STATEMENT OF WORK Rev 1.pdf

STATEMENT OF WORK (SOW)

PART 1: GENERAL INFORMATION

1.1 Description of Services

Allen-Bradley Programmable Logic Controller (PLC) & Industrial Operator Interface

Modernization, and Remediation. The Contractor shall provide turnkey industrial automation engineering, hardware procurement, software and logic migration, human-machine interface (HMI) application conversion, physical control cabinet retrofitting, operational technology (OT) cybersecurity hardening, commissioning, and technical training. These are required to modernize and remediate obsolete End-of-Life (EOL)

Allen-Bradley Programmable Logic Controllers (PLCs) and legacy PanelView operator terminals across designated facility automation and utility control systems.

1.2 Background

Existing facility and industrial process automation cabinets currently utilize obsolete, legacy Allen-Bradley PLC platforms—specifically SLC 500 series modular controllers

(SLC 5/03 and SLC 5/05)—accompanied by legacy PanelView operator interface terminals (PanelView 1000 and PanelView 1250), as well as an operational fleet of twenty-nine (29) MicroLogix 1400 units. The original equipment manufacturer

(Rockwell Automation) has designated the SLC 500 and legacy PanelView (standard and early Plus) product lines as End-of-Life (EOL), discontinuing component fabrication, routine technical support, and critical cybersecurity vulnerability patches.

Original legacy electrical schematics and cabinet wiring prints for this equipment are severely limited, outdated, or entirely nonexistent due to decades of historical facility modifications. Consequently, contractor performance relies upon rigorous physical field discovery, wire tracing, and generation of verified Input/Output (I/O) Charts rather than legacy print verification.

Because these legacy controllers and operator terminals govern critical facility utilities, environmental controls, and mission-essential process systems, unscheduled processor or communication failures represent severe operational liabilities. Modernization to current

Allen-Bradley CompactLogix 5380 architectures, replacement of legacy PanelView 1000 and PanelView 1250 terminals with modern EtherNet/IP graphic terminals, and firmware remediation/port hardening across the twenty-nine (29) surviving MicroLogix 1400 units are required to re-establish life-cycle supportability and ensure compliance with federal

OT cybersecurity mandates.

1.3 Scope of Work & Equipment Stratification

The Contractor shall furnish all personnel, engineering, supervision, tools, test equipment, transportation, authentic Allen-Bradley hardware, pre-wired conversion harnesses, mounting adapter kits, and materials necessary to satisfy individual tasks.

The scope of work is organized across two primary operational modernization tiers:

• Tier 1 (Modular Process & Operator Interface Migrations): Turnkey hardware migration and software refactoring of three (3) designated legacy Allen-Bradley SLC

500 systems (PLC 1, PLC 2, and PLC 3) utilizing 1746 I/O chassis to Allen-Bradley

CompactLogix 5380 architectures. This tier includes the turnkey modernization of three (3) designated Human-Machine Interface (HMI) operator terminals consisting of two (2) legacy PanelView 1000 terminals and one (1) legacy PanelView 1250 terminal. Modernization of these HMIs shall utilize engineered OEM adapter mounting bezels requiring zero alteration of existing enclosure door sheet metal cutouts. Specific host SLC 500 control cabinets receiving HMI upgrades shall be identified by the Government following contract award.

• Tier 2 (In-Place Fleet Servicing): On-site firmware flashing, security hardening, logic extraction, and documented baseline archival for twenty-nine (29) operational

Allen-Bradley MicroLogix 1400 controllers without physical panel alteration.

1.4 Baseline PLC Hardware & I/O Inventory

The primary industrial control platforms to be modernized under Tier 1 comprise the following hardware and card configurations:

Controller

Identifier

Existing

Processor &

Firmware

Chassis Slot

Configuration

& Installed

1746 I/O

Modules

Total Installed

I/O Points

Target

Modernized

Platform

PLC 1 Allen-Bradley

SLC 5/03

Cat. No. 1747-

L532C/D

Memory: 16K

OS: OS302

• Two (2) 1746-

IA16 (16-Point

120VAC

Digital Input)

• Four (4) 1746-

OA16 (16-Point

120VAC

Digital Output

Triac)

• 32 Discrete

Inputs

• 64 Discrete

Outputs

Total: 96

Points

Allen-Bradley

CompactLogix

5069 High-

Density I/O

Bulletin 1492-to-1746

Conversion

Kits

PLC 2 Allen-Bradley

SLC 5/03

Cat. No. 1747-

L532B

Memory: 16K

OS: OS302

• Two (2) 1746-

IA16 (16-Point

120VAC

Digital Input)

• Four (4) 1746-

OA16 (16-Point

120VAC

Digital Output

Triac)

