W911RQ-19-R-0017-0002_AMENDMENT.pdf

W45G18911400S3

AMENDMENT OF SOLICITATION/MODIFICATION OF CONTRACT

Except as provided herein, all terms and conditions of the document referenced in Item 9A or 10A, as heretofore changed, remains unchanged and in full force and effect.

15A. NAME AND TITLE OF SIGNER (Type or print)

30-105-04EXCEPTION TO SF 30

APPROVED BY OIRM 11-84

STANDARD FORM 30 (Rev. 10-83) Prescribed by GSA

FAR (48 CFR) 53.243

The purpose of this amendment is to change the offer due date and time and changes to paragraph 5.5.1, 5.5.7 and 5.24 on the statement of w ork.

All other terms and conditions of the solicitation, except those addressed by this amendment, remain unchanged and in full force and effect.

1. CONTRACT ID CODE PAGE OF PAGES

J 1 23

16A. NAME AND TITLE OF CONTRACTING OFFICER (Type or print)

16C. DATE SIGNED

BY 23-Jul-2019

16B. UNITED STATES OF AMERICA15C. DATE SIGNED15B. CONTRACTOR/OFFEROR

(Signature of Contracting Officer)(Signature of person authorized to sign)

8. NAME AND ADDRESS OF CONTRACTOR (No., Street , County, State and Zip Code) X W911RQ19R0017

X 9B. DATED (SEE ITEM 11)

02-Jul-2019

10B. DATED (SEE ITEM 13)

9A. AMENDMENT OF SOLICITATION NO.

11. THIS ITEM ONLY APPLIES TO AMENDMENTS OF SOLICITATIONS

X The above numbered solicitation is amended as set forth in Item 14. The hour and date specified for receipt of Offer X is extended, is not extended.

Offer must acknowledge receipt of this amendment prior to the hour and date specified in the solicitation or as amended by one of the following methods:

(a) By completing Items 8 and 15, and returning 1 copies of the amendment; (b) By acknowledging receipt of this amendment on each copy of the offer submitted;

or (c) By separate letter or telegram which includes a reference to the solicitation and amendment numbers. FAILURE OF YOUR ACKNOWLEDGMENT TO BE RECEIVED AT THE PLACE DESIGNATED FOR THE RECEIPT OF OFFERS PRIOR TO THE HOUR AND DATE SPECIFIED MAY RESULT IN

REJECTION OF YOUR OFFER. If by virtue of this amendment you desire to change an offer already submitted, such change may be made by telegram or letter, provided each telegram or letter makes reference to the solicitation and this amendment, and is received prior to the opening hour and date specified.

12. ACCOUNTING AND APPROPRIATION DATA (If required)

13. THIS ITEM APPLIES ONLY TO MODIFICATIONS OF CONTRACTS/ORDERS.

IT MODIFIES THE CONTRACT/ORDER NO. AS DESCRIBED IN ITEM 14.

A. THIS CHANGE ORDER IS ISSUED PURSUANT TO: (Specify authority) THE CHANGES SET FORTH IN ITEM 14 ARE MADE IN THE

CONTRACT ORDER NO. IN ITEM 10A.

B. THE ABOVE NUMBERED CONTRACT/ORDER IS MODIFIED TO REFLECT THE ADMINISTRATIVE CHANGES (such as changes in paying office, appropriation date, etc.) SET FORTH IN ITEM 14, PURSUANT TO THE AUTHORITY OF FAR 43.103(B).

C. THIS SUPPLEMENTAL AGREEMENT IS ENTERED INTO PURSUANT TO AUTHORITY OF:

D. OTHER (Specify type of modification and authority)

E. IMPORTANT: Contractor is not, is required to sign this document and return copies to the issuing office.

14. DESCRIPTION OF AMENDMENT/MODIFICATION (Organized by UCF section headings, including solicitation/contract subject matter where feasible.)

10A. MOD. OF CONTRACT/ORDER NO.

2. AMENDMENT/MODIFICATION NO. 5. PROJECT NO.(If applicable)

6. ISSUED BY

3. EFFECTIVE DATE

23-Jul-2019

CODE

RED RIVER ARMY DEPOT

DIRECTORATE FOR CONTRACTING

100 JAMES CARLOW DRIVE BLDG 431

TEXARKANA TX 75501-5000

W911RQ 7. ADMINISTERED BY (If other than item 6)

4. REQUISITION/PURCHASE REQ. NO.

CODE

See Item 6

FACILITY CODECODE

EMAIL:TEL:

W911RQ19R0017

SECTION SF 30 BLOCK 14 CONTINUATION PAGE

SUMMARY OF CHANGES

SECTION SF 1449 - CONTINUATION SHEET

SOLICITATION/CONTRACT FORM

The required response date/time has changed from 02-Aug-2019 05:00 PM to 09-Aug-2019 05:00 PM.

The following have been modified:

STATEMENT OF WORK

Statement of Work (SOW) for a

Diesel Engine Driven HMPT Cross Drive Transmission Dynamometer

1. General. This SOW sets forth the minimum requirements for the procurement, turn-key installation, commissioning, testing, and training for a diesel engine driven, electric motor loaded, Hydro Mechanical Power Train (HMPT) transmission dynamometer test system with a self-contained closed loop liquid cooling system.

