Attachment_0001_Statement_of_Work.pdf

Attachment 0001

STATEMENT OF WORK (SOW)

FOR THE

DEPLOYABLE POWER GENERATION & DISTRIBUTION SYSTEM (DPGDS)

PRIME POWER UNIT (PPU) (MEP-PU-810A/B)

RECAPITALIZATION

08 March 2016

PREPARED BY:

PROJECT MANAGER

EXPEDITIONARY ENERGY & SUSTAINMENT SYSTEMS (E2S2)

ATTN: SFAE-CSS-E2-M

5850 DELAFIELD ROAD, BUILDING #324,

FORT BELVOIR, VA 22060-5863

Distribution Statement: Further distribution as directed by: Product Manager, Expeditionary Energy & Sustainment Systems5850 Delafield Road, Building 324Fort Belvoir, VA 22060

TABLE OF CONTENTS

DPGDS PPU, MEP-PU-810A/B, Recapitalization SOW

Section:

1. Scope 3

1.1 MEP-PU-810 Generator Set Program Office 5

1.2 Data Requirement 5

1.3 Contract Data Requirements List (CDRL) 5

2. Applicable Documents 6

2.1 Department of Defense Specifications 6

2.2 Department of Defense Standards 6

2.3 Purchase Description 7

2.4 Other Government Documents 7

2.5 Availability of Department of Defense Documents 7

2.6 Non-Government Standards and Other Publications 8

2.7 Availability of Non-Government Standards and Other Publications 8

3. Requirements 8

3.1 First Articles Phase 8

3.2 Production Phase 12

3.3 Program Management 13

3.4 Data Submission 16

3.5 Configuration Management 17

3.6 Quality Assurance 19

3.7 Item Unique Identification Designator (IUID) 20

3.8 Product Drawings and Associated List 23

3.9 Test and Evaluation 28

3.10 Safety 36

3.11 Investment Spares, Initial/Repair Parts, and Mission Readiness 43 Spares Packages (MRSP) Kits

3.12 Pollution Prevention Program (PPP) 44

3.13 Warranty Provisions 45

3.14 Integrated Product Support (IPS) Program Requirements 52

3.15 Software Support 86

3.16 Contractor Manpower Reporting (CMR) 87

3.17 Security Requirements 86

Appendices:

A Government Furnished Property/Information 89 B AutoCAD Drawings 91 C TDP Selection Worksheet 96 D First Article Phase Test Matrix 98 E Procedure for the Pre-Production Physical Configuration Audit (PREPCA) 102 F Procedures for the Production Physical Configuration Audit (PPCA) 106 G Provisioning Requirements Statement 110 H Data Requirements Form for ARP No. 113 I Provisioning Data Element Definitions 122 J ETM Requirements Matrix 138 K Input Data Requirements 149 L Deliverables Schedule 150

1. SCOPE

a. Background: The MEP-PU-810 Deployable Power Generation and Distribution System (DPGDS) Prime Power Unit (PPU) is a wheel-mounted, dual diesel engine driven, prime power (Type II), utility Class 2A, Mode I unit that produces 840 kilowatts (kW), 4160 volts line-to-line at 60 Hertz (Hz) and 700 kW, 3800 volts line-to-line at 50 Hz with an 0.8 power factor, lagging. As depicted in Figure 1 below, the MEP-PU-810 was configured in two versions. The USAF version, the MEP-PU-810A, was a new family of air transportable bare base electric power generation and distribution system to support the U.S. Air Force’s (USAF) Harvest Falcon and Harvest Eagle expeditionary mission sets. It is in a towed trailer configuration that is capable of being air transported by a C-130 aircraft. The U.S. Army version, the MEP-PU-810B, was designed to be more maneuverable in support of ground elements. It was designed with a 5th wheel configuration approved by the Department of Transportation (DOT) for over the road use at 55 miles per hour (MPH).

Figure 1: System Configurations

The system is capable of powering distribution networks to customers up to a distance of two miles away via transformers at 208/120 volts alternating current (VAC). Capable of operating in Auto, Manual, and Utility modes, the DPGDS allows flexibility of monitoring and controlling operations from Generator Control Panels (GCPs) and/or remote operation via the Operators Remote Terminal (ORT). This capability allows the system, or an operator to start, stop, add and remove generators, operate in parallel, and provides the ability to form a power grid.

Each power unit is equipped with two (2) Tier I Caterpillar 3456 Electrical Power Generation (EPG) Engines. These six (6) cylinder, four (4)-cycle engines are a liquid-cooled, turbo-charged, and after-cooled with 15.8 Liters (964 cubic inch) of displacement.

Each power unit is equipped with two (2) Caterpillar Model SR4B generators. These generators are a brushless, rotating armature exciter, single-bearing, air-cooled, open drip-proof unit. Each generator is directly connected to an engine. The generator is a permanent magnet pilot excited (PMPE) generator that receives power for the voltage regulator from

MEP-PU-810A Prime Power Unit MEP-PU-810B Prime Power Unit the pilot exciter, rather than the main armature as in self-excited generators. The pilot exciter consists of permanent magnet (PM) rotor and PM armature (stator). The pilot exciter operates independently. The generator is Wye connected. For 60 Hz operation the output is 4160 volts line to line, 2400 volts line to neutral, 3 phase, 4 wire. For 50 Hz operation the output is 3800 volts, 3800 volts line to line, 2200 volts line to neutral, 3 phase, 4 wire.