• 32 Discrete

Inputs

• 64 Discrete

Outputs

Total: 96

Points

Allen-Bradley

CompactLogix

5069 High-

Density I/O

Bulletin 1492-to-1746

Conversion

Kits

PLC 3 Allen-Bradley

SLC 5/05

Cat. No. 1747-

L553C

Memory: 64K

Comm: 10/100

Ethernet / RS-

• Four (4) 1746-

IA8 (8-Point

120VAC

Digital Input)

• Three (3)

1746-OA16

(16-Point

120VAC

Digital Output

Triac)

• Two (2) 1746-

NI8 (8-Channel

Analog

Current/Voltage

Input)

• 32 Discrete

Inputs

• 48 Discrete

Outputs

• 16 Analog

Inputs

Total: 96

Points

Allen-Bradley

CompactLogix

5069 Discrete

& Analog I/O

Bulletin 1492-to-1746

Conversion

Kits

1.5 Period of Performance: See delivery schedule

1.6 Place of Performance, Physical Security & Safety Work Authorization

All on-site operations shall take place within designated facility mechanical, electrical, and control room environments located at CCAD. The Contractor shall comply with all base access control regulations, physical security protocols, and safety review mandates prior to entering depot property.

1.6.1 Base Access Requirements (DBIDS)

All contractor personnel requesting access to the installation shall be U.S. citizens and must successfully pass a National Agency Check (NAC) background screening. The

Contractor shall complete and submit the Defense Biometric Identification System

(DBIDS) Access Form (attached to the solicitation/contract) for each employee requiring installation access to the Contracting Officer’s Representative (COR) at least fourteen

(14) calendar days prior to the scheduled site arrival date. Contractor personnel must present valid, unexpired government-issued photo identification to obtain their physical access badges at the visitor control center.

1.6.2 CCAD Facility Access & Escort Provisions

For entry into CCAD industrial complexes, flight line boundaries, and designated control room facilities, the Contractor shall complete and submit the CCAD Escort Form

(attached to the solicitation/contract) to the COR at least fourteen (14) calendar days prior to the planned arrival date. Contractor personnel shall remain under continuous government escort while operating within secure or restricted depot facilities.

1.6.3 Mandatory Contractor Security & Threat Awareness Training

The Contractor shall ensure that all personnel scheduled to perform physical on-site work or surveys complete the following mandatory DoD training courses prior to arrival.

Signed and dated training completion certificates for each on-site employee shall be submitted to the COR concurrently with the CCAD Escort Form:

1. Anti-Terrorism (AT) Level 1 Training (Course JS-US007):

o Accessible online via Joint Knowledge Online (JKO):

https://jkodirect.jten.mil o Certificates must be current within twelve (12) months of contract performance.

2. Operations Security (OPSEC) Training:

o Accessible online via the Center for Development of Security Excellence

(CDSE): https://securityawareness.usalearning.gov o Certificates must be current within twelve (12) months of contract performance.

3. iWatch Army Training:

o Accessible online via the Department of Homeland Security / Army Media

Portal: https://www.dhs.gov/medialibrary/assets/video/37054 o Verification of training completion must be provided prior to site entry.

Failure to submit approved security forms and training certificates within the required 14-calendar-day window shall not constitute grounds for government-caused project delay or cost adjustment.

1.6.4 Safety Work Authorization & SOH Advisory Workflow:

Consistent with federal acquisition regulations and established CCAD chain of command:

https://jkodirect.jten.mil/ https://securityawareness.usalearning.gov/ https://www.dhs.gov/medialibrary/assets/video/37054

1. The Contractor shall submit required safety deliverables—specifically the

Abbreviated Accident Prevention Plan (A-APP) and Activity Hazard Analysis

(AHA)—directly to the Contracting Officer (KO) and Contracting Officer's

Representative (COR).

2. The KO/COR will route the submitted documents to the CCAD Safety and

Occupational Health (SOH) Office (AMCD-CSH) for technical safety evaluation.

3. The SOH Office will review the safety submissions and return a formal recommendation of acceptance or rejection to the KO/COR within five (5) business days of receipt.

4. The KO remains the sole authority for formal written acceptance and contractual authorization to proceed. Under no circumstances shall the Contractor perform on-site physical work, tool use, wiring, or cutovers until the KO has formally accepted both the A-APP and AHA in writing.

1.7 Mandatory Operational Outage Constraint & Business Hours Rule

Because facility control panels support active mission operations and building life-safety systems, extended or open-ended facility downtime is strictly prohibited.

For all hardware modernization cutovers executed under Tier 1 (PLC 1, PLC 2, and PLC

3, including integrated HMI replacements), the control cabinet outage shall span a maximum of eighty-one (81) consecutive hours from Monday morning through Thursday afternoon. However, to maintain facility safety, security oversight, and staff escort availability, all active contractor physical labor, installations, point-to-point testing, and commissioning activities shall occur strictly during established facility business hours: 06:00 to 18:00 (6:00 AM to 6:00 PM Local Time).

During non-business overnight hours (18:00 to 06:00), target control cabinets shall remain locked, de-energized, and secured under government and contractor Lock-

Out/Tag-Out (LOTO) controls.