1.1. Scope. The vendor shall construct an attached steel awning with concrete pad on the South side of building M376A to house the fuel storage tank for the diesel engine and the external heat radiating unit for the self-contained liquid cooling system. The vendor shall be responsible for providing all components of the complete system excluding the Cummins input drive diesel engine and the transmission control module. This includes the dynamometer loads; engine fuel supply system; load, control, and data acquisition systems; self-contained cooling systems for the engine, transmission, fuel, and load systems;

self-contained air supply system; supplies and construction labor for the building addition; equipment, supplies, and manpower for the system installation, offloading, and unpacking of all equipment. The Government will furnish the vendor a new functional Cummins VTA-903 675 Horsepower (HP) diesel engine to be used as a prime mover for the system, a transmission control module, and test/development transmission assets. The vendor shall be responsible for integrating the Government Furnished Equipment (GFE) into the equipment design, installing and making it fully operational and functional. All GFE shall be returned to the Government at the time of dynamometer system installation. The vendor shall be responsible for transport of all GFE to and from the vendor’s facility.

1.2. Background. The purpose of the subject dynamometer test system is to facilitate testing of military cross drive type transmissions such as the Bradley Fighting Vehicle System (BFVS) transmission and Multiple Launch Rocket System (MLRS) transmission. The dynamometer shall provide input power to the transmission using a Cummins VTA-903 675HP diesel engine while providing independent electric motor loading to the output drives of the transmission, closely simulating in-vehicle real world operating conditions.

1.3. Place of Performance. The test system shall be delivered, installed, and made fully operational at building M376A on Red River Army Depot (RRAD) located at Texarkana, Texas 75505.

1.4. Period of Performance. The vendor shall furnish, install, make operational, and return all test and return items of this Statement of Work no later than nine (9) months after the date of contract award.

1.5. Recognized Holidays: The contractor is not required to perform on the following holidays:

New Year’s Day Labor Day Martin Luther King Jr.’s Birthday Columbus Day President’s Day Veteran’s Day Memorial Day Thanksgiving Day Independence Day Christmas Day

2. Objective. The dynamometer system shall serve to accomplish all performance and test requirements listed in the NMWR test procedures and this Scope of Work. The dynamometer system shall provide complete control, performance monitoring, and data acquisition and storage from a separate existing control room in building M376A. The vendor shall provide and install a fully self-contained closed loop non-evaporative ethylene glycol and water based cooling system that rejects heat from the drive engine, output motor loads, transmission under test, and engine supply fuel to the outside air. This cooling system shall be a completely self-contained unit that is independent of the existing RRAD water cooling system.

Upon delivery of the subject equipment, the vendor shall provide complete turn-key installation services for the system. The vendor shall provide training services to operator, maintenance, and calibration personnel at RRAD – Texarkana, TX.

3. General Requirements.

3.1. Item Condition. The items offered shall be new and a current production model. A current production model is defined as the manufacturer’s current production model which, on the date this solicitation is issued, has been designed, engineered and sold or is being offered for sale through advertisements or manufacturer’s published catalogue or brochures. Products such as a prototype unit, pre-production model, or experimental units do not qualify as meeting the requirements specified herein.

The equipment shall be complete, so that when connected to the utilities identified herein, it can be used for any function for which it was designed and constructed. The system shall be a standalone unit, and shall not rely on any existing facility dynamometer, control, instrumentation, or cooling provisions.

3.2. General Safety. The equipment shall be fitted with safety devices or coverings for any parts that present safety hazards. The equipment shall include provisions to isolate and lock out all sources of hazardous energy, either input to the equipment or generated by the equipment, to ensure safety of operation and maintenance personnel.

3.3. General Standards Compliance. General compliance shall include, but not necessarily be limited to the following:

3.3.1. Occupational Safety and Health Administration (OSHA) 29 CFR 1910: Code of Federal Regulations, Occupational Safety and Health Standards.

3.3.2. National Fire Protection Agency (NFPA) 70: National Electric Code (NEC), most current edition.

3.3.3. NFPA 37: Standard for the Installation and Use of Stationary Combustion Engines and Gas Turbines.

3.3.4. American Concrete Institute International (ACI) 318 Building Code Requirements for Structural Concrete.

3.3.5. ACI 530/530.1 Building Code Requirements and Specification for Masonry Structures.

3.3.6. American Institute of Steel Construction (AISC) 303 Code of Standard Practice for Steel Buildings and Bridges.

3.3.7. AISC 360 Specification for Structural Steel Buildings.

3.3.8. NMWR 9-2520-281-2, National Maintenance Work Requirement Containing National Maintenance Repair Standards Including RPSTL for Transmission: Crossdrive, Hydromechanical HMPT 500-3ECB and HMPT-800, dated 31 October 2014 (or most recent).

3.3.9. Government shall coordinate all local air quality permitting and exemptions with local authority having jurisdiction. Manufacturer/installer shall provide all necessary information to Owner/End User to facilitate this process.

3.4. Environmental Protection. The equipment shall be designed and constructed, so that under the operating service, transportation and storage conditions described herein, the equipment shall not emit materials hazardous to the ecological system as prescribed by federal, state, and local statutes in effect at the time of offer.

3.4.1. Compliance with Environmental Laws and Regulations: Contractor shall comply with all applicable federal, state, and local environmental laws, statutes, regulations, executive orders, permits, Army regulations (with supplements), as well as Major Subordinate Command (MSC) and installation regulation, policy, Host Tenant Agreement, Interagency Service Support Agreement, or Status-of-Forces Agreement. Contractor shall immediately report any conflicts between applicable federal, state, local environmental laws, statutes, executive orders, and provisions of Army Regulation 200-1, and any specifications within this contract to the Contracting Officer Representative (COR).

