. All necessary measures taken by the Contractor to assure that the quality of an end product or service shall meet contract requirements.

C.2.1.7. SUBCONTRACTOR. One that enters into a contract with a prime Contractor. The Government does not have privity of contract with the subcontractor.

C.2.1.8. WORK DAY. The number of hours per day the Contractor provides services in accordance with the contract.

C.2.1.9. WORK WEEK. Is defined as Monday through Friday, unless specified otherwise.

C.2.2. Acronyms:

A-B-C-N A phase, B phase, C phase, and Neutral

AC Alternating Current

AGM Army Gold Master

ANSI American National Standards Institute

APU Auxiliary Power Unit

ASTM American Society for Testing and Materials

ATP Acceptance Test Procedure

BOM Bill of Materials

CCAD Corpus Christi Army Depot

CFR Code of Federal Regulations

COR Contracting Officer Representative

CR Change Request

CT Current Transformer

DMWR Depot Maintenance Work Requirement

DR Decision Request

DVD Digital Video Disk

FR Fault Report

GCU Generator Control Units

GUI Graphical User Interface

HZ Frequency in Hertz

IAW In Accordance With

I/O Input/Output

K Kilo

KO Contracting Officer

KVA Kilo Volt Amp

KVAR Kilo Volt Amp Reactive

KW Kilowatts

MIL-STD Military Standard

MS Microsoft

NEC National Electric Code

NEMA National Electrical Manufacturers Association

O&M Operation & Maintenance

OSHA Occupational Safety & Health Administration; Occupational Safety a nd Health Act

QCP Quality Control Plan

SOP Standard Operating Plan

TAT Turn Around Time

TPS Test Program Sets

U.S. United States

UUT Unit Under Test

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PART 3

FURNISHED PROPERTY, EQUIPMENT, AND SERVICES

C.3. FURNISHED ITEMS AND SERVICES:

C.3.1. Services:

The Government will provide a lead project engineer who will be the COR and who will be the Contractors prime contact for the

Government. Upon request, the Government will provide the most recently available standard building and facility drawings for review.

C.3.2. Utilities:

All utilities in the facility will be available for the Contractor. The Contractor shall instruct employees in utilities conservation practices. The Contractor shall be responsible for operating under conditions that preclude the waste of utilities.

C.3.3. Equipment:

Computer system hardware will be provided by CCAD. IAW DI-IPSC-81434A NOT1, Computer Hardware Specifications (A003), the contractor shall provide CCAD IT Department with a detailed list of computer specifications during Critical Design review to enable CCAD to purchase the appropriate hardware.

C.3.4. Facilities:

The Government will provide the existing electrical/air/water service. The Contractor shall be responsible for operating under conditions that preclude the waste of utilities, which include turning off the water faucets or valves after each use.

PART 4

REQUIREMENTS

C.4. REQUIREMENTS:

C.4.1. Generator Test Stand Description:

The Generator Test Stand shall have the ability to test eight different generator and Auxiliary Power Units components on one Generator

Test Stand and shall include a state of the art test analysis with new adapters that minimizes Operator interaction with the UUT and adapter hardware. This analysis shall include modern and new adapters with the capability to produce the required testing results with minimal operator interaction with the test stand and UUT.

C.4.2. State Of The Art Production Model:

The contractor shall use the current available equipment and technology for the Generator Test Stand and shall not use obsolete equipment. The Generator Test Stand shall be based upon a current production model which utilizes proven design concepts and equipment which have performed satisfactorily under operating conditions by either Government or industry performing generator and APU production run validation and verification. Products such as prototypes, pre-production models or experimental units are not permissible. It shall not be permissible to use reclaimed parts as is, or rebuilt from scrap or other used equipment. Generator Test Stand shall perform aircraft generator testing in accordance with Depot Maintenance Work Requirements (DMWR) 1-6115-502, 1-6115-504, 1-6115-508, 1-6115-511, 1-6115-513, 55-6115-496, 55-6115-507 and Naval Air Technical Manual 03-5AG-47 for UUT testing procedure and process methods, C.4.3. Generator Test Stand Floor Plan:

Contractor shall utilize the existing floor plan layout as illustrated in Appendix E for the overall physical dimension design of the

Generator Test Stand.