Outage & Work

Parameter

Operational Standard Enforcement &

Regulatory Rule

Authorized Cutover Start Monday at 06:00 Local

Time

Government executes

LOTO and signs panel release.

Daily Authorized Work

Hours

06:00 to 18:00 Daily (Mon

– Wed)

06:00 to 15:00 on

Thursday

Active on-site contractor labor permitted only during these business hours.

Overnight Security

Envelope

18:00 to 06:00 Overnight Control panels secured under LOTO; no active contractor work.

Mandatory Cutover

Completion

Thursday at 15:00 Local

Time

Contractor delivers fully operational PLC and HMI running live process loads.

Maximum Cabinet

Outage Window

81 Consecutive Elapsed

Hours

Enclosure de-energized from Mon 06:00 to Thu

15:00. Non-negotiable.

Maximum Active Labor

Window

45 Cumulative Working

Hours

Mon: 12 hrs; Tue: 12 hrs;

Wed: 12 hrs; Thu: 9 hrs.

Operational Process

Resumption

Thursday at 16:00 Local

Time

Facility personnel resume active mission support operations.

1.8 Business-Hours Cutover Milestone Schedule

For each major PLC and HMI replacement under Tier 1, the Contractor shall execute on-site operations strictly during the 06:00 to 18:00 daily work window in accordance with the following phase schedule:

• Phase A: LOTO, Field Wire Audit, & Legacy Extraction (Monday 06:00 to

12:00 | 6 Working Hours): Formal safety verification of zero electrical energy, field wire tagging audit against approved pre-cutover I/O Charts, unseating of legacy 1746 wiring arms from the 1746-IA16, 1746-OA16, 1746-IA8, and 1746-NI8 cards, dismounting and extraction of legacy SLC 500 chassis, and unbolting/extraction of legacy PanelView 1000/1250 terminals from cabinet doors.

• Phase B: Mechanical Installation, 1492 Swing-Arm Integration, & HMI Bezel

Mounting (Monday 12:00 to 18:00 | 6 Working Hours): Structural installation of new 5069 chassis mounting plates, seating of Bulletin 1492 conversion modules, physical snapping of legacy 1746 swing-arms into conversion assemblies, installation of Stratix industrial Ethernet switches, connection of pre-molded conversion cables to

5069 I/O modules, mounting of replacement PanelView graphic terminals into existing door cutouts using OEM adapter bezels with zero sheet metal cutting, and landing of 24VDC power drops. Control cabinet closed and secured under LOTO at

18:00.

• Phase C: 100% Loop Verification & Point-to-Point Testing (Tuesday 06:00 to

18:00 | 12 Working Hours): Beginning promptly at 06:00 Tuesday, execute complete end-to-end electrical signal verification of every discrete input/output

(120VAC), analog 4–20mA / 0–10V channel (specifically on PLC 3's NI8 circuits), and safety interlock loop. Loop checks shall be validated against the Master I/O Chart through Bulletin 1492 test interfaces without disturbing field terminations.

Verification of HMI power-up, Ethernet physical link, and IP communications.

Control cabinet secured under LOTO at 18:00.

• Phase D: Logic Download, HMI Runtime Transfer, & Cold Simulation

(Wednesday 06:00 to 18:00 | 12 Working Hours): Beginning promptly at 06:00

Wednesday, download converted Studio 5000 Logix Designer project files (.ACD), transfer FactoryTalk View ME runtime applications (.MER) to new PanelView terminals, verify CIP communication paths and online tag browsing, execute cold simulation of process sequences, verify alarm trips and safety interlocks against I/O

Chart designations, and test touchscreen navigation, pushbuttons, numeric entry displays, and multistate indicators. Control cabinet secured under LOTO at 18:00.

• Phase E: Site Acceptance Testing (SAT), Live Load Commissioning, & Handoff

(Thursday 06:00 to 15:00 | 9 Working Hours): Beginning promptly at 06:00

Thursday, execute joint Government-Contractor live testing under active process loads, fail-safe shutdown testing, verification of local HMI operational control and remote SCADA polling (if applicable), formal SAT sign-off, removal of contractor

LOTO locks, and operational handover to facility personnel by 15:00.

1.9 Mandatory Rollback & Contingency Protocol

To prevent facility operations from experiencing unscheduled downtime beyond the

Thursday 15:00 deadline, the Contractor shall enforce two rigid decision milestones aligned with daily business hours:

• Go / No-Go Decision Board (Wednesday at 17:00 Local Time | Close of

Wednesday Business Hours): Prior to concluding work on Wednesday, the

Contracting Officer's Representative (COR) and Contractor Project Manager shall convene to evaluate point-to-point test logs, logic simulation results, and HMI communication health. If loop verification against the Master I/O Chart is less than

100% complete or systemic hardware/software defects are identified, the board shall assess remediation viability.