The recapitalization of the DPGDS captures the tremendous advancements in power generation technology over the past fifteen years and increases the useful life of the original system. The government envisions these recapitalized systems filling a capability gap until FY2033 when a new replacement system (the Prime Power Mobile Production System) is scheduled to be introduced to the force.

b. Task. This effort shall:

1) Replace the current engine with a new engine that shall allow the PPU to meeting all of the current performance criteria. This effort shall require any changes to the control and power distribution system, housing, etc. that are necessary to incorporate the replacement engine only. All work shall be documented in a Maintenance Work Order (MWO) which the contractor shall apply to the fleet of MEP-810s.

2) Refurbished the generators to include using the EnduraSeal process to increase the reliability of the generator

3) Acquire a complete technical data package (TDP) for the entire recapitalized system for both configurations, delivery of Mission Readiness Spares Package (MRSP) Kits, and the full complement of engineering and logistics supporting data.

c. Program Structure. The recapitalization effort shall be executed on one production contract, structured into a 32-month base period with a 28-month production period, and five

(5) twelve (12) option production periods (120 month contract) . Following a full and open competition solicitation, the contract shall be awarded to one vendor for the entire effort following a source selection. This recapitalization effort shall feature a Fixed Price Incentive Firm Target (FPIFT) contract for the First Articles Phase, and for the production phase, a Firm Fixed Price (FFP) contract. The contract shall include joint Government and contractor First Article testing in accordance with the Federal Acquisition Regulation (FAR) 52.209.

The base period contract shall cover the design, test and evaluation of the MWO for the recapitalization and government/contractor First Article testing activities on six generator sets (3 each MEP-PU-810A and MEP-PU-810B models) over a period of 32 months from FY2016-FY2018. The generators shall be provided upon contract award as Government Furnished Property (GFP). The first 18 months shall be dedicated to design of the MWO, and initial TDP and logistics deliverables. The following 14 months of the base period is dedicated to a rigorous, integrated First Article Test per FAR 52.209; and finalization of the TDP and logistics deliverables. Logistics deliverables shall include technical publications, full provisioning, training, and course materials. All first article generators shall undergo

Final Inspection Report (FIR) based acceptance to ensure that the systems are both operational and complete according to the specifications outlined in the purchase description. At the end of the base period, the final configuration shall be defined and documented in the final TDP delivered to the Government. The follow-on option shall take advantage of the completed TDP as it shall be provided to the contractor for the remainder of the Recapitalization effort.

The option period of the contract is dedicated to the application of the MWO on up to 180 MEP-PU-810A/B generator sets over a period of 88 months. This option period also allows the production of MRSP Kits. The Government shall provide up to 180 generators to the contractor, issued as GFP on an agreed upon schedule. It is the Governments intent to provide these systems at a Full Mission Capable (FMC) standard as described in Army Regulation (AR) 750-1.

1.1 MEP-PU-810 Generator Set Program Office

The recapitalization effort on the MEP-PU-810 is managed by the Product Manager, Large Power Sources for the Project Manager Expeditionary Energy & Sustainment Systems.

This office is located at Fort Belvoir, VA. The office can be reached at:

Product Manager, Mobile Electric Power Systems (MEPS) Project Manager Expeditionary Energy & Sustainment Systems 5850 Delafield Road, Building 324 Fort Belvoir, VA 22060

1.2 Data Requirements

Unlimited data rights are required. DFARS 252.227-7014 “Rights in Noncommercial Computer Software and Noncommercial Computer Software Documentation”, DFARS 252- 227-7013 “Rights in Technical Data – Non-Commercial Items” and other appropriate data rights clauses are included elsewhere in this solicitation.

1.3 Contract Data Requirements Lists (CDRL)

The CDRL forms (DD Form 1423-1) are provided as a separate attachment. All delivery dates are in the format of “Days After Award” (DAW). Days After Award are in calendar days, not work days.

2. APPLICABLE DOCUMENTS

The following documents are applicable to this Statement of Work (SOW) and attached appendices to the extent specified herein.

2.1 Department of Defense Specifications

MIL-PRF-28001 Markup Requirements and Generic Style Specification for Exchange of Text and Its Presentation

SAE-GEIA-STD-0007 Logistics Product Data Handbook

MIL-PRF-63002 Modification Work Orders

MIL-PRF-32216 Performance Specification, Evaluation of Commercial Off the Shelf (COTS) Manuals and Preparation of Supplemental

MIL-PRF-87268 Performance Specification, Interactive Electronic Technical-General Content, Style, Format, and User- Interaction Requirements

MIL-PRF-29612 Performance Specification, Training Data Products

2.2 Department of Defense Standards

MIL-STD-130 Department of Defense Standard Practice Identification Marking of U.S. Military Property

ANSI/EIA-748 Earned Value Management Systems MIL-STD-2361B (AC) Digital Publications Development MIL-STD-2073-1 Dodd Standard Practice for Military Packaging MIL-STD-31000 Technical Data Packages MIL-STD-40051-2 Preparation of Digital Technical Information for Page

Based Technical Manuals

MIL-STD-1686 Electrostatic Discharge Control Program for Protection Of

Electrical and Electronic Parts, assemblies and Equipment (Excluding Electrically initiated Explosive Devices)

TA-HB-00701 Handbook and Guide for Logistics Product Data Reports MIL-DTL-53072 Detail Specification: Chemical Agent Resistant Coating

(CARC) System Application Procedures and Quality Control Inspection

MIL-DTL-64159 Detail Specification: Camouflage Coating, Water Dispersible Aliphatic Polyurethane, Chemical Agent Resistant

2.3 Purchase Description

PD 6115-0132, 21 July 2015, entitled Purchase Description

2.4 Other Government Documents

MIL-HDBK-1222 Guide to the General Style and Format of U.S. Army Work Package Technical Manuals