3.4.2. Conformance with Environmental Management System: Contractor shall take the necessary actions to identify, monitor, and control those contract operations and activities that pose risk of contamination, or can negatively impact the natural and/or human environment.

3.5. Hazardous Materials Restriction. The equipment shall contain neither mercury nor mercury compounds, or be exposed to free mercury during manufacture. Asbestos and materials containing asbestos shall not be used on or in the equipment. The use of polychlorinated biphenyl on or in the equipment is prohibited.

3.6. Lubrication. Means shall be provided to ensure adequate lubrication of all moving parts. If the design of the equipment includes a recirculating lubrication system, the system shall include a cleanable or replaceable filter. Each lubricant reservoir shall have at least a 24 hour capacity and means for determining fluid level. All oil holes, grease fittings and filler caps shall be labeled and readily accessible.

3.7. Interchangeability. All parts of the end item shall be manufactured to standards and tolerances that will provide for the interchangeability of respective parts between end items of the same model without modification of the part or the equipment. All replacement parts shall be available commercially within the continental United States.

3.8. Controls. All mechanical, electrical, hydraulic and pneumatic operating controls required for transmission testing shall be located convenient to the operator's work station(s). The test stand shall be able to be operated from a control room that is separate from the location of the test stand. The control room shall be located in an existing enclosure in building M376A.

3.9. Warranty. The transmission test stand furnished under this specification shall be guaranteed for a period of one (1) year, against defective materials, design, and workmanship. Upon receipt of notice from the Government of failure of any part of the system during the warranty period, that part or parts shall be replaced promptly with new parts at the expense of the vendor. The vendor shall provide installation services for replacement items during the warranty period at the expense of the vendor. The warranty is to begin upon final acceptance by the Government.

3.10. Equipment Assembly. The equipment shall be constructed of parts that are new, without defects and free of repairs. The equipment construction shall include all components, parts, and features necessary to meet the performance requirements specified herein. All parts subject to damage from environmental hazards (such as dust, debris, or residue) shall be sealed or otherwise protected. The structure shall withstand all forces encountered during the operation of the equipment to its maximum rating and capacity without permanent distortion or failure.

3.11. Castings and Forgings. All castings and forgings shall be free of defects, scale, and mismatching.

No processes such as welding, peening, plugging, or filling with solder or paste shall be used for reclaiming any defective part. Such processes shall be used only for enhancing surface finish and appearance.

3.12. Welding, Brazing, and Soldering. Welding, brazing or soldering shall be employed only where those operations are included in fabrication of the original design. These operations shall not be employed as repair measures for defective parts. Any excess material used for such operations shall be thoroughly removed from the part(s) upon completion of the operations.

3.13. Surfaces. All surfaces shall be clean and free of harmful or extraneous materials. All edges shall be either rounded or beveled unless sharpness is required to perform a necessary function. Except as otherwise specified herein, the condition and finish of all surfaces shall be in accordance with the manufacturer's commercial practices.

3.14. Painting. The equipment shall be painted in the manufacturer's standard color provided it results in a highly wear resistant finish which guarantees continued protection to the surfaces covered against all service conditions.

3.15. Measuring and Indicating Devices. All measuring and indicating devices such as dial indicators, pressure gages, temperature indicators, depth stops, scales, and other similar devices used on the equipment shall be graduated in the U.S. Customary System of Units (US). Markings on all measuring and indicating devices shall be permanently and legibly engraved or etched on a non-glare background.

All dials and other type indicating devices shall be securely mounted in place.

3.16. Maintainability. The equipment shall be designed and constructed to permit maintenance personnel to easily service the equipment using a minimal number of tools. All parts subject to wear, breakage, or distortion shall be accessible for adjustment, replacement, or repair. Consistent with required maintenance and design of the equipment, the vendor shall provide any special tools required to service the unit. The equipment shall be equipped with access covers to facilitate inspection, cleaning, repair, or replacement of parts.

4. Government Furnished Equipment (GFE). The Government will furnish the vendor the below listed components. These components shall be returned to the Government at the time of equipment installation at RRAD. In the event of damage to any of these components, the vendor shall be responsible for all costs incurred for repair or replacement of damaged items. The Government shall not be responsible for any lost or damaged GFE once it has left the origin Government facility. The vendor shall be responsible for transport and shipping fees to and from the vendor’s facility.

4.1. Equipment: The Government will furnish the following equipment:

4.1.1. Cummins VTA-903 675HP Diesel Engine – One (1) each

4.1.2. Transmission Control Module – One (1) Each

4.1.3. The Government will furnish the following Test and Return equipment below to the contractor solely for the purpose of performance under this contract:

4.1.3.1. HMPT Transmission – HMPT500 ECB Towable – Two (2) each

4.1.3.2. HMPT Transmission – HMPT800 – Two (2) each

4.2. Utilities: All utilities in the facility will be available for the contractor’s use in the performance of this contract. The contractor shall instruct employees in utilities conservation practices. The contractor shall operate under conditions that preclude the waste of utilities, which include turning off the water faucets or valves after using the required amount.

5. Tasks and Technical Requirements. The vendor shall furnish, install, and make operational all of the components required to meet the details of this purchase description. The Government will furnish the prime mover diesel engine and transmission control module, and the vendor shall be responsible for integrating and installing the items into the vendor’s design and making it fully operational. Any other components required to meet the test capability described in the applicable NMWR shall be provided in accordance with the vendor’s standard practice.