• Hard Rollback Trigger (Thursday at 08:00 Local Time | 2 Hours into Thursday

Shift): If the modernized controller, network, or HMI displays unresolved faults, bus errors, or logic discrepancies by 08:00 Thursday, the Contractor shall immediately abort the upgrade. The Contractor shall utilize the remaining seven (7) business hours

(08:00 to 15:00) to reinstall the legacy SLC chassis, re-seat the original 1746 wiring arms, reinstall the legacy PanelView terminal, restore legacy logic, and deliver a fully operational system prior to Thursday 15:00.

Any rollback necessitated by contractor negligence, flawed conversion logic, deficient engineering, or defective equipment shall be executed entirely at the Contractor's expense without contractual relief or schedule extension.

1.10 Tier 2 Servicing Constraints (MicroLogix 1400 Fleet)

Servicing of the twenty-nine (29) MicroLogix 1400 controllers shall occur during standard facility business hours (06:00 to 18:00) in scheduled maintenance blocks not to exceed four (4) consecutive hours per controller. The Contractor shall extract, verify, and archive an offline ladder logic backup (.RSS) prior to executing firmware flashing or port configuration changes.

PART 2: DEFINITIONS & ACRONYMS

• A-APP (Abbreviated Accident Prevention Plan) USACE EM 385-1-1 Appendix A

• AHA (Activity Hazard Analysis)

• AQL (Acceptable Quality Level): The maximum allowable error rate, defect density, or schedule slippage permitted under the contract.

• BOM (Bill of Materials): A comprehensive, itemized list of all commercial part numbers, hardware revisions, firmware versions, and sub-assemblies.

• CIP (Common Industrial Protocol): An open, industrial protocol standard supporting EtherNet/IP and CIP Security cryptographic profiles.

• CDR (Contract Discrepancy Report): A formal written government notification issued to document deficient contractor performance.

• COR (Contracting Officer's Representative): The government technical official designated in writing by the Contracting Officer under DFARS 201.602-2 to monitor contractor performance.

• FRCS (Facility-Related Control Systems): Operational Technology (OT) infrastructures governing physical utility, environmental, and facility equipment.

• HMI (Human-Machine Interface): Industrial operator interface terminals providing graphical visualization, alarming, and control over process automation.

• I/O Chart (Input/Output Termination Chart): A structured engineering spreadsheet and verification record documenting every discrete and analog control circuit, including field wire number, terminal block identifier, signal level, legacy rack/slot/channel address, new Logix tag name, and operational device description.

• KO (Contracting Officer): A warranted government official with legal authority to enter into, administer, modify, and terminate federal contracts.

• LOTO (Lock-Out / Tag-Out): The formal isolation and de-energization of hazardous electrical and mechanical energy sources in accordance with OSHA standards (29 CFR 1910.147).

• OEM (Original Equipment Manufacturer): The primary commercial equipment fabricator (specifically Rockwell Automation / Allen-Bradley).

• PRS (Performance Requirements Summary): The contractual matrix identifying performance standards, AQLs, surveillance methodologies, and remedies.

• QASP (Quality Assurance Surveillance Plan): The government plan detailing how surveillance of contractor performance will be executed.

• SAT (Site Acceptance Testing): Formal commissioning verification executed jointly under live operational loads to establish final government acceptance.

PART 3: GOVERNMENT FURNISHED PROPERTY, AND EQUIPMENT,

(GFP/GFE)

3.1 Facility & Cabinet Access

The Government will provide escorted physical access to target control rooms, electrical closets, and control panels during authorized business hours (06:00 to 18:00).

3.2 Legacy Program Software & Screen Archive Files

The Government will provide existing legacy program application files (.RSS files for

SLC 500 / MicroLogix and .PBA / .PBE / .APA application archive files for legacy

PanelView terminals) from existing archives within five (5) calendar days of award. The

Contractor remains responsible for verifying that provided archive files match installed field logic and graphical runtime displays during pre-cutover audits.

Existing Electrical Prints Notice: The Contractor is explicitly advised that original electrical schematics, cabinet layout drawings, and inter-panel wiring diagrams for the target automation equipment are largely unavailable, incomplete, or nonexistent. The

Government cannot and will not provide definitive electrical prints. The Contractor shall extract and establish all wiring baselines directly through physical wire audits and ladder logic address cross-referencing.

3.3 Utilities & Workspace

The Government will furnish 120VAC single-phase utility electrical power, ambient workspace lighting, and access to basic facility sanitary conveniences at no charge to the

Contractor during on-site execution.

3.4 Government Furnished Material (GFM)

No Government Furnished Material will be provided. The Contractor shall furnish all new controllers, chassis, power supplies, I/O modules, pre-wired conversion kits, HMI terminals, adapter bezel mounting plates, communication cables, and panel hardware required for contract execution.