DOD 4100.39-M Federal Logistics Information System (FLIS) Procedures Manual (General and Administrative Information)

DOD 5220.22-M National Industrial Security Program

DA PAM 750-8 The Army Maintenance Management System (TAMMS) User’s Manual

AR 700-18 Provisioning of U.S. Army Equipment AR 700-139 Army Warranty Program AR 350-1 Army Training and Leader Development AR 750-1 Army Materiel Maintenance Policy AR 381-12 Threat Awareness and Reporting Program (TARP) AR 25-2 Information Assurance TRADOC TR 350-70 Army Learning Policy and Systems H6-1 Federal Item Name Directory (FIND) for Supply

Cataloging CFR-TITLE 49 Code of Federal Regulations AFMAN 24-204 Preparing Hazardous Materials For Military Air

Shipments SAE-AS6500 Manufacturing Management Program MIL-HDBK-29612-2 Instructional Systems Development/Systems

Approach to Training and Education FED-STD-595 Paint Specifications

2.5 Availability of DoD Documents

Copies of these documents are available online at https://assist.dla.mil/ or from the Standardization Document Order Desk, 700 Robbins Avenue, Building 4D, Philadelphia, PA 19111-5094.

2.6 Non-Government Standards and Other Publications

ANSI/EIA 632 Processes for Engineering a System ANSI/EIA 649 National Consensus Standard for Configuration

Management ANSI/ISO 8632.14 Computer Graphics Metafile (CGM) ASME Y14.1 Decimal Inch Drawing sheet size and format ASME Y14.1M Metric sheet size and format ASME Y14.24 Types and applications of engineering drawings ASME Y14.34 Associated Lists ASME Y14.35M Revision of engineering drawings ASME Y14.41 Digital products definitions ASME Y14.5 Dimensioning and Tolerancing ASME Y14.100 Engineering drawing practices IEEE-1776-2008 Recommend Practice for Thermal Evaluation of

Unsealed or Sealed Insulation Systems for AC Electric Machinery Employing Form-Wound Pre- Insulated Stator Coils for Machines rated 15 000 V and Below

2.7 Availability of Non-Government Standards and Other Publications

ANSI documents are available from the American National Standards Institute, 11 West 42nd Street, 13th Floor, New York, NY 10036.

ASME documents are available from the American Society of Mechanical Engineers, 345 East 47th Street, New York, NY 10015.

ANSI/EIA documents are also available from the Electronic Industries Association, 2001 I Street NW, and Washington, DC 20005.

IEEE documents via the IEEE Standards Association at https://standards.ieee.org/findstds/standard/1776-2008.html

3. REQUIREMENTS

As stated, the contractor shall be provided the items and information identified in Appendix A to this SOW as Government Furnished Property (GFP); otherwise the contractor shall provide the facilities, services, personnel, parts, supplies, materials, equipment and all else necessary and required to develop, a Modification Work Order (MWO) to replace the current engine with a new engine and apply EnduraSeal coating on the generators, manufacture and apply the MWO to Government provided PPUs, test, and deliver, the ordered quantities of recapitalized systems, Mission Readiness Spare Package (MRSP) Kits and all support documentation detailed elsewhere within this SOW. All items ordered shall meet the requirements of this SOW and Purchase Description (PD) 6115-0132, either specified or referenced herein and all other contract requirements.

3.1 First Article Phase

3.1.1 Development of First Articles

The contractor shall develop a Modification Work Order (MWO) for the recapitalization effort apply it to six PPU’s (3 each A and B models) and deliver the First Articles (FA) 540 DAW .

The first eighteen (18) months shall be dedicated to the design of the MWO, initial TDP and logistics deliverables. The Government shall perform a FA Test IAW with para 3.9.3.1.

Logistics deliverables shall include technical publications, full provisioning, training, and course materials. All first article generators shall undergo Final Inspection Report (FIR) based acceptance, to ensure that the systems are both operational and complete according to the specifications outlined in the purchase description. At the end of the base period, the final configuration shall be defined and documented in the final TDP delivered to the Government. The first article generators shall be refurbished at the conclusion of the FA phase. The Order of Precedence for this development effort shall be (1) this SOW, then (2)

PD 6115-0132.

All generator set test models delivered for testing and evaluation as part of the First Articles phase shall contain the identical EPA certified engine(s) intended for end item delivery in the production phase of this contract.

The contractor shall describe and demonstrate a plan for ensuring continued supportability of the selected engines for a minimum of ten (10) years from the completion of this contract.

The vendor shall apply the MWO and return the recapitalized PPUs to the government’s possession. The Government intends to differentiate recapitalized systems by assigning new model numbers. The recapitalized MEP-PU-810A shall become a MEP-PU-810C. The recapitalized MEP-PU-810B shall become a MEP-PU-810D.

Some of the major elements of the recapitalization are called out in SOW paragraphs 3.1.2

– 3.1.6.

3.1.2 Re-engine Power Plant

Each MEP-PU-810 system (both configurations) currently is equipped with two 3456 Tier I Caterpillar EPG Engines. The contractor shall replace these engines with a TIER II engine or better to meet current acceptable Environmental Protection Agency (EPA) Tier requirements. The government shall pursue an EPA national security exemption waiver if required for the selected engine. The size engine required shall produce 400 kW minimum (800kW for full system), while operating on JP-8 fuel (refer to Purchase Description, paragraph 3.7.3).