5.1. Test Capability. The dynamometer test system shall be able to test Hydro Mechanical Power Train (HMPT) cross-drive transmissions commonly used in tracked military vehicles such as the Bradley Fighting Vehicle System (BFVS) family, and the Multiple Launch Rocket System (MLRS) family of vehicles and similar. At the completion of installation, the dynamometer system shall be able to test the following transmissions in accordance with their respective technical document. The equipment shall be capable of performing all portions of the tests listed in the associated documentation, including Final Test, Control Test, and Rated Steer Torque Control Test. The technical documents will be provided by RRAD.

5.1.1. HMPT 500 ECB Towable - NMWR 9-2520-281-2 Dated 31 October 2014 (or newest version)

5.1.2. HMPT 800 - NMWR 9-2520-281-2 Dated 31 October 2014 (or newest version)

5.2. NMWR Conflicts. In the event of a conflict between the general requirements of this specification and the testing requirements of the above NMWR, the vendor shall immediately notify the Contracting Officer.

5.3. Dynamic Deceleration and Inertia Testing. The vendor shall provide a means to perform all deceleration and inertia testing in the NMWR test procedure in accordance with the manufacturer’s standard practice. Inertia simulation is permissible provided the requirements of the NMWR tests are met.

5.4. Dynamometer Input Engine (Government Furnished).

5.4.1. Quantity: 1

5.4.2. Manufacturer: Cummins Engine Co., Inc.

5.4.3. Model: VTA-903 Series

5.4.4. Type: V8 Cylinder, 90 degree arrangement

5.4.5. Power Rating: 675 braking horsepower (BHP)

5.4.6. Top speed: 3200 revolutions per minute (RPM)

5.4.7. Torque: 2,600 lb-ft continuous from 0 to 1,600 RPM

5.4.8. Displacement: 903 cubic inches (14.8 liters)

5.4.9. Dry weight: 2,500 pounds, nominal

5.4.10. Starter: 24 VDC Starter

5.4.11. Overall dimensions: 56”L x 40” W x 50” H

5.5. Dynamometer Input Engine Accessories and Control (Vendor Responsibilities). The vendor shall be responsible for installing, integrating, and making the engine fully operational with the vendor’s system design. The vendor shall supply and install the external accessories required for engine control, mounting, cooling, fuel supply, fuel storage, exhaust, air intake, and operation in accordance with the following specifications:

5.5.1. Engine Mounting. The engine and engine components shall be mounted to a single heavy duty skid type frame constructed of fully welded steel structural members. The engine mounting method shall provide isolation of engine vibration from the input driveline of the transmission under test using a torsional dampener, or other vibration mitigating method. The vendor shall mount and install the engine in a manner that isolates engine vibration from the building foundation, building structure, UUT, and other components of the test system. This shall be accomplished using an anti-vibration mounting pad, isolated or floating mounting pad, or similar. If concrete foundation modification is required by the vendor’s design, the vendor shall be responsible for providing all labor and materials for the foundation modification. Concrete foundation modification shall be coordinated with RRAD Department of Public Works. Coordinate engine mounting height to facilitate height, angle, and alignment of the input drive shaft to the full range of test transmissions for optimal drive train performance. The engine shall be mounted in a manner that allows maintenance personnel to easily access and replace the engine.

5.5.2. Drive Shaft. Vendor shall provide torsionally resilient driveshaft of a size, configuration, and material necessary to properly handle the specified loads and forces while minimizing parasitic power losses and damaging vibration from the engine to the transmission under test. A torsional vibration dampener shall be included in the driveline to minimize harmful vibrations from the drive engine. Include connecting driveshaft joint(s) to transmit constant velocity to the transmission under test, as necessary.

Include coupling match plate capable of being connected to all specified test transmissions. Drive shaft assembly shall be phased and balanced for the specified engine speeds, shall be aligned and installed at such an angle to eliminate harmful vibrations to equipment and test transmissions. The vendor shall install the driveline in a manner that will prevent system vibrations from causing damage to the input driveline components and transmission under test. Vendor shall provide and install a latchable safety cover guard(s) over the entire driveshaft assembly. Cover guard(s) shall conform to all OSHA requirements. The cover guards shall either be removable or capable of being opened on hinged access panel(s) to perform work on the drive shaft assembly. Paint cover guard(s) in a safety yellow corrosion resistant enamel.

5.5.3. Engine Control. The engine shall be fully controllable by means of on-board electronic engine control modules, complete with sensors, software, actuators, solenoids, and data connection back to the control room workstation. Features and functions shall include the following at a minimum:

5.5.3.1. Control input engine throttle through electrical signal.

5.5.3.2. Control engine start/stop from operator control console computer.

5.5.3.3. Control input engine stop/start as a result of automatic shutdown from test procedure, emergency shutdown, or manual shutdown request from control room workstation computer.

5.5.3.4. Control input engine functions through any programmable automated or manual user defined run patterns received from the control room workstation computer.

5.5.3.5. Control input engine functions as a result of receiving signals from programmed warnings or system shutdown features resulting from various high or low level limit alarms.

5.5.3.6. Receive, interpret, and process information from various on-board engine sensors and provide resulting diagnostic information to the control room workstation computer.

5.5.3.7. Capability to initiate automatic shutdown of entire dynamometer system upon detecting high temperatures or low pressures, or other faults of critical engine functions.