C.4.4. Generator Test Stand Requirements:

Contractor shall ensure that proper instrumentation and test apparatus are included for carrying out test program objectives in accordance with government approved DMWR s and Navy Tech Manuals. The contractor shall adapt existing Generator accessory test equipment as necessary, recommend modifications to measurement techniques, obtain approval from the Government Project Engineer if any new instrumentation and wiring set-ups are required to obtain specific approved test objectives. The Contractor shall perform the following requirements:

C.4.4.1. Generator Test Stand:

1) New Generator Test Stand.

a) Contractor shall pre-build and order parts for the New Generator Test Stand after the Critical Design Review as outlined in C.5.2.

b) New Generator Test Stand shall be fully assemble and operational before shipment to CCAD.

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c) The Control Console System shall include:

i) Operator Control Console

ii) 375 Kilowatts (KW) AC Motor and 18K/30K Dual Pad Gearbox.

iii) AC Drive Power Supply Assembly

iv) System Assembly to include:

(1) UUT Interface Cabinet

(2) Power Distribution Assembly

(3) Signal Conditioning and Data Access Object sub-system

(4) ABC-N Short Circuit Capability

(5) Constant Speed Drive Governor Demag / Remag Power Supply

(6) Permanent Magnet Generator Demag Power Supply.

v) 213 KW / 213 Kilo Volt Amp Reactive (KVAR) Load Bank.

vi) UUT Cooling Hydraulic Cart to include:

(1) Patch Filter.

(2) Dual Scavenge Pumps

(3) Automatic Pressure or Flow Control.

vii) Operator Control & Monitoring User Interface.

viii) Manuals on Computer Disc (CD).

d) Deliver a Universal Generator Adapter.

i) Supports eight different configurations. See the technical configuration description for details on the adapter in Appendix B.

e) Deliver a Universal GCU and the required software to replicate the current requirements through 2017.

f) The new Console shall provide near user interface as the K738 XL also in use at Corpus Christi Army Depot.

g) Contractor shall pay particular attention to serviceability for the system and ensure repair parts are readily available to the Government.

h) Provide an individual Phase Short Circuit Capability which provides A-N, B-N, A-B, B-C, A-C and ABC-N short circuit capability on the Generator test stand.

i) Provide a 100 MHz Color Oscilloscope.

j) Installation:

i) Contractor shall provide project management for the following steps of the installation process:

(1) Electrical installation of 440 Kilo Volt Amp (KVA) Transformer.

(2) Electronic installation of Control Console.

(3) Electrical installation of AC Power Supply.

(4) Electrical installation of 213 KW/ 213 KVAR Load Bank.

(5) Installation of a 375 KW AC Motor.

k) Provide training as required for the new console

i) Contractor shall provide 10 days of start-up, and debugging on site at Corpus Christi Army Depot.

ii) Contractor shall provide one (1) day of training.

iii) This training shall not be separately price and should be included in the total price of the Generator Test

Stand.

C.4.4.2. Microprocessor Device:

The microprocessor device, ADD32 Plus, incorporates many self-diagnostic tests. This device provides variable coordinated control, process communication, and on-line status information. This PC board, the ADD32 Plus, is required.

1) New Controller shall replace the old controller in the same footprint.

2) New Controllers new software shall be uploaded before shipping to CCAD.

C.4.4.3. Low Voltage Metering:

Contractor shall provide a Waveform Capture capability to the control console to afford low voltage metering, graphing, and data analysis tools to aid in the following measurements and outlined in Appendix A:

1) Generator Phase Voltage All three phases shall be displayed for current transformer phase check tests, and monitored for Amplitude Modulation and Frequency Modulation.