3.1.3 Upgrade the Generator

Both generators in the MEP-PU-810 system are Caterpillar Model SR4B. All DPGDS generators are required to have EnduraSeal Vacuum Pressure Impregnation (VPI) process applied. If current SR4B generators are used they shall be removed, inspected, and determination made if the generator shall need to be refurbished, or just cleaned and baked if already equipped with the EnduraSeal windings. The EnduraSeal VPI process to be performed shall include but not limited to: disassemble, clean and inspect all parts, perform mechanical inspection, Total Indicated Runout (*TIR) on shaft and rotor, MIC all mechanical fits, electrical inspection, test exciter and diode assembly. If diodes are replaced, MSC diodes shall be used as replacements (MSC D2241 P0647). Also conducted is a core loss test, stator core pre burn with IR scan, burn out stator windings, strip stator, bead blast stator, core loss stator core with IR scan, manufacture EnduraSeal coils, install and surge test coils, connect stator. Additionally, a Vacuum Pressure Impregnation (VPI) and overcoat stator, perform underwater ac HI-POT test IAW IEEE STD 1776-2008, burn and strip rotor, bead blast rotor, rewind rotor connect all coils shall be performed. The contractor shall VPI and overcoat rotor windings, dynamically balance rotor, prepare all parts for assembly, install new 100 OHM platinum windings resistance temperature detectors (RTDS), install new terminal board.

Install new bearing, assemble generators, paint and install new stickers. The refurbished generators shall be covered by a five (5) year warranty.

This shall enhance the system’s operational performance in extreme humid environments.

Operational environments include long-term deployments, where systems are exposed to salt fog and ocean mist/spray. During the life of the current system, it has been required to operate in such environments on several operational deployments, and due to these environmental conditions experienced reliability problems.

3.1.4 Upgrade Control Components

The Primary Distribution Center (PDC) is an integral component of the PPU assembly.

There are two Feeder Outputs and one Tie Output in the PDC. The output of the PDC is the same as the two Generators. The PDC shall be updated with commercially available components designed to replace all obsolescent parts and meet all performance requirements herein. The PDC contains the following equipment:

Local Control Panel (LCP), which contains two Generator Control Panels;

Master Control Panel (MCP) (center panel on the Local Control Panel);

Internal power distribution bus and power distribution circuit breakers (Vacuum

Contactors);

Potential transformers / current transformers required for providing low voltage sensing information for the PU control system;

Controls for automated control and monitoring of the onboard generators;

Distribution load-break connectors;

Other connectors required so that allow multiple PUs to work together as a system.

The vast majority of parts for the control system are no longer available nor supported by the original manufacturer. The control system needs to be streamlined and updated using commercially available technology. A recapitalized system shall be able to be operated in Auto, Manual, and Utility modes. This flexibility allows an operator to control operations from the Generator Control Panels (GCPs). This includes the ability to start, stop, add and remove load, parallel units and add or remove systems from the bus, as well as monitor all control functions. A new recapitalized system shall provide the capability for remote operations and capability to parallel up to sixteen (16) PPUs together (32 engines). The PPU shall meet the High-Altitude Electro-Magnetic Pulse (HEMP) resistance requirement for operations. Refer to specific requirements in section 3.10 of the Purchase Description.

3.1.5 Corrosion Control and Painting

All surfaces of the PPU shall be inspected and treated for corrosion as specified in paragraph 3.12 of Purchase Description 6115-0132. All surfaces shall be corrosion free prior to the painting of the unit. Required treatment and painting shall be IAW MIL-DTL- 53072. The referenced drawings identified within the PD and SOW shall outline the treatment and painting for those items on the drawings. The color shall be Green 383, Tan 686 or desert tan lusterless (33446 of FED-STD-595). A flat finish shall be used on the interior floors of the PPU trailer. All surfaces of the PPU, regardless of the material selected, shall have topcoat color that shall be green or tan in accordance with FED-STD- 595B(1). PPU's shall have a finish coat of CARC paint IAW MIL-DTL-64159 or MIL-DTL- 53039.

3.1.6 Technical Data Package (TDP)

This effort shall require the contractor to develop a complete TDP (as discussed in paragraph 3.8.1) and logistics products necessary to provide life cycle support. The contractor shall develop and deliver associated logistics products to include technical and logistics data, Technical Manual (TM), MWO, provisioning data, training documentation and other associated products. Mission Readiness Spares Packages (MRSP) Kits shall be developed to support operations at critical sites world-wide.

3.1.7 Government Furnished Property

See Appendix A of this Statement of Work (SOW).

3.1.8 Associated Data

Not Used.

3.2 PRODUCTION PHASE

A Production phase delivery order shall implement the approved MWO on up to 180 MEP- PU-810 A and B generator sets converting them to MEP PU- 810 C and D models. Also the production phase shall include the delivery of MRSP Kits, Investment Spares, and Initial Spares/Repair Parts. This period takes place over a period of eighty-eight (88) months.

The Government shall provide PPU’s to the contractor, issued as GFP on an agreed upon schedule. Additionally, there shall be Quality Assurance Production Testing (commission testing shall be conducted on each unit).

It is projected that the first production phase delivery order shall be for ninety-eight (98) MEP-PU-810s, broken out into the following configurations/quantities:

Thirty-five (35) MEP-PU-810 C Model Generator Sets

Sixty-three (63) MEP-PU-810 D Model Generator Sets

3.2.1 MEP-PU-810 (Prime Power Unit) Configurations

Both MEP-PU-810 (PPU) configurations shall be manufactured, assembled, inspected and tested for acceptance IAW this SOW and the PD. The Order of Precedence for this production phase shall be (1) this SOW, and (2) PD 6115-0132. Deliveries shall begin within 6-8 months of the contract incorporation of a Delivery order; and shall be completed with twelve months.