PART 4: CONTRACTOR FURNISHED ITEMS (CFE)

4.1 Authentic Factory-New Hardware

The Contractor shall furnish 100% authentic, factory-new Allen-Bradley automation hardware and operator interface terminals procured exclusively through authorized commercial distribution channels. The provision of surplus, refurbished, used, or grey-market equipment is strictly prohibited and constitutes grounds for immediate rejection of goods and termination for default.

4.2 Software Licensing & Programming Platforms

The Contractor shall maintain and utilize active, fully compliant commercial licenses for

Rockwell Automation programming software, including Studio 5000 Logix Designer

Professional Edition (latest stable release), FactoryTalk View Studio for Machine Edition

(ME), RSLogix 500 Professional, and PanelBuilder32.

4.3 Calibrated Test Equipment & Tooling

The Contractor shall furnish all calibrated instrumentation required for field wire identification, loop verification, network certification, and commissioning, including

Fluke multi-function process calibrators (voltage, current, and RTD/TC simulation), true-

RMS digital multimeters, signal tracers, oscilloscopes, cable certifiers, and OT network protocol packet sniffers. Test instrumentation shall possess traceable calibration certificates dated within twelve (12) months of use.

4.4 Personal Protective Equipment (PPE) & Safety Tooling

The Contractor shall furnish all safety equipment required to comply with NFPA 70E

Category 2 standards, including arc-flash face shields, 8-calorie arc-rated clothing, electrically insulated hand tools rated to 1,000V, and individual LOTO hasps, locks, and tags.

PART 5: SPECIFIC TECHNICAL TASKS & REQUIREMENTS

5.1 Task 1: Baseline Field Audit, I/O Chart Generation, & Modernization Design

Package

Within thirty (30) calendar days of award, the Contractor shall conduct a physical, on-site engineering audit across target control cabinets (PLC 1, PLC 2, PLC 3, and the ML1400 fleet) during normal business hours.

• Because existing cabinet prints are limited or nonexistent, the Contractor may need to perform physical circuit ringing, field device cross-referencing, and terminal strip tracing to generate a complete and authoritative baseline of existing control circuits.

• The audit shall verify the installed baseline card configurations:

• PLC 1: Confirming two (2) 1746-IA16 cards, four (4) 1746-OA16 cards, 1747-

L532C/D processor, memory allocations, and power consumption.

• PLC 2: Confirming two (2) 1746-IA16 cards, four (4) 1746-OA16 cards, 1747-

L532B processor, memory allocations, and power consumption.

• PLC 3: Confirming four (4) 1746-IA8 cards, three (3) 1746-OA16 cards, two (2)

1746-NI8 analog input cards, 1747-L553C processor, analog input scaling, and communication links.

• ML1400 Fleet: Validating physical locations, network addresses, and firmware revisions across all twenty-nine (29) units.

• Following contract award, the Government will designate the specific three (3) SLC

500 control cabinets that will receive HMI modernizations, identifying which two (2) cabinets house legacy PanelView 1000 terminals and which one (1) cabinet houses the legacy PanelView 1250 terminal.

• The Contractor shall develop and submit a comprehensive Modernization Design

Package for COR approval, including:

• Master Input/Output (I/O) Charts: Fully detailed engineering schedules (in searchable PDF and editable Microsoft Excel format) documenting every discrete and analog signal across PLC 1, PLC 2, and PLC 3. Each I/O line item shall identify:

1. Cabinet identifier and terminal strip block number.

2. Physical field wire tag numbers (both active and return/common).

3. Signal type and electrical range (120VAC digital input/output, 4–20mA / 0–

10V analog input).

4. Field device tag, operational description, and engineering units.

5. Legacy SLC addressing coordinate (I:e.s/b, O:e.s/b, N7:x).

6. Modern Studio 5000 tag name and user-defined data structure.

7. Assigned Bulletin 1492 conversion module terminal pinout and destination

5069 I/O channel.

8. Criticality designation (e.g., life-safety, permissive interlock, trip circuit).

• Cabinet Physical Elevation & Layout Sketches: Dimensioned sketches indicating proposed mounting locations for the replacement 5069 chassis, power supplies, Stratix switch, and Bulletin 1492 conversion blocks.

• HMI Adapter Bezel Installation Details: Mechanical dimensional drawings detailing adapter bezel mounting configurations across existing door cutouts for the PV1000 and PV1250 replacements.

• Network Architecture Single-Line Diagram: Detailing EtherNet/IP topologies, IP address allocations, subnet configurations, and Device Level Ring (DLR) layouts.

• Bill of Materials (BOM): Itemized list specifying Rockwell Automation catalog part numbers, firmware levels, and sub-assemblies for all proposed components.

5.2 Task 2: Tier 1 Modernization – Legacy SLC 500 to CompactLogix 5380 (PLC 1, PLC 2, & PLC 3)

The Contractor shall engineer, procure, and install modern Allen-Bradley automation components to replace the three (3) legacy SLC systems in strict accordance with the baseline equipment inventory:

• Hardware Replacement Architecture:

• PLC 1 & PLC 2 Modernization: Replace existing 1747-L532 processors, chassis, power supplies, two (2) 1746-IA16 cards, and four (4) 1746-OA16 cards with Allen-Bradley CompactLogix 5380 controllers (5069-L330ERM or equivalent), matching 5069 high-density discrete input and output modules, power supplies, and Stratix managed switches.