2) Current Transformer (CT) Phase Voltage All three phases can be displayed for CT phase checks tests, and monitored for three phase voltage measurements.

3) Speed Sensor this signal shall be monitored and displayed on control console. Field Voltage & Field Current these signals shall be displayed for waveform checks.

C.4.4.4. Universal Electrical Adapter:

Contractor shall provide a Generic Drive Room and Control Test Adapter. The Universal Electrical Adapter shall support the following configuration requirements (Appendix B):

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1) The Universal Electrical Adapter shall provide additional automation when testing generators utilizing the Automation

Test Program Set (TPS) application software.

2) The Universal Electrical Adapter shall reduce changeover time when switching from one type generator to a different type generator.

3) The Universal Electrical Adapter shall communicate with the low voltage metering Channels (Waveform Capture).

C.4.4.5. Software:

All computer systems shall be provided by the CCAD. The Contractor shall provide the CCAD Information Technology department with a detailed list of computer specifications to enable the CCAD Information Technology department to purchase the appropriate computer hardware. The Computer Hardware Specifications detailed list shall be provided concurrently with the 100% Design Submittal IAW DI-IPSC-

81434A, NOT 1, A003).

IAW DI-IPSC-81434A, NOT 1, A004, the Contractor shall provide CCAD an Automation Software solution to enable Operators, Technicians and

Industrial Test Procedure Creators to connect, communicate, and exchange information via a Graphical User Interface (GUI) in a control and data acquisition environment with the following requirements:

1) Automation Software shall be written using the most modern Microsoft Windows application so it is a true Windows based program.

2) Automation Software shall allow the Operator to execute the Test Procedures as defined by the governing DMWRs and

NAVAIR test documentation with little Operator interaction with the Generator Test Stand.

3) Automation Software shall provide the ability print a detailed test report, save the test report to the hard drive or do both.

4) The GUI shall provide different access levels of users.

a) Operators Access Level allows complete system operation ability to manipulate the Generator Test Stand and

UUT but does not have the capability to modify the system software.

b) Test Procedure Creators Access Level allows programming ability to perform data entry.

c) Calibration Access Level allows Calibration Technicians the ability to make adjustments to gain and offset values to bring generator test stand instrumentation into specification limits.

5) IT Industrial System Requirements:

a) Physical Environment Specifications: Any vendor provided equipment shall be able to operate in the environment it will be placed within. Temperature, humidity, and the use of harsh chemicals or liquids in designated installation areas may dictate the use of appropriate National Electrical Manufacturers Association (NEMA) rated enclosures and certified equipment. These same conditions will dictate the use of rugged peripheral equipment. Cabinets containing industrial computer systems shall meet the following specifications: they shall maintain an average maximum internal operating temperature of less than 95 degrees Fahrenheit with a sustained average external temperature of up to 115 degrees Fahrenheit. The cabinets shall also provide for a maximum internal average humidity of 80% when the external average humidity is 98%.

b) Computer Hardware Specifications: All network capable Industrial computer systems installed at CCAD must be connected to and communicate through the CCAD Industrial Local Area Network (ILAN). Standard desktop Industrial computer systems will be provided by CCAD when available. When providing a custom computer solution, the contractor shall provide CCAD

IT with a detailed list of required equipment specifications used to determine the feasibility of a standard CCAD system. When

CCAD cannot provide the required hardware (e.g. rack mounted and integrated systems) the contractor shall provide it. The hardware must meet the following minimum requirements:

i) Intel Core i5-5675C or better

ii) System clock speed must be 3.3 Ghz or better

iii) Random Access Memory must be 8GB or better (1DIMM)

iv) Windows Aero-capable graphics card with 1GB VRAM

v) 500GB SATA drive with 16MB cache

vi) DVD-RW/CD-RW

vii) RJ-45 and Wireless capable Network Interface card (NIC)

c) Peripheral Equipment: Any installed peripheral equipment shall be capable of generating data output onto a dedicated computer system through either a standard serial cable connection (e.g. USB, RS-232) or an Ethernet connection. If an