3.2.2 Mission Readiness Spares Packages (MRSP) Kits, Initial Spares, and Investment Spares

MRSP Kits, Initial Spares, and Investment Spares shall be in accordance with SOW paragraph 3.11.1 – 3.11.3. Deliveries shall be completed within four (4) months after contract award of a firm-fixed price (FFP) production delivery order.

3.2.3 Government Furnished Property (GFP)

The Government shall provide the contractor with MEP-PU-810A and B Model Generator Sets as Government Furnished Property on an agreed upon schedule for the production phase. The government shall be responsible for the shipping costs associated with the movements of the MEP 810 units. Movement shall include the shipment to and from the factory to final destination determined by the government.

3.2.3.1 Corrosion Control

Of the DPGDS units in the DoD inventory that may be recapitalized, the Government has determined that 60 percent shall require minimal corrosion mitigation; 30 percent shall require moderate corrosion mitigation; and 10 percent shall require substantial corrosion control mitigation. For the systems identified for the initial production order (98 systems), the Government assesses these systems shall require minimal corrosion mitigation.

3.2.4 Associated Data

All associated data deliverables shall be as specified within this SOW.

3.3 PROGRAM MANAGEMENT

The contractor shall be responsible for establishing and maintaining an effective internal management and control system to ensure that appropriate contract goals and objectives are met, resources are safeguarded, laws and regulations are followed, and reliable data are obtained, maintained, and fairly disclosed through applicable contract data requirements. The management system utilized by the contractor shall provide for the capability to plan and control organization, schedule, cost, technical performance, accurate progress reporting procedures, and forecast potential results of alternate program actions.

3.3.1 Conferences and Reviews

The contractor shall ensure that appropriate personnel, including sub-contractors, are available to address and resolve agenda items for all directed conferences and reviews.

The Government reserves the right to call for conferences, Program/Design Reviews, or In- Process Reviews (IPRs) to discuss contract issues on an as-needed basis. The conferences and reviews shall take place at either the Government or contractor’s facility at the discretion of the Government. The contractor shall provide provisions, reports, and documentation to accommodate up to twenty (20) Government attendees. Specific dates for all reviews shall be determined by agreement between the contractor and Procuring Contracting Officer (PCO) to avoid scheduling reviews on weekends and holidays. In general, these conferences and reviews shall last a maximum of five (5) days; however, the Government reserves the right to establish the conference/review duration as necessary dependent upon final agenda requirements.

3.3.1.1 Post Award Conference

The contractor shall convene a Post Award Conference at the contractor’s facility no later than fifteen (15) days after contract award. The Government shall provide the agenda to the contractor five (5) working days prior to the start of the Post Award Conference. No more than twenty (20) Government personnel shall attend. The conference shall be no more than two (2) days in duration. An exact date shall be established within five (5) days after contract award.

3.3.1.2 Program/Design Reviews

3.3.1.2.1 Major Program Design Review Schedule

Technical Design and Integrated Product Support (IPS) Reviews shall be conducted at the following schedule with specific dates and duration to be determined:

a. First Design Review at 90 days after contract award

b. Second Design Review at 210 days after contract award

c. Third Design Review at 270 days after contract award

d. Others as required and specified by the Government.

3.3.1.2.2 Program Design Review Requirements

Each review shall include, but is not limited to the following:

a. Status of all hardware designs; and shall also include all data deliverables as applicable.

b. Status of parts that have been ordered or received.

c. Status of all fabrication and assembly actions.

d. Status and overview of program funds.

e. Status and overview of all scheduled hardware and data deliverables.

f. Status and overview of program funding and schedule. See SOW paragraph 3.3.2.

g. Status of production delivery orders, if applicable.

h. Other topics as required by the Government.

3.3.1.3 Preliminary Design Review (PDR)

A PDR shall be jointly conducted at 360 DAW. This PDR shall include (1.) the PPT model examination in accordance with SOW paragraph 3.9.3.2 and, (2.) a review of all data submittals due at or before 360 DAW. The PDR shall be conducted at the contractor’s facility. Once the examination is complete the contractor PPT testing shall begin. To support the PDR, the contractor shall, have the Product Drawings, (third submittal), IAW SOW paragraph 3.8.3.e; and the Operator and Maintainer Technical Manuals, first submittal, IAW SOW paragraph 3.14.3.2.4.a.

3.3.1.4 Critical Design Review (CDR)

A Critical Design Review (CDR) shall be jointly conducted at 540 DAW. The CDR shall be located at the contractor’s facility. The contractor shall present the results of the contractor PPT, corrections to test failures and FA PPUs with modification applied for examination.

This CDR shall also include (1.) the Pre-Production Test (PPT) model examination in accordance with SOW paragraph 3.9.3.2 and, (2.) the contractor shall validate, the drawings to be submitted at the fourth drawing submittal and the IPS data delivered (i.e., Maintenance Allocation Charts (MAC) and second submittal Technical Manuals) are in agreement with the PPT models under test. The government reserves the right to conduct independent validation of the contractor testing. Also, a presentation of the results of the contractor PPT Testing SOW paragraph 3.9.3.3.1 of this SOW shall be provided.

Prior to the start of this CDR, the mini PCA IAW SOW paragraph 3.8.3.f and the technical manual validation IAW SOW paragraph 3.14.3.2.6 shall be completed. The results of these activities shall be presented as part of this CDR.

This CDR shall be successfully completed prior to the commencing of the Government PPT test detailed in paragraph 3.9.3.3.2 of this SOW. Failure to successfully complete the actions of this CDR shall prevent the PPT models from entering Government conducted

PPT.

Upon successful completion of the CDR, the contractor shall ship the PPT test units to Aberdeen Proving Ground, Maryland for the Government conducted portion of the PPT (requires Government concurrence that the contractor conducted PPT testing is satisfactorily complete).