5.5.3.8. The engine control modules shall communicate with other engine components and sensors by means of standard SAE J1939 Controller Area Network (CAN) protocol or similar.

5.5.3.9. The vendor shall provide and install data connection between the engine control module, data acquisition console system, and the workstation for the intercommunication of diagnostic information and control commands.

5.5.4. The system shall include data acquisition instrumentation capable of collecting and sending real time engine performance data to the control room workstation and data acquisition system. The data shall be viewable on the operator control room console. At a minimum, the collected engine performance data shall include:

5.5.4.1. Input shaft speed

5.5.4.2. Input shaft torque

5.5.4.3. Engine coolant flow

5.5.4.4. Engine coolant pressure

5.5.4.5. Engine coolant temperature

5.5.4.6. Engine oil flow

5.5.4.7. Engine oil pressure

5.5.4.8. Engine oil temperature

5.5.4.9. Engine intake air temperature

5.5.4.10. Engine exhaust temperature

5.5.4.11. Engine fuel consumption

5.5.4.12. The vendor shall provide all necessary wiring, cabling, connections, and conduit for all instrumentation

5.5.5. Data Link Port. The vendor shall provide an engine ECM connection port in the control room to allow the operator to interface a PC with Cummins INSITE engine ECM communication software for data analysis purposes. The access port shall allow connection with a SAE J1939 nine (9) pin connector.

5.5.6. Engine Cooling System. The vendor shall provide and install a complete closed loop corrosion free non-evaporative cooling system capable of transferring heat from the input drive engine coolant to a vendor provided heat exchanger and external radiating unit. The heat exchanger shall reject the engine coolant heat to a corrosion free ethylene glycol and water based closed loop non-evaporative exterior vendor provided radiating unit. This external cooling unit shall also be used to provide transmission oil and output load cooling. The vendor shall provide all piping, pumps, valves, wiring, connections, conduit, filters, and coolant liquid for the complete system. The cooling system shall be fully self-contained, and shall not rely on any existing cooling provisions. The coolant system shall include at a minimum:

5.5.6.1. A liquid to liquid heat exchanger(s) and external radiating system

5.5.6.2. A filter system to filter coolant liquid for the protection of all pumps

5.5.6.3. A coolant pump for circulation of coolant between the drive engine and heat exchanger

5.5.6.4. A coolant liquid temperature controller

5.5.6.5. An input engine coolant circuit pressure gauge

5.5.6.6. A manual air purge valve

5.5.6.7. Automatically activating safety pressure relief valves

5.5.7. Exhaust System. The vendor shall provide and install an engine exhaust system consisting of steel high temperature ductwork connected to the input engine exhaust port, and in turn, shall be connected to a vendor provided architectural support structure for exhausting fumes above the canopy of the building.

The exhaust system shall include an outdoor mounted exhaust muffler or silencer for the purpose of reducing noise generated from the engine. Size and select muffler or silencer unit in accordance with engine manufacturer exhaust requirements.

5.5.7.1. Ductwork shall consist of double walled nominal 20 gauge 304 stainless steel sheet metal with high temperature insulation material.

5.5.7.2. Size ductwork in accordance with exhaust needs of the input engine.

5.5.7.3. Design and install ductwork layout to minimize airflow restrictions, to minimize supports, and to avoid accidental contact from personnel when around input engine.

5.5.7.4. Provide and install suspended roof or floor supports or other framework to support exhaust ducting. Provide secondary structural support to connect to primary building structure where required.

5.5.7.5. Seal all ductwork connections with ductwork manufacturer’s recommended high temperature sealant or tape.

5.5.7.6. Continuous ductwork runs shall be constructed of single piece ductwork where possible. Avoid unnecessary ductwork joints.

5.5.7.7. Design and installation shall account for thermal expansion resulting from transport of hot exhaust gasses. Provide and install expansion joint(s) where necessary.

5.5.7.8. Design and installation shall account for sudden increase in pressure from the engine exhaust.

5.5.7.9. Vendor shall be responsible for all ductwork routing, including routing through and above the building canopy.

5.5.8. Air Intake System. The vendor shall provide and install an engine air intake system consisting of steel ductwork connected to the input engine air intake port. Shall be connected to a vendor provided architectural support structure for providing engine air intake. The intake air may be drawn from inside the test cell.

5.5.8.1. Ductwork shall consist of nominal 20 gauge 304 stainless steel sheet metal minimum.

5.5.8.2. Size ductwork in accordance with intake needs of the input engine.

5.5.8.3. Provide intake air filter and conditioning unit.

5.5.8.4. Design and install ductwork layout to minimize airflow restrictions, to minimize supports, and to avoid accidental contact from personnel when around input engine.

5.5.8.5. Provide and install suspended roof or floor supports or other framework to support intake ducting.

Provide secondary structural support to connect to primary building structure where required.

5.5.8.6. Seal all ductwork connections with ductwork manufacturer’s recommended sealant or tape.

5.5.8.7. Continuous ductwork runs shall be constructed of single piece ductwork where possible. Avoid unnecessary ductwork joints.