Ethernet connection is used to interconnect a dedicated PC to peripheral equipment, the contractor shall supply an extra

Network Interface Card (NIC). The NIC must have a RJ-45 port to allow an ANSI Standard 802.3, 100Base-T, or an IEEE 802.3ah, 1000Base-T ethernet connection which supports the full TCP/IP stack implemented by firmware.

d) Programmable Logic Controllers (PLC)s: Any PLC installed at CCAD shall be manufactured by Allen Bradley and must provide an Ethernet connection to allow for connection to the Industrial Network. If an Ethernet connection is used to interconnect the PLC to peripheral equipment an additional Ethernet port must be provided.

e) Operating System (OS) Specifications: If applicable, the systems OS must be Microsoft Windows 7, Windows

Server 2012R2, or Red Hat Linux version 5. Any OS supplied with the system must contain all necessary service packs, updated patches, and hot fixes.

f) Army Gold Master: The Army Golden Master (AGM) is a collection of security settings for Microsoft Operating systems that must be applied to all Army computer systems. CCAD will supply the AGM to the contractor, the contractor shall ensure their software functions as intended, when installed on top of the AGM.

g) Security Technical Implementation Guides (STIGs): STIGS are configuration standards for the Department of

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Defense and contain technical guidance to lock down information systems and software applications that might otherwise be vulnerable to malicious attacks. The contractor shall be responsible for ensuring all appropriate STIGs are implemented and their software runs acceptably.

h) System Software Specifications: If network capable, industrial systems are required to interact with other network resources on the CCAD ILAN. These systems shall be capable of connecting to and communicating through a windows based network and must operate using domain-level user accounts through Active-Directory. All supplied software must be capable of operating in a multi-user environment and data which contains permissions information shall be hidden from view and inaccessible to those with less than administrator level access. Shared accounts shall not be used, and users shall only be authorized the minimum security rights to operate the application software. Users will not have access to system or software configuration items (e.g., Control Panel, software and hardware installation). Under no circumstances will the intended end user log in using the Administrator or Root account for routine operation of the equipment. The use of these accounts will be restricted to only administrative activities which will be carried out by CCAD Information Technology personnel. All software products shall employ a minimum of three permission based levels of access.

i) Administrator - Full control at root level, restricted to CCAD IT personnel and when required, the contractor or vendor.

ii) Maintenance - Mid-level control required to perform maintenance and alter control parameters as needed.

iii) Operator - Minimum control necessary to perform the routine operation of software. The Operator shall not be able to alter the programming of software, make changes to executable files, or modify control parameters.

i) Software Installations: If installing application code at CCAD, the contractor shall install the code within a standard container (i.e., Program Files) and located in a volume separate from the standard System Files. Interactive applications are required to run as services and daemons and any time WEB services are used, file types (e.g., XML, HTML) must be separated.

j) Software Licensing: When installed, the licensing for computers, control units e.g., Programmable Logic

Controllers, or other IT systems will be surrendered to the Information Technology Configuration Manager and will become the property of the Government upon acceptance of the system.

k) Application Incompatibility: If an application will interfere with the operation of the industrial system, i.e., (McAfee Anti-Virus), the contractor shall provide a written statement to the CCAD IT Directorate explaining the technical restrictions placed upon them.

l) Special Hardware and Software: If any special programming software or programming software interface devices

(such as hardware "keys", dongles or "PIC" modules) were required to access software, these programs and devices shall be included along with necessary registration information. If custom application software was written and provided, a copy of the required compiler and compiler license shall be provided as well. At acceptance, all these items shall become property of the government. Software and hardware purchased for this project shall be registered to Commander, Corpus Christi Army Depot,Corpus