3.3.1.5 Provisioning Guidance Conference

The Provisioning Guidance Conference specified by the Provisioning Requirements Statement (Appendix G) shall be conducted immediately following the Post Award Conference held15 DAW.

3.3.1.6 Provisioning Conference

The Provisioning Conference shall be conducted in the 610 to 620 DAW timeframe; the exact dates will be confirmed during the provisioning guidance conference as specified by the Provisioning Requirements Statement (Appendix G), the Government approved baseline TDP (signed 4th drawing submittal) (LS036), engineering data for provisioning (EDFP), and the 1st Provisioning Parts List (PPL) submittal, shall be available for this conference. One each MEP-PU-810C and MEP-PU-810D Model Generators Sets shall be made available by the contractor to support the Provisioning Conference. The Provisioning Conference shall be conducted at a location to be determined by the Government.

3.3.1.7 Technical Manual Guidance Conference

The Technical Manual Guidance Conference shall be conducted immediately following the Post Award Conference specified in SOW paragraph 3.3.1.1. The Technical Manual Guidance Conference shall allow the Government to elaborate on expectations for all Technical Manuals; review the schedule and answer any questions the contractor may have.

3.3.1.8 Training Conferences

Guidance and scheduling for subsequent Training Conferences shall be established by the Government at the Technical Manual Guidance Conference.

3.3.2 Earned Value Management System (EVMS)

The contractor shall comply with the American National Standards Institute/Electronics Alliance Standard, ANSI/EIA 748 Earned Value Management Systems (EVMS). The reports include:

DI-MGMT-81466, Contract Performance Report (CPR) DI-MGMT-81650, Integrated Master Schedule DI-MGMT-81334 Contract Work Breakdown Structure (CWBS) An Integrated Baseline Review (IBR) shall be conducted at each of the Major

Program reviews identified in SOW paragraph 3.3.1.2.

3.3.3 Contract Funds Status Reports (CFSR)

The contractor shall prepare and provide the CFSR IAW DI-MGMT-81468. The CFSR reporting level shall be at the total contract level.

3.4 DATA SUBMISSIONS

Unless otherwise specified, data deliverables required under this contract (as set forth on the CDRLs), upon Government approval and to the maximum extent practical, shall be submitted via electronic-mail and electronic-media.

3.4.1 Electronic Media

Unless otherwise specified, the digital file format for data deliverables shall be Microsoft Office 2010 or higher, to include as follows:

Documents shall be prepared in “Microsoft Word” word processor format.

Spreadsheet data shall be in “Microsoft Excel” format.

Charts shall be prepared in “Microsoft PowerPoint” format.

Program Schedules shall be prepared in “Microsoft Project” format.

All drawings shall be provided in AutoCAD electronic media, paragraph 3.8.2

All CD ROMs or DVDs submitted in response to the data requirements of this contract shall include an external label that provides the following information:

a. Contract Number.

b. Title and subtitle (as applicable) of data product.

c. Program name, supplier and version of software used to generate data.

d. Date of submission.

e. Applicable CDRL and CLIN

3.4.2 Electronic Mail

The Government shall provide the contractor an electronic mail address for submission of data subsequent to contract award. Data transmitted in this manner shall conform to requisite file formats. Classified information shall not be transmitted via electronic mail.

3.4.3 Data Submittals into Invoicing, Receipt, Acceptance, and Property Transfer (iRAPT) (Formerly Wide Area Work Flow [WAWF])

The contractor shall enter all data submittals into the Invoicing, Receipt, Acceptance, and Property Transfer (iRAPT) system. See the DoD website for the latest information https://wawf.eb.mil/index.xhtml.

3.4.4 Access to Technical Data

The contractor shall provide in-plant access to Government personnel for all Technical and Logistics Data used in support of all efforts in support of the recapitalization. The contractor shall provide copies of all documents generated through the course of the contract when requested.

3.4.5 Color Photographic Prints

The contractor shall provide separate digital files and five (5) each 8 x 10 color photographic prints for both the MEP-PU-810 C and D Generator Set (fully assembled); the re-engined power plant (engine), the upgraded generator, and new control components IAW the SOW and CDRL for DI-MISC-80192A. Each photo set (digital file and prints) shall consist of four (4) side views of the item plus the top view. The digital files shall be prepared at the highest resolution image necessary for an 8” x 10” size photograph.

3.5 CONFIGURATION MANAGEMENT

3.5.1 Configuration Management System (CMS)

The contractor shall implement and maintain a Configuration Management System (CMS) IAW Electronic Industries Association (EIA) Standards EIA 649-1.

3.5.2 Configuration Baseline (CB)

The Configuration Baseline (CB) for the entire contract shall be PD 6115-0132, and all associated equipment configurations as follows:

a. MEP-PU-810A Model ( MEP-PU-810C);

b. MEP-PU-810B Model (MEP-PU-810D).

c. The CB shall be updated once the TDP is approved by the Government at the 4th drawing submittal.

3.5.3 Configuration Items (CI)

Each CI, (MEP- PU 810 C and MEP-PU 810 D) as developed, shall conform to the cited CB and (if applicable) all subsequent CB’s that are made contractually binding by the PCO.

Configuration changes not directly affecting the CB do not require Government approval prior to incorporation. However, prior to incorporation, the Government shall be notified. A change shall be documented by the contractor.