5.5.8.8. Vendor shall be responsible for all ductwork routing, including attachment to the building structure.

5.5.9. Engine Fuel System. The vendor shall provide and install a complete fuel delivery system for the drive engine. The fuel system shall handle and store all fuel going to and coming from the input engine. It shall be a closed loop system with supply and return fuel pump and a cooling mechanism to maintain fuel temperature. The primary control, fuel conditioning, and metering unit shall be wall mounted in a single cabinet inside building M376A, include a primary water separator and fuel filter for all incoming supply fuel, and a secondary fuel filter for all return fuel. The system shall include a fuel priming system. The fuel system shall be capable of the following:

5.5.9.1. Capable of handling and measuring JP8 type fuel and diesel fuel

5.5.9.2. Fuel measurement range appropriate for drive engine

5.5.9.3. Capable of providing fuel pressure appropriate for drive engine

5.5.9.4. Measuring the supply fuel temperature

5.5.9.5. Measuring the return fuel temperature

5.5.9.6. Measuring the rate of fuel consumption

5.5.9.7. Calculating the volume of fuel flow

5.5.9.8. Calculating the brake specific fuel consumption

5.5.9.9. Calculating the total fuel burned

5.5.9.10. Capable of cooling supply fuel to maintain consistent engine performance.

5.5.9.11. Reporting all measurements and calculations back to the control room workstation for storage and reporting

5.5.9.12. Shall contain an operator activated emergency shutdown device to stop all fuel flow

5.5.9.13. Shall contain a heat activated emergency shutdown device to stop all fuel flow in the event of a facility fire

5.5.10. Fuel Cooling System. The fuel system shall include a means to cool the supply fuel as required to maintain consistent and ideal engine performance as required by the NMWR test procedure. The cooling system shall be stand alone, and shall not rely on existing facility cooling provisions.

5.5.11. Fuel Storage Tank. The vendor shall provide a minimum 1000 gallon, but not greater than 1100 gallon fuel storage tank to facilitate fuel storage and supply. The storage tank shall include a spill containment pan with drain. The storage tank shall meet the following requirements minimum:

5.5.11.1. Above ground, closed top, double wall steel storage tank approved for flammable and combustible liquid storage at atmospheric pressure.

5.5.11.2. Tank shall be constructed of ASTM A569 or A36 steel, 12 gauge minimum, fully welded.

5.5.11.3. Shall meet National Fire Protection Association (NFPA) Section 30 Flammable and Combustible Liquids Code.

5.5.11.4. Shall meet NFPA 30A code for Motor Fuel Dispensing Facilities and Repair Garages.

5.5.11.5. Shall meet Uniform Fire Code Article 79.

5.5.11.6. Shall meet Underwriters Laboratory, Inc. Standard UL 142.

5.5.11.7. Shall contain a sight gauge, analog non-electronic, readable in gallons, appropriately sized to tank.

5.5.11.8. Shall be labeled in accordance with applicable NFPA and OSHA safety regulations.

5.6. Output Load System. The unit shall utilize dual electric motor type load units to provide output loading to the transmission under test. Hydro viscous, hydrostatic, water brake, or eddy current load units are not permissible. The load units shall be provided with an air to liquid cooling system with outdoor heat radiating device. The load units shall be capable of both motoring and absorbing in both clockwise and counter clockwise directions, and shall allow individual and synchronized operator control of speed, torque, and power in both automatic and manual modes. Return of excess electrical energy generated by the load units to the facility input power grid is not permissible. The load units shall have telescoping shaft slide assemblies to facilitate attachment to the unit under test (UUT). The output units shall be rated for multi-directional and variable load and speed control. All critical data from the load system shall be displayed for operator viewing in real time from the control room workstation, including speed, torque, pressure, and temperature. The vendor shall provide and install all components of the load system, including motors, motor controllers and drive units. In addition to meeting the minimum NMWR test requirements, the load units shall be rated to the following minimum specifications:

5.6.1. Minimum top speed – 3,650 rpm

5.6.2. Minimum 4,950 lb.-ft. from 0 to 605 rpm continuous output torque loading – 570 HP shall be attainable from 605 – 3,650 RPM continuously.

5.6.3. Minimum 7,425 lb.-ft. from 0 to 605 rpm intermittent output torque loading for up to 1-minute – 855 HP shall be attainable from 605 – 3,650 RPM for up to 1 minute.

5.6.4. Minimum 8,000 lb.-ft. from 0 to 605 rpm intermittent output torque loading for up to 20 seconds – 921 HP shall be attainable from 605 – 3,650 RPM for up to 20 seconds.

5.6.5. Shall be able to be controlled by automated run patterns.

5.6.6. Shall be able to be independently controlled by manual operator control.

5.7. Transmission Cooling System. The vendor shall provide a standalone closed loop liquid to liquid non-evaporative transmission cooling unit to facilitate transmission oil cooling. The system shall be a corrosion free ethylene glycol and water based system. The cooling system shall serve to remove heat from the transmission oil and dissipate the heat to the outside air using an external radiating system. The transmission cooling unit shall be fully self-contained, and shall not rely on existing facility cooling provisions. The vendor shall provide all piping, pumps, valves, wiring, connections, conduit, filters, and coolant liquid for the complete system. The transmission coolant system shall include at a minimum:

5.7.1. A liquid to liquid heat exchanger(s) and external radiating system

5.7.2. A filter system to filter transmission oil and coolant liquid

5.7.3. Working pressure range appropriate for transmission under test

5.7.4. A transmission oil temperature controller to regulate transmission oil temperature

5.7.5. An instrumentation system to provide transmission oil and coolant system temperature data to the operator control room console