Christi, Texas 78419.

m) Certificate of Networthiness (CoN). Networthiness certification ensures Automated Information Systems (AIS) utilizing the Army Network are developed in compliance with the Clinger Cohen Act and are secure, supportable, sustainable, and compatible with the Army Enterprise Infrastructure (AEI) (as defined in AR 25-1). All new AIS capabilities and all capability modifications and upgrades must be assessed to validate their networthiness (network security, network impact, compatibility with the infrastructure, infrastructure requirements, spectrum support, security policy compliance, JTA-A standards compliance, communications and information manpower, training, logistics support, schedule, and funding). If software is installed within the system, the contractor shall work with CCAD IT Department personnel to check for CoN availability and when not available, ensure a CoN is requested and all documentation is submitted.

n) Software Acceptance: If software has been customized for CCADs use or is any software other than Commercial

Off The Shelf (COTS); the contractor shall provide copies of all source code, firmware and software used in the system, as well as one set of backup and configuration software for PLCs, control and communication computers, and data acquisition. All programs shall have been tested and fully operational before acceptance.

o) Documentation Requirements: A complete set of instruction manuals shall be provided that contain all the information necessary to operate, maintain, and reinstall all software and hardware in the system. Step by Step instructions shall be provided to facilitate the rebuilding of the system in the event of a fatal system crash. The vendor or contractor shall provide network design drawings to the Information Technology Directorate. These drawings should include complete directional data flow diagrams that include all ports and protocols in use. The vendor or contractor shall provide to

Industrial Automation at least two electronic copies of all control unit programs. These copies should include description files of the ladder logic and any cabling required to connect to the control systems. No control units will be password protected and no other form of lockout measure shall be implemented by anyone other than CCAD IT employees. The vendor or contractor shall also provide electrical wiring diagrams for all installed control systems to the CCAD Industrial Automation group.

p) Proposals or specifications that deviate from those described herein shall be coordinated for specific approval or rejection by the CCAD Information Technology representatives prior to shipment, installation, or acceptance of the equipment.

C.4.4.6. Government Equipment Transition:

1) After the Critical Design Review (CDR) and a minimum of 60 days prior to final delivery notify CCAD of shipment for preparation of installation.

a) Once the items arrive at CCAD. The customer will prepare for the stand to be out of production service for a

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maximum of 90 days.

2) This will allow time for the shipment, installation, debugging of the software and training.

3) The customer will also need to have on hand, one of each generator listed in the technical description.

4) Installation:

a) CCAD will provide physical installation of the test stand.

b) Contractor shall provide a knowledgeable engineer/technician to provide onsite installation guidance.

c) Contractor shall conduct equipment startup and check-out.

C.4.4.7. Marking:

The contractor shall mark the Generator Test Stand in accordance with Military Standard (MIL-STD)-130, Identification Marking of United

States (U.S.) Military Property.

C.4.4.8. Nameplate:

Contractor shall provide a corrosion-resistant nameplate securely attached to the equipment. If the equipment is a special model, the model designation shall include the model of the basic standard item and a suffix identified in the manufacturer's permanent records.

As a minimum, the name plate shall provide all information listed below. (The captions may be shortened or abbreviated, provided the entry for each caption is clear as to its identity if cleared by the COR.)

Note: The serial number of the equipment shall also be imprinted on the cabinet member in a prominent location.