3.5.4 Configuration Baseline Changes

Upon approval of the 4th submittal drawings, no changes or departures from the approved CB are acceptable except for changes or departures which are submitted IAW this SOW and CDRL for DI-MISC-80711 are approved by the Government Configuration Manager, and are incorporated into the contract by the PCO:

Project Manager Expeditionary Energy & Sustainment Systems

ATTN: SFAE-CSS-E2-M

5850 Delafield Road, Bldg 324 Fort Belvoir, Virginia 22060-5809.

Configuration Control shall be affected by the following Configuration Control Documents (CCDs), with reference and guidance provided by EIA-649-1 as follows:

a. Engineering Change Proposal (ECP), includes both the engineering change and the supporting documentation by which the change is described and suggested. An ECP describes changes to the CI and associated configuration and IPS documentation that are affected by the proposed engineering change.

b. Notice of Revision (NOR). A NOR depicts changes that must be made to technical documentation (one NOR per document) following approval of an ECP.

c. Specification Change Notice (SCN). A SCN is used to delineate the exact change(s) in a specification from PD 6115-0132 that shall be distributed to users when approved.

d. Request for Variance (RFV). A RFV describes a proposed departure from (e.g.

non-conformance with) the contractually-specified configuration documentation for a specific number of units or for a specified time. Request for Variances is a term for what was formerly known as a Request for Deviation (RFD) or a Request for Waiver (RFW).

The contractor shall provide all necessary supporting data to include all technical and associated logistical elements. Each ECP, NOR, SCN, or RFV shall be uniquely and sequentially identified by the contractor. The forms to be used are ECP Form DD1692,cited in DI-SESS-80639,NOR Form DD1695, cited in DI-SESS-80642,cited in DI-SESS- 80643,and RFV Form DD1694.,Cited in DI-SESS-80640. All are referenced and part of

EIA-649-1

3.5.4.1 Change Proposals

All Change Proposals shall identify any cost increases, or decreases, and if requested by the PCO, shall set forth a “not to exceed” price.

3.5.4.2 Proposal Submittal

The contractor shall submit two (2) copies of each proposal to the Contract Administration Office/Administrative Contracting Officer (CAO/ACO) to confirm compliance withEIA-649-1 and this SOW. One copy of the proposal shall be returned to the contractor within five (5) working days after receipt by the CAO/ACO, stating whether or not the proposal is in compliance. Any unresolved differences between the CAO/ACO and the contractor shall be elevated to the PCO for resolution.

3.5.4.3 Proposal Distribution

For proposals, which the CAO/ACO has determined to be in compliance with EIA-649-1and this SOW, the contractor shall immediately forward the original per CDRL DI-MISC-80711A.

3.5.4.4 Contract Incorporation

Government acceptance of a proposal shall be affected by the issuance of a written contract change order or execution of a supplemental agreement incorporating said proposal. The Government shall notify the contractor in writing regarding proposals determined to be unacceptable with supporting rationale.

3.5.4.5 Contractor Officials

The contractor shall identify to the PCO, ACO, and the technical office identified on the CDRL for DI-MISC-80711A, the name(s) of the official(s) of its organization who are authorized to sign CCDs at the post award conference.

3.5.4.6 Value Engineering Change Proposals (VECPs)

Value Engineering Change Proposals (VECPs) shall be submitted in the same manner as described above. The subject heading in the letter of submission shall contain the letters VECP in bold type. Additionally the letter shall address in detail the cost savings resulting from the VECP.

3.6 QUALITY ASSURANCE

The contractor shall implement and maintain a quality system that ensures the functional and physical conformity of all products or services provided IAW this SOW.

The contractor shall implement and maintain a quality system that ensures the functional and physical conformity of all products or services provided IAW this SOW. Responsibility for Inspection - Unless otherwise specified in the contract/purchase order, the Contractor is responsible for the performance of all inspection requirements as specified herein. Except as otherwise specified in the contract/purchase order, the Contractor may use his own or any other facilities suitable for the performance of the inspection requirements specified herein, unless disapproved by the Government. The Government reserves the right to perform any of the inspections set forth in the specification where such inspections are deemed necessary to assure supplies and services conform to prescribed requirements.

Records - Records of all inspection work by the Contractor shall be kept complete and available to the Government during the performance of contract/purchase order and for a period of 365 calendar days after final delivery of supplies.

At any point during the contract performance, the Government has the right to review the contractor’s quality system to assess its effectiveness in meeting contractual requirements.

3.6.1 Quality Assurance Control

The Contractor, during the contract performance entirety, shall implement and maintain quality assurance and control on documentation, materials (conforming and non-conforming), manufacturing operations and processes, test inspection equipment to ensure that functional and physical conformity of all products or services. The Contractor shall perform internal quality audits to verify the effectiveness of their quality approach. These requirements are commonly accepted practices employed by industry in both national and international manufacturing environments. Quality Assurance shall be IAW contract requirements in section E of the contract. For Electronic components Quality Assurance Program and MIL-STD-1686, Department of Defense Standard Practice for Electrostatic Discharge Control Program for Protection of Electrical and Electronic Parts, Assemblies and Equipment.

At any point during the contract performance, the Government has the right to review the Contractor’s quality system to assess its effectiveness in meeting contractual requirements.

Certification of compliance or registration of the quality system, by an independent standards organization or auditor, IS REQUIRED. A copy of such certification shall be attached with the offer in response to the solicitation as proof of system compliance.

3.7 ITEM UNIQUE IDENTIFICATION DESIGNATOR (IUID)

This IUID requirement shall be included in the fixed price. At the contract award kick-off meeting the contractor shall meet with representatives from the Government to discuss proper procedures and process for input of IUID data into the registry. IUID registry instructions and guidance are to be followed as per below.

3.7.1 IUID Data Submission Guidance

The latest IUID Data Submission guidance may be found at:

http://www.dodprocurementtoolbox.com/page/overview/data-submission.