• PLC 3 Modernization: Replace existing 1747-L553C processor, chassis, power supply, four (4) 1746-IA8 cards, three (3) 1746-OA16 cards, and two (2) 1746-

NI8 analog input cards with an Allen-Bradley CompactLogix 5380 controller, 5069 discrete input/output modules, high-density 5069 analog current/voltage input modules, power supplies, and Stratix managed switches.

• Mandatory Pre-Wired Conversion Requirement:

• The Contractor shall utilize Rockwell Automation Bulletin 1492 pre-wired conversion systems (e.g., 1492-AIFM conversion modules and pre-molded interface cables) designed specifically to accept existing legacy 1746 removable terminal blocks / wiring arms.

• Conversion modules shall be deployed for all 1746-IA16, 1746-OA16, 1746-IA8, and 1746-NI8 cards.

• Point-by-point field wire landing is strictly prohibited due to business-hour limitations.

• Logic Translation & Tag Aliasing:

• Convert legacy RSLogix 500 program files (.RSS) into native Studio 5000 Logix

Designer project format (.ACD).

• Refactor legacy register-based memory structures (e.g., I:1/0, O:2/0, N7:0, B3:0, T4:0) into descriptive, human-readable user-defined tag data structures mapped directly to the approved Master I/O Chart.

• For PLC 3, ensure all analog raw counts (0 − 32767 or 4000 − 20000) are accurately converted into floating-point engineering units within the

CompactLogix controller while preserving alarm clamp limits and rate-of-change routines.

• Preserve 100% operational functional equivalence across all interlocks, permissive start circuits, safety shutdown routines, and automated staging logic.

• Execution Envelope: Execution shall occur strictly within the mandatory business-hours cutover schedule (Monday 06:00 through Thursday 15:00, working 06:00 to

18:00 daily).

5.3 Task 3: Tier 1 Human-Machine Interface (HMI) Modernization (3 Specific

Units)

Across the three (3) designated SLC 500 control cabinets (to be identified by the

Government after contract award), the Contractor shall modernize legacy operator interface terminals as follows:

• Target Equipment Quantities & Form Factors:

• Modernization of two (2) legacy Allen-Bradley PanelView 1000 terminals.

• Modernization of one (1) legacy Allen-Bradley PanelView 1250 terminal.

• Zero Cutout Alteration Requirement:

• To prevent hot-work safety hazards, eliminate airborne conductive particulate contamination inside operating cabinets, and maintain NEMA ratings, the

Contractor shall utilize pre-engineered OEM adapter bezel mounting plates

(Rockwell Bulletin 2711P mounting adapter kits or equivalent).

• No cutting, filing, punching, drilling, or physical alteration of existing cabinet door sheet metal cutouts is permitted. The replacement terminals shall clamp securely into existing cutout dimensions using adapter bezel assemblies, maintaining a minimum NEMA 4X / IP66 front-panel environmental seal.

• Replacement Terminal Specifications:

• Replacement units shall be factory-new Allen-Bradley PanelView Plus 7

Performance or PanelView 5000 graphic terminals featuring high-resolution color touchscreen displays (minimum 10-inch for PV1000 replacements; minimum 12-inch for PV1250 replacement), dual-port Ethernet supporting DLR, and 24VDC operating power.

• Furnish and install industrial panel-mount 120VAC-to-24VDC power supplies if existing terminals were powered by 120VAC.

• Application Conversion & Tag Re-Addressing:

• Convert existing legacy HMI application files (.PBA, .PBE, or .APA) into native

FactoryTalk View Machine Edition (ME) runtime files (.MER) or View Designer projects (.VPK).

• Maintain complete operational equivalence across graphical display screens, alarm summaries, diagnostic displays, trend charts, and password access tiers.

• Re-address all graphic screen tags from legacy direct register-based addresses

({::[PLC]N7:0}, {::[PLC]B3:0}) to native Studio 5000 tag aliases corresponding exactly to the refactored controller tag database established in the Master I/O

Chart.

• Execution Within Business Hours Outage: All physical removal, adapter bezel mounting, power wiring, network integration, runtime downloading, and dynamic display validation shall occur concurrently during the respective cabinet's business-hours cutover schedule (working 06:00 to 18:00 daily).

5.4 Task 4: Tier 2 Fleet Servicing – MicroLogix 1400 Firmware Servicing &

Hardening (29 Units)

• For each of the twenty-nine (29) assigned MicroLogix 1400 controllers, the

Contractor shall upload the running logic program, verify full rung comments and tag symbols, and archive an uncorrupted offline backup (.RSS) prior to executing installation.