1) Type

2) Size

4) Nomenclature

5) Manufacturer's Name

6) Manufacturer's Model Number

7) Manufacturer's Serial Number\

8) Date of Manufacture

9) Contractor Number

10) Power Characteristic and Rating

11) Federal Stock Number or Plant Equipment Code

12) U.S. or Country of origin

13) Date of Manufacture

14) Electrical Power Requirements

C.4.5. General Requirements:

C.4.5.1. Generator Test Stand Safety:

The design and configuration of all equipment shall follow the best mechanical and industrial practices and shall minimize hazards to personnel, equipment and material. This requires the contractor implementing mechanical devices or motorized transport devices for

Generator installations. This requires the contractor to implement manufacturing ergonomics in the Generator Test Stand to reduce risk factors. Hazards to personnel or equipment resulting from equipment component failures shall be identified and safety provisions shall be incorporated to the maximum possible extent with regard to anticipated working and operating conditions of personnel. The design of this Generator Test Stand shall comply with all safety regulations and codes. Contractor shall follow requirements as specified in MIL-

STD-882E Department of Defense Standard Practice - System Safety. The safety of the operator shall be a high consideration. The noise level shall comply with the current OSHA requirements.

C.4.5.2. Safety Devices:

The Generator Test Stand shall be equipped with the safety devices required by 29 Code of Federal Regulations (CFR) 1910 Occupational

Safety and Health Administration (OSHA). These shall include, but are not to be limited to, limit switches on any automated movements and a red, mushroom-shaped emergency stop button. The emergency stop button shall immediately shut down all operations. The emergency button shall require an active reset on the part of the operator to resume operation. No automatic resets are permitted. The Generator

Test Stand shall be equipped with a minimum of one main breaker at the operator station which shall disconnect all electrical flow to the system.

C.4.5.3. Noise:

Operations of Generator Test Stand shall not subject personnel or operators to dB noise levels that exceed OSHA Section 1910.95 standards, Occupational Noise Exposure. Permissible noise exposure shall be based on OSHA time weighted average of over an eight (8) hour testing sound level of 80 dB. The test shall be run using OSHA approved equipment and procedures. When the test is run, all equipment must be operating.

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C.4.5.4. Surface Finish: surface shall be free of sharp edges and corners.

C.4.5.5. Painting:

The Generator Test Stand shall be painted with two (2) coats of enamel or lacquer or other suitable coating to prevent corrosion.

If dissimilar metals are used in intimate contact, suitable protection against galvanic corrosion shall be applied, such as proper electrical insulation of the joints or by excluding electrolyte if this is feasible.

C.4.5.6. Cabling, Wiring, and Connectors:

The contractor shall provide Generator Test Stand cabling and wiring in compliance with the requirements of the National Electric Code

(NEC) for interconnecting electrical cable, for attachment of wires and leads, and shall include all cabling, wiring, functional boxes, and connectors necessary to interconnect internal components in their operating position.

Cabling shall also be provided by contractor between components and entry panels, including connectors. Sufficient cable length and test cables and extender cords shall be provided for any mounted equipment to permit operation and maintenance. Each electrical cable harness shall contain a minimum of 10% additional cabling to allow for future cable breakages.

C.4.5.7. Circuit Breakers and Fuses:

Except as otherwise specified herein, selection and application of circuit breakers and fuses shall conform to the NEC. Fuses shall not be used to provide over current protection in multiphase powered equipment. If fuses are used in single phase power applications, then blown fuse indicators shall be provided by contractor.

C.4.5.8. Main Disconnect Switch:

Contractor shall provide the actual service currents based on UUT loading. The service size will be used to properly size the safety disconnect and over current protection ratings per local codes and regulations. A manually operated fusible disconnect safety switch of adequate size to carry the maximum electrical load of the equipment shall be provided by the contractor for connection to the specified electrical supply service. This switch shall be readily accessible to the operator and constructed so that personnel required to perform any type of maintenance can physically lock this disconnect into the "OFF" position.

C.4.5.9. Electrical Installation:

CCAD will furnish all labor and material required for complete installation of all electrical equipment supplied in accordance with installation drawings and schematics provided by the Contractor. Installation design shall conform to all local codes and National Fire

Protection Association-70 (NFPA-70). All electrical wiring shall be designed and installed per the current requirement of Joint

Industrial Council Electrical Standards.