5.8. Load Motor System Cooling. The vendor shall provide a fully self-contained air to liquid closed loop corrosion free non-evaporative cooling system to provide cooling to the load motor units. The system shall be a corrosion free air to ethylene glycol and water based system. The load cooling unit shall be fully self-contained, and shall not rely on existing facility cooling provisions. The cooling system shall serve to remove heat from the load units and dissipate the heat to the outside air using an external radiating system. The load motor cooling system shall include at a minimum:

5.8.1. An air to liquid heat exchanger(s) and external radiating system

5.8.2. A filter system to filter coolant liquid

5.8.3. A temperature controller to regulate temperature of the load units

5.8.4. An instrumentation system to provide load motor and coolant system temperature data to the operator control room console

5.9. External Cooling Radiator System. The vendor shall provide and install an outside liquid to air heat radiating device on a vendor constructed steel reinforced minimum six (6) inch thick concrete slab to provide cooling for the drive engine, output load motors, transmission oil, and prime mover fuel. The external cooling system shall serve to remove heat from the dynamometers, drive system, and transmission under test and transfer it to the outside air. The vendor shall be responsible for supplying, constructing, and installing the concrete foundation and structural material to house and support the cooling system. The vendor shall utilize the area on the South side of building M376A near the fuel tank storage location for the external radiating system. Main power will be provided by RRAD inside building M376A. The vendor shall install a dedicated utility disconnect for the radiating system. The vendor shall install all conduit, piping, and electrical utilities for the vendor’s proposed unit. Connection to utilities shall be the responsibility of the vendor.

5.10. Input Torque Unit. The system shall utilize a heavy duty maintenance free input torque measuring unit that does not contain slip rings or bearings. The vendor shall provide tooling and equipment to calibrate the input torque unit that is traceable to National Institute of Standards and Technology (NIST) calibration standards. The input torque unit shall provide input torque data for display on the operator’s control room console. The input torque unit shall be of a heavy duty design that is capable of continuous long term duty under the operating conditions required by the test procedure without damage to the torque sensing unit.

5.11. Transmission Mounting. The vendor shall provide a method to securely mount the transmission under test in the appropriate position to allow the operator to connect the transmission to the test system.

The mounting system shall provide sufficient stability for the transmission during test as required by the NMWR test procedure.

5.12. Oil Sump. The unit shall incorporate an oil drip pan or sump beneath the transmission mounting area for the purpose of collecting waste oil from the UUT. The sump shall be covered by slip resistant steel grating. The sump shall be provided with a pump system to remove waste oil from the sump.

5.13. Compressed Air Supply. If the vendor’s design requires compressed air for operation, the vendor shall provide and install a complete stand-alone compressed air supply system. The compressed air supply system shall not rely on any existing RRAD facility air supply provisions. The compressed air supply system shall provide clean and dry compressed air sufficient to meet the air requirements of the manufacturer’s design.

5.14. Software and Control. The dynamometer system shall be able to be operated and controlled from within an existing separate control room that is housed near the dynamometer unit. The system shall include a Windows based PC workstation to provide command, control, monitoring, and data acquisition for the test system. The control and command system shall utilize a high speed Allen Bradley based Programmable Logic Controller (PLC) system that is of a current production version at the time of manufacture of the dynamometer system. The control system shall use open architecture components that can be replaced by common commercially available parts. The PLC system shall allow operators with super user access to modify, define, program, adjust, and troubleshoot the PLC control system. The vendor shall provide and install all components of the complete control room system. The computer control system shall consist of at a minimum:

5.14.1. Windows 10 or later based workstation with DVD writer, keyboard, mouse, 16GB RAM minimum.

5.14.2. Minimum of two (2) operator login levels such as “operator” and “super user” – Critical test parameters shall not be able to be edited without “super user” permission.

5.14.3. Dual RAID hard disk configuration minimum two (2) Terabyte each disk.

5.14.4. Minimum of two (2) 22” minimum color monitors.

5.14.5. Color LaserJet Printer.

5.14.6. Workstation desk for operator control console.

5.14.7. Graphical control system that displays real-time test data including temperature, pressure, torque, and speed.

5.14.8. Allows operator to enter transmission serial and part numbers.

5.14.9. Capability to view, save, recall, and print complete test reports displaying transmission serial and part numbers.

5.14.10. Capability to pause a test routine to allow operator adjustments, and resume without having to restart the complete test.

5.14.11. Segmented entry point test options for each NMWR transmission function test.

5.14.12. Shall allow super user to program, create, setup, store, and run custom operator defined test routines.

5.14.13. Manual control of run patterns and dynamometer settings including input speed and torque, output speed and torque, and transmission throttle and steer settings.

5.14.14. Provides super users with the capability to define and modify test sequences and templates within the software package.

5.14.15. Provides a test hold function to allow measured values to stabilize before values are recorded.

5.14.16. Provides the capability to recall data from previously tested units and allows the operator to select specific tests to rerun.

5.14.17. Provides operator adjustable data sampling rates for critical portions of testing such as control test.

5.14.18. Provides operator with a software based tracking system to track hours of operation since last oil change for transmission oil and drive engine oil.