• The Contractor shall generate an extracted I/O and communication summary for each installed unit to document active channels and physical terminations.

• The Contractor shall update controller firmware to the latest manufacturer-supported

Long-Term Support (LTS) release utilizing Rockwell Automation ControlFlash Plus via a direct serial or point-to-point Ethernet connection.

• Cybersecurity Service Deactivation: In accordance with NIST SP 800-82r3 guidelines, the Contractor shall permanently disable embedded HTTP web server daemons, BOOTP/DHCP network broadcast discovery protocols, and unencrypted remote programming sockets.

• The Contractor shall re-download the original program, verify process communication health, and monitor the unit under operating load for a minimum of two (2) hours to verify zero processor faulting.

• Servicing shall be completed within a four (4) hour maintenance window per controller during normal business hours (06:00 to 18:00).

5.5 Task 5: Operational Technology Cybersecurity Hardening & Validation

• Across all upgraded controllers, HMI terminals, and network switches, the Contractor shall execute system hardening compliant with NIST SP 800-82 (Revision 4) and

UFC 4-010-06:

• Physically cap and administratively disable all unused RJ-45 switch ports and controller/HMI Ethernet adapters.

• Deactivate legacy, plaintext management protocols (Telnet, HTTP, SNMPv1/v2).

• Configure CIP Security cryptographic integrity on EtherNet/IP trunks where supported by hardware.

• Deliver an OT Cybersecurity Hardening Report itemizing port security matrices, firmware validation checksums, and baseline vulnerability scan verification.

5.6 Task 6: Site Acceptance Testing (SAT), Final Verified I/O Charts, & Training

• Site Acceptance Testing: During Phase E of each cutover (Thursday 06:00 to 15:00), the Contractor shall execute a rigorous, written SAT protocol witnessed and approved by the COR. Testing shall validate automatic sequencing, manual operator overrides, HMI touch response, setpoint tracking, alarm reporting, and automated emergency stop / fail-safe reactions. Every point listed on the Master I/O Chart (including discrete 120VAC circuits on PLC 1/2/3 and analog loops on PLC 3) shall be individually exercised and verified under live conditions.

• Final Verified I/O Charts & Closeout Documentation: Within fifteen (15) calendar days following SAT acceptance, the Contractor shall deliver three (3) secure, USB media sets and an electronic repository transfer containing:

• Final As-Commissioned Master I/O Charts: Complete, certified I/O schedules

(in searchable PDF and Excel format) reflecting final point-to-point test verification signatures, live signal scaling parameters, wire tag designations, and terminal numbers for every circuit in the modernized panels.

• Cabinet Elevation & Layout Diagrams: Final drawings showing physical component layouts, 1492 module locations, and HMI adapter bezel details.

• Program Archives: Fully annotated Studio 5000 project archive files (.ACD) and

FactoryTalk View ME project archive files (.APA and runtime .MER) containing complete tag descriptions and screen documentation matching the final I/O

Charts.

• OEM Literature: Original equipment manufacturer cut sheets, adapter kit mounting instructions, and technical user manuals.

• On-Site Technical Instruction: The Contractor shall deliver sixteen (16) cumulative hours of structured technical training to government operations and maintenance technicians during standard business hours. Instruction shall cover processor diagnostics, LED status interpretation, 1492 module replacement, I/O Chart troubleshooting methodologies, HMI runtime backup/restoration, offline program uploading/downloading, and scheduled backup procedures.

5.7 Contractor Safety Deliverables & Compliance

• Abbreviated Accident Prevention Plan (A-APP): Prior to commencing any on-site physical labor, wiring, installation, or testing, the Contractor shall submit an

Abbreviated Accident Prevention Plan (A-APP) conforming to EM 385-1-1

(Appendix A) to the Contracting Officer (KO) and Contracting Officer’s

Representative (COR) for official routing and review.

• Activity Hazard Analysis (AHA): Concurrently with the A-APP, the Contractor shall submit a task-specific AHA to the KO and COR. The AHA must identify hazards and control measures for:

• Working inside active electrical/control panels (NFPA 70E compliance).

• Joint Government/Contractor Lock-Out/Tag-Out (LOTO) energy isolation.

• Debris and hazard containment (strict compliance with the ‘Zero Sheet-Metal

Cutout’ mandate to prevent conductive metallic shavings in active control rooms).

• Site Acceptance Testing (SAT) and system commissioning.

• Work Authorization Constraint: Under no circumstances shall the Contractor perform on-site physical work, tool-use, or system cutovers until the KO has formally accepted both the A-APP and AHA in writing.

PART 6: APPLICABLE PUBLICATIONS & MANDATORY STANDARDS

The Contractor shall execute all work in strict conformance with the following mandatory publications and standards (current editions at time of award):

1. NIST SP 800-82 (Revision 4): Guide to Industrial Control Systems (ICS) Security.

2. UFC 4-010-06: Unified Facilities Criteria: Cybersecurity of Facility-Related Control

Systems (FRCS).