The contractor shall submit IUID data via the Wide Area Work Flow (WAWF) Paperless Contracting Environment per the latest published guidance and sample construct figures are located in IUID 101. The Basics located at:

http://www.acq.osd.mil/dpap/pdi/uid/docs/IUID_101_The_Basics_v3_05_2010_v2.pdf

3.7.2 Requirements for Item Unique Identification Designation (IUID)

The contractor shall comply with DFARS 252.211-7003, Item Identification and Valuation to provide IUID, or DOD recognized unique identification equivalent, for all applicable equipment and line replaceable items with an acquisition cost of $5,000 or more. IUID markings shall be per the latest version of MIL-STD-130.

Bar code plate. Each generator set shall have a bar code plate, with bar code and serial number corresponding with the bar code that is uniquely numbered for each individual generator set. The bar code plate shall be permanently attached in a readily viewable location, outside the generator set housing. The contractor shall mark all Contract Production Phase deliverables IAW the following requirements:

a. IUID Marking. The contractor shall provide a UID, or DoD recognized unique identification equivalent, for all items delivered with an acquisition cost of $5,000 unit price or more to include the MEP-PU-810, both configurations, the engines, alternator and control components. In addition, the contractor shall apply IUID markings to all equipment and reparable items for which the Government’s unit acquisition cost is less than $5,000, when they are mission essential, or controlled inventory items, or other items that the Government has identified in this contract as requiring IUID markings. IUID markings shall be IAW PD 6115-0132, paragraph 3.19.3.10.

b. Commercial Markings. All other items shall have acceptable commercial markings that meet the guidelines in DoD Guide to Uniquely Identifying Items http://www.acq.osd.mil/dpap/pdi/uid.

c. Permanency and Legibility. The IUID marking and identification plates, tags, or labels when used on equipment, parts, assemblies, subassemblies, units, sets, or groups shall be as permanent as the normal life expectancy of the item and be capable of withstanding the environmental test and cleaning procedures specified for the item.

Legibility shall be as required for ready readability per MIL-STD-130.

d. Deleterious Effect. Marking of items shall be accomplished in a manner that shall not adversely affect the life and utility of the item. Marking materials creating hazardous conditions shall not be used. Placement and choice of the marking shall not create hazardous conditions.

3.7.3 IUID Coding

IUID markings and readability requirements shall comply with MIL-STD-130. The human readable characters and the machine readable IUID zymology shall be marked on the hardware.

a. The order of priority when there are space limitations shall be IAW the MIL-STD-

130. The 2D machine readable IUID is the minimum requirement when there are severe space limitations.

b. If the technical data has not specified the marking location, markings shall be located such that they are visible during item use, provided that sufficient space is available, and do not interfere with equipment operations.

c. Serial Numbers. The contractor shall meet the requirements of MIL-STD-130 to establish the IUID. The contractor shall insure that the IUID is unique for that item and distinguishable from all other items forever.

d. IUID List. The contractor shall maintain an accurate, current list of IUIDs for all manufactured items on this contract. Dates of manufacture, substitutions, shop changes, etc. shall be included on this list. The list shall be available for inspection by the PCO or other Government representative at any time during the life of this contract.

3.7.4 IUID Report

The contractor shall provide and maintain an accurate, IUID Report for all manufactured items on this contract per CDRL for DI-MGMT-81858. Dates of manufacture, substitutions, shop changes, etc. shall be included in this report.

3.7.5 Correction of Noncompliant Equipment UID and Technical Data

This contract contains configuration control requirements (see SOW paragraph 3.5); thus, the contractor shall initiate the appropriate configuration control document to correct all affected drawings/specifications which conflict with or omit the marking requirements stipulated above.

3.7.6 Government Purchase of Product/Technical Data

a. The contractor shall prepare IUID Plate drawings (see SOW paragraph 3.8) for major assemblies including the MEP-PU-810 (both configurations), the engines, alternator and control components, and any other generator set component with a projected acquisition cost of $5,000 per unit price or more. In addition, the contractor shall prepare a UID plate drawing for reparable items for which the Government’s unit acquisition cost is less than $5,000 when they are mission essential, or controlled inventory items, or other items that the Government has identified in this contract as requiring IUID markings.

b. The contractor shall include IUID marking requirements on each applicable component drawing. Location shall be depicted on the pictorial and other details presented in the notes.

3.7.7 IUID Data Submittals

The contractor shall enter data submittals into the Wide Area Work Flow (WAWF) system.

See the DoD website for the latest information http://www.acq.osd.mil/dpap/pdi/uid.

3.7.8 IUIDs on Embedded Items

IUID markings are required for embedded items.

3.8 PRODUCT DRAWINGS & ASSOCIATED LISTS

3.8.1 Purpose

Product level drawings are necessary to enable the Government to competitively purchase all end items, and support logistic activities of fielded items. Product drawings shall depict all end item components and the assembly and integration thereof. The product drawings shall define the requirements of form, fit, function, and interface as required in this SOW.

The resultant complete system Technical Data Packages (TDPs) shall be used by the contractor to manufacture and assemble end items ordered during the production phase of this contract. All production end items ordered shall be inspected and accepted using these TDPs. Product drawings shall also contain all test procedures associated with individual components, subassemblies, and assemblies as necessary to comply with this SOW. If any special Test Fixtures are required, all information, documentation, software, and firmware necessary to produce and utilize these test fixtures shall be included in the drawings.

Product drawings shall be made IAW this SOW and the CDRL for DI-SESS-81000E.

3.8.2 Drawing Submittal Requirements

a. The contractor shall furnish a complete separate Technical Data…