5.14.19. Display warnings, faults, errors, and remedies on the operator’s display.

5.14.20. Shall allow manual and automatic independent control of engine and transmission throttle settings.

5.14.21. Shall allow manual and automatic control of transmission output loading.

5.14.22. Shall allow automatic and manual control of transmission steer setting.

5.15. Data Display. The control system shall provide the operator with real time data display of all critical UUT and test station data required to successfully monitor and perform NMWR testing and transmission failure analysis and troubleshooting. Data display shall include at a minimum:

5.15.1. Transmission input torque

5.15.2. Transmission output torque (both sides)

5.15.3. Transmission input speed

5.15.4. Transmission output speed (both sides)

5.15.5. Transmission input oil temperature

5.15.6. Transmission output oil temperature

5.15.7. Transmission oil flow rate

5.15.8. Transmission input oil pressure

5.15.9. Transmission output oil pressure

5.15.10. Engine fuel flow rate

5.15.11. Engine fuel temperature

5.15.12. Engine coolant temperature

5.15.13. Engine coolant pressure

5.15.14. Engine coolant flow

5.15.15. Engine intake air temperature

5.15.16. Engine exhaust temperature

5.15.17. Load unit temperatures

5.15.18. Load unit torque settings

5.15.19. Load unit speed settings

5.15.20. Engine throttle setting

5.15.21. Engine RPM

5.15.22. Transmission throttle setting

5.15.23. Transmission steer setting

5.15.24. Transmission range setting

5.15.25. Service brake pressure

5.15.26. Service brake torque

5.15.27. Transmission Pressures – Ranges 1, 2, 3, make up, auxiliary, disconnect clutch, and all other clutch pressures

5.16. Graphical User Interface (GUI). The location, layout, and appearance of the data display and operator control computer interface shall be similar, where applicable, to the existing HMPT dynamometer control system at RRAD (see Exhibit 1 and 2). This shall serve to provide ease of use, continuity across multiple test stations, and minimize training requirements.

5.17. Manual Control. The system shall provide the operator with manual control capability from the operator control console. The manual control functions shall include at a minimum:

5.17.1. Input speed setting

5.17.2. Independent and synchronized load unit torque for each side

5.17.3. Independent and synchronized transmission and drive engine throttle settings (single rod and dual rod control)

5.17.4. Transmission steer setting

5.17.5. Service brakes

5.18. Automated Test. The vendor shall provide an automated pre-programmed test routine for each of the transmission types to be tested. The test routine shall be in accordance with NMWR test procedures.

The system shall provide a complete end to end test option, and entry point segmented tests for each functional NMWR test. The test type shall be selectable by the operator from the control room computer console.

5.19. Throttle, Range, and Steer Control. The vendor shall provide a complete automated control system to facilitate control of transmission throttle, range selection, and steering functions as required by the NMWR test. The throttle, range, and steer functions shall be controlled by automated test routine, and shall provide the operator with manual control from the control room workstation. The control system shall be control room software based, and shall not require the operator to enter the test cell for manipulation.

5.20. Emergency Stop. The vendor shall provide an emergency stop switch located at the operator’s control room workstation, and an emergency stop switch located within the transmission test cell that is readily accessible by the operator. An emergency stop function shall be incorporated into the software control system. The emergency stop function shall stop the drive engine, de-energize the dynamometer system, and stop fuel flow to the engine.

5.21. Test Cell Surveillance System. The system shall include a color video test cell surveillance system to allow the operator to view critical areas within the test cell. The surveillance system shall include:

5.21.1. Minimum four (4) remotely controlled test cell surveillance color video cameras. Cameras shall be high definition with minimum two (2) megapixel 1080p resolution.

5.21.2. Minimum 32” color monitor inside the control room to view the live camera feed. This monitor shall be separate from the operator control workstation monitors.

5.21.3. Camera control system to provide pan, tilt, zoom, focus, and contrast control from within the control room.

5.22. Oil Storage and Filtration. The vendor shall provide an oil storage and filtration cart to facilitate storage, filtering, heating, and reuse of transmission oil. The oil storage unit shall serve to hold transmission oil for the purpose of filling the UUT prior to test, and pumping of UUT oil back to the oil storage and filtration unit after test by means of an electric pump. The oil storage and filtration unit shall meet the following minimum specifications:

5.22.1. Housed on a mobile rolling cart to facilitate relocation

5.22.2. Minimum 55 gallon holding capacity

5.22.3. Minimum 1 HP electric pump

5.22.4. Replaceable filter to facilitate oil filtering and reuse of used transmission oil

5.22.5. Heating capability with adjustable thermostat to adjust oil temperature for cold weather operations

5.23. Test Cell Dimensions and Equipment Orientation. The dynamometers and engine drive system shall fit inside RRAD building M376A, with an approximate internal dimension of 57 ft. x 30 ft. The drive engine shall be positioned in the South end of building M376A with the driveline to the transmission under test facing North. The system shall allow maintenance access to the engine via forklift from the South bay access door of building M376A. The system shall allow entry via forklift through the North bay access door of building M376A to facilitate transmission placement for testing. Overall principal dimensions shall be verified by the vendor in detail to establish limits of space in all directions required for installation; operation and servicing; amount of clearance required to permit opening of doors and removal of plug-in units; clearance for travel or rotation of any moving parts, and interface piping and interface connections. The dynamometer system shall be installed in a manner that allows the existing overhead bridge crane in building M376A to provide lift service to the test system.

5.24. Awning and Slab Construction. The contractor shall design-build a concrete slab covered by a steel framed and steel roof awning to provide a foundation and weather protection for the fuel storage tank for the system. The contractor shall coordinate design-build with RRAD Directorate of Public Works before build. All plans and specifications shall be submitted to the Government prior to any construction.

The slab construct shall serve as the foundation for the external heat radiating portion of the cooling system. The slab and awning shall be constructed on the South side of building M376A.