3. NFPA 70: National Electrical Code (NEC).

4. NFPA 70E: Standard for Electrical Safety in the Workplace.

5. OSHA 29 CFR 1910.147: The Control of Hazardous Energy (Lockout/Tagout).

6. Rockwell Automation Publication 1492-TD008: Wiring Systems and Conversion

Assemblies Technical Data.

7. Rockwell Automation Publication 2711P-TD009: PanelView Plus 7 Performance

Terminals User Manual & Adapter Kit Specifications.

8. IEEE Standard C62.41: Guide on the Surge Environment in Low-Voltage AC Power

Circuits.

9. USACE EM 385-1-1: Safety and Health Requirements Manual (specifically

Appendix A for A-APP).

10. DA PAM 385-10: Army Safety Program

PART 7: TECHNICAL EXHIBITS

Technical Exhibit 1: Performance Requirements Summary (PRS) Matrix

The Contractor's performance will be evaluated against the following standards.

SOW Task

Reference

Required

Operational

Standard

Acceptable

Quality Level

(AQL)

Method of

Surveillance

Government

Contractual

Remedy

SOW 5.1

(Design

Package & I/O

Charts)

Master I/O

Charts, BOM, HMI bezel details, and layout sketches are 100% complete, legible, and accurately document all field terminations across PLC 1, 2, and 3.

Zero missing active I/O circuits; max 2 minor redlines resolved within

5 working days.

100%

Technical

Document

Review by

COR and

Controls

Engineering

Staff

Submittal rejected;

contractor revises at no additional cost.

SOW 5.2 &

5.3 (OEM

Hardware)

100% authentic, factory-new

Allen-Bradley components and HMI terminals supplied via authorized channels with

Zero tolerance for counterfeit, refurbished, surplus, or grey-market parts.

100% Physical

Inspection of

OEM

packaging, tamper seals, and serial tags

Immediate rejection of components;

mandatory replacement within 10 days at contractor expense.

traceable serial records.

SOW 1.7 &

1.8 (Business

Hours

Outage)

All active cutover work executed strictly during business hours

(06:00–18:00);

full cutover completed by

Thursday

15:00.

Zero active work during overnight hours

(18:00–06:00);

zero unscheduled downtime past

Thursday

15:00.

Continuous

On-Site

Surveillance &

Daily Outage

Logs by COR

Issuance of formal CDR;

negative

CPARS rating;

contractual default remedies.

SOW 5.2

(1492

Conversions)

Bulletin 1492 pre-wired conversion assemblies utilized on all eligible legacy

1746 wiring arms across

PLC 1, 2, and

3.

100% utilization where catalog conversion blocks exist;

zero unauthorized manual rewiring.

100% Physical

Cabinet

Inspection prior to power-up

Immediate work stop order if manual rewiring is attempted;

contractor remediates at own cost.

SOW 5.3

(HMI Zero

Cutout

Alteration)

2x PV1000 and

1x PV1250 replaced using adapter bezels with zero cutting, drilling, or alteration of cabinet door cutouts;

NEMA 4X seal verified.

100% compliance.

Zero hot-work or metal shavings inside cabinet.

100% Physical

Inspection of enclosure doors prior to and after mounting

Immediate rejection;

contractor replaces damaged cabinet door at own expense if cut.

SOW 5.2 &

5.3 (Logic &

HMI

Migration)

Converted

Studio 5000 logic and

FactoryTalk

View ME runtime

Zero logic execution faults; zero unmapped legacy registers; zero

Pre-Cutover

Code Review

& Simulation

Bench Audit

Logic/HMI package rejected;

mandatory code restructuring at maintain 100% functional equivalence to legacy systems with descriptive tag refactoring mapped to I/O

Charts.

missing HMI screens or dead tags.

contractor expense.

SOW 5.4

(ML1400

Servicing)

29x units flashed to LTS release; offline backups captured; web servers and broadcast ports deactivated within 4-hour window.

100% uncorrupted backup verification;

zero open unencrypted web or discovery ports.

Post-Flash

Configuration

Audit & File

Verification

Re-servicing of unit at contractor expense prior to invoice approval.

SOW 5.5

(Cyber

Hardening)

Strict compliance with NIST SP

800-82r3;

unused ports disabled.

Zero open unencrypted management ports; 100% port closures verified via audit log.

Port Scan

Audit &

Switch/HMI

Configuration

File Review

Payment withheld until security artifacts clear verification.

SOW 5.6

(SAT & Final

I/O Charts)

Successful completion of live load SAT;

delivery of final certified

Master I/O

Charts, .ACD, and

.APA/.MER

files;

completion of

16-hr training.

100% SAT test point pass; ≥

80% trainee competency score; zero omissions in final I/O records.

Direct

Observation of

SAT and

Training; 100%

Audit of

Closeout I/O

Charts

Payment withheld until all closeout deliverables