PWS_ALTERNATOR_REFURBISHING_REVISED.pdf

Performance Work Statement (PWS)

SR4B Alternator Maintenance and Refurbishment

SCOPE: This PWS covers the assembly and disassembly, physical and mechanical inspection, cleaning, maintenance, electrical testing, and refurbishment (dip and bake) of 12 Caterpillar

SR4B alternators.

BACKGROUND: The SR4B is part of Deployable Power Generation and Distribution System

(DPGDS). The DPGDS is a system of electrical power generation and distribution equipment that is designed to support U.S. Air Force bare base and U.S. Army prime power requirements.

The prime movers (engine) for each alternator are Caterpillar 3456 Electric Power Generation

(EPG). They are liquid-cooled, 6 cylinder, four-cycle, turbo-charged, and after- cooled and have a 15.8 Liter (964 cubic inch) displacement. Generator information is as follows:

Alternator: The alternator is a brushless, rotating armature exciter, single-bearing, air-cooled, open drip-proof unit. The alternator is directly connected to the engine. The alternator is a

Permanent Magnet Pilot Excited (PMPE) generator that receives power for the voltage regulator from 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, wye connected generator. For

50 Hz operation, the output is 2200/3800 volts, 3800 volts line-to-line, 2200 volts line-to–neutral, 3-phase, 4-wire, wye connected. Alternator data plate is as follows:

Required Services:

1) Alternator Assembly / Disassembly: The alternator will be delivered completely disconnected from the prime mover and all other generator components. Contractor is responsible for all assembly and disassembly inherent in performance of the cleaning, inspections, electrical testing, maintenance, and refurbishment (dip and bake) of alternators.

2) Pickup and Return: All proposals will include a separate pricing option for the pickup of

SR4B alternators and the return of the SR4B alternators to:

SFC Michael Huges / CW3 Anthony Jellison

249th Engineer Battalion

BLDG #1416

Fort Belvoir, VA 22060

3) Physical and Mechanical Inspection: Inspect physical and mechanical condition of alternator housing, bolted connections, anchorage, alignment, grounding, rectifiers, all components of the rotating field assembly (RFA), main armature, terminal leads, bearing, cables, and space heaters. (References: Service Manual SR4B SENR5359-01;

ANSI/NETA MTS-2015)

4) Cleaning: Before cleaning “as found” test(s) will be performed to determine the condition of insulation (See Electrical Testing). Cleaning will be performed to remove all contaminants such as dirt, grease, salt or oil. Cleaning will be accomplished either by washing with an approved solvent IAW with manufacturer’s directions or with steam cleaning when justified by dirty and greasy windings. Windings shall be oven dried after cleaning. After the windings and insulation have dried, the windings should be “dipped and baked” in a suitable varnish. (Reference: CAT Cleaning and Drying of Electric Set

Generators SEHS 9124)

5) Maintenance: Contractor will be responsible for checking and balancing the rotor, replacing the main rotor bearing, installing a complete rectifier heat sink assembly (PN:

290-5564 or equivalent), machine work to repair the ODE bearing housing, inspect PM exciter stator, identify any broken parts, contractor provides a parts list to the

Government to have parts shipped to contractor for install, and painting the alternator to match as closely as possible the original color (Caterpillar Yellow). The 249th Engineer

Battalion (customer) will supply the main rotor bearings for replacement and PM exciter stator parts identified by the contractor, at the time of alternator delivery to the contractor.

6) Repairs: If the equipment sent for refurbishment is found to be deficient and requires additional repairs, a cost estimate will be provided to the Government. The Government will determine whether the quoted cost of the repair is fair and reasonable based upon government pricing for the parts required, estimated labor rates based on previous contracting, and historical pricing of previous repairs, and decide whether to fund the repair. If the repair is not funded, the contractor will complete the refurbishment in accordance with this PWS and return ship.

7) Electrical Testing: Each alternator will be tested in its “as found” and “as left” (after refurbishment) condition. Test values will be adjusted for temperature and humidity IAW

ANSI/NETA 2015 MTS standards. Testing results will be supplied to the 249th Engineer

Battalion via (1) digital and (1) hard copy upon completion of each alternator refurbishment. The contractor is also responsible for maintaining testing records. These records shall be tracked by alternator serial number. The following Components of each alternator will be tested (Reference SR4B Generator Service Manual – SENR5359):

- (CR1-CR6) Rectifier

- (CR7) Varistor

- (L1) Exciter Field (Stator)

- (L2) Exciter armature (Rotor)

- (L3) Main Field (rotor)

- (L4) Main armature (stator)

- (L5) Pilot exciter armature

- (PM) Permanent Magnet

Alternators will be tested IAW with ANSI/NETA 2015 MTS standards to include:

- Insulation resistance test (PI/DAR)

- Surge Test

- Winding resistance test

- Hi-Pot tests

- Step Voltage tests w2ct9ae9 Highlight

Period of Performance: The period of performance for this contract begins on the effective date of award and will continue until all items of equipment are refurbished; not to exceed one year.