An across-the-line fused disconnect switch shall be included with the equipment supplied. The disconnect switch lever shall be located on the face of the control cabinet (readily available to the operator and clearly identified). All electrical circuits shall be fused as required to protect the different components of the system. "Allen Bradley", "Square D", or equal, relays, starters, switches and disconnects shall be provided by contractor.

Input voltage shall be a single source of 480 volts, 60 Hertz, 3 phase, 3 wire with ground. Contractor shall provide step down transformer(s) for other required voltages.

All control wiring shall be 120 volt, 60 Hertz, single phase. A step down transformer with a fused 120 volt, 60 Hertz secondary shall be provided for operation of control and indicating devices. Lower control voltage is acceptable. An input circuit breaker of industrial type with thermal overload and short circuit protection shall be provided (circuit breaker shall conform to Underwriters

Laboratories 489). The Contractor may utilize an existing 120 volt, 60 hertz, single phase power source for lighting. Contractor shall follow requirements as specified in the following: American National Standards Institute/National Electrical Manufacturers Association

(ANSI/NEMA) ICS 1 Industrial Controls and Systems and ANSI/NEMA MG 1 Motors and Generators.

C.4.5.10. Electrical Protection:

The contractor shall provide a Generator Test Stand with protection from thermal overload, short circuit, spikes, or surges.

C.4.6. Workmanship Requirements:

The contractor shall provide workmanship commensurate with quality equal to that of the contractor's commercial equipment of the type specified herein. This section contains workmanship requirements which are in addition to any contained in sections 4.4 and 4.5.

C.4.6.1. Electrical:

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Workmanship for electrical systems shall include the following:

1) Identification of electrical systems and components shall be included.

2) All wires shall be identified at each termination by marking with numbers corresponding to those on the Contractor-supplied electrical drawings and schematics.

3) All terminals on terminal boards will be marked plainly to correspond with the markings on the Contractor supplied electrical drawings and schematics.

4) All components shall be marked to correspond with the terminology on the Contractor supplied electrical drawings and schematics so that removal of components will not remove the identification of the component in its enclosure.

C.4.6.2. Mechanical:

1) Workmanship for mechanical systems shall include, but not be limited to the following:

a) All bare contact surfaces where parts are to be joined shall be primed.

b) Torque for all bolts, studs and set screws will be set to components manufacturers' standards.

c) Bolts in like locations to be of equal length.

d) Locking devices (lock washers) on all threaded fasteners.

e) Cotter keys to be proper size and uniformity in like installations with ends down, where possible.

C.4.7. Control Function Requirements:

C.4.7.1. Process Parameters:

The system shall be capable of interrupting the processing cycle when detected tolerances for any parameters are exceeded.

C.4.7.2. Monitoring Functions:

The system shall monitor all of the process parameters and all safety interlocks. For the process parameters, there shall be factory preset alarm levels. If a parameter goes out of designated value by more than a predetermined amount, both a warning message shall be displayed to the monitor and an audible buzzer will be sounded. The warning alarm shall not shut down the process unless the parameter exceeds the designated shut down limits. When the operator acknowledges any alarm condition, the buzzer shall be silenced. When the alarm condition is corrected, the message shall be cleared off the monitor. These limits shall be determined and preset based on individual process developed and stored in the control for each part program. These limit conditions shall have the provisions to be modified by the programmer.

C.4.7.3. Information Displays:

The information display shall be menu driven and display a list of part numbers that were pre-programmed to be processed. The operator shall be able to enter in the part number to be processed either via the keyboard or the bar code /scanner reader wand. Both methods shall be provided and configured into the software so that the operator has the choice for entering in the part number. After the operator has logged in the parts information, the machine shall be ready to process the part.

C.4.7.4 . Data Collection Display and Hard Copy Printouts:

The system shall be able to display the collected data in graphic and alphanumeric mode during the process cycle and shall have the functions to print out the graphic and alphanumeric data to a printer.

C.4.8. Training:

The contractor…