General:

a. Final proposals should include pricing / information for the following:

1. Pricing for pickup and drop-off of alternators at the address indicated above.

2. Unit pricing for the assembly / disassembly, physical and mechanical inspection, cleaning, maintenance, electrical testing, and refurbishment (dip and bake) of each Caterpillar SR4B alternator.

3. Complete description of the services to be delivered as part of refurbishment.

4. Estimate of the time it takes to refurbish each alternator.

b. Up to six alternators can be sent out for refurbishment at one time and must be returned within 30 days of contractor notification that alternators are available for pick

up. Notification will be in memorandum format, issued to the contractor via e-mail.

c. If damage is found during inspection and maintenance, the contractor will provide an invoice for the repair to the 249th EN BN. The government will decide within 10 business days whether to execute the repair. Repairs will be executed via modification at the labor rate shown in CLIN 0001. If the repair is not funded, the contractor will complete the refurbishment in accordance with this PWS and return ship.

d. Upon completion of each refurbishment, an invoice will be submitted to the KO, through the 249th EN BN Logistics Officer for payment.

Security:

AT Level 1 Training: All contractor employees, to include subcontractor employees, requiring access to Army installations, facilities, controlled access areas, or require network access, shall complete AT Level I awareness training within 30 calendar days after contract start date or effective date of incorporation of this requirement into the contract, whichever is applicable.

Upon request, the contractor shall submit certificates of completion for each affected contractor employee and subcontractor employee, to the COR or to the contracting officer (if a COR is not assigned), within 5 calendar days after completion of training by all employees and subcontractor personnel. AT Level I awareness training is available at the following website:

http://jko.jten.mil/courses/atl1/launch.html; or it can be provided by the RA ATO in presentation form which will be documented via memorandum.

Access and General Protection/Security Policy and Procedures: All contractor and all associated sub-contractors employees shall comply with applicable installation, facility and area commander installation/facility access and local security policies and procedures (provided by http://jko.jten.mil/courses/atl1/launch.html%3B w2ct9ae9 Highlight government representative). The contractor shall also provide all information required for background checks to meet installation/facility access requirements to be accomplished by installation Provost Marshal Office, Director of Emergency Services or Security Office.

Contractor workforce must comply with all personal identity verification requirements (FAR clause 52.204-9, Personal Identity Verification of Contractor Personnel) as directed by DOD, HQDA and/or local policy. In addition to the changes otherwise authorized by the changes clause of this contract, should the Force Protection Condition (FPCON) at any installation or facility change, the Government may require changes in contractor security matters or processes.

Contractors who do not require CAC, but require access to a Department of Defense (DoD) facility or installation: Contractor and all associated sub-contractors employees shall comply with adjudication standards and procedures using the National Crime Information Center

Interstate Identification Index (NCIC-III) and Terrorist Screening Database (TSDB) (Army

Directive 2014-05 / AR 190-13), applicable installation, facility and area commander installation/facility access and local security policies and procedures (provided by government representative, as NCIC and TSDB are available), or, at OCONUS locations, in accordance with status of forces agreements and other theater regulations.

iWATCH and/or CorpsWatch training: The contractor and all associated sub-contractors shall receive a brief/training (provided by the RA) on the local suspicious activity reporting program.

This locally developed training will be used to inform employees of the types of behavior to watch for and instruct employees to report suspicious activity to the project manager, security representative or law enforcement entity. This training shall be completed within 30 calendar days of contract award and within 30 calendar days of new employees commencing performance with the results reported to the COR NLT 5 calendar days after the completion of the training.

Pre‐screen candidates using E‐Verify Program: The Contractor must pre-screen Candidates using the E-verify Program (http://www.uscis.gov/e-verify) website to meet the established employment eligibility requirements. The Vendor must ensure that the Candidate has two valid forms of Government issued identification prior to enrollment to ensure the correct information is entered into the E-verify system. An initial list of verified/eligible Candidates must be provided to the COR no later than 3 business days after the initial contract award." *When contracts are with individuals, the individuals will be required to complete a Form I-9, Employment Eligibility

Verification, with the designated Government representative. This Form will be provided to the

Contracting Officer and shall become part of the official contract file.

http://www.uscis.gov/e-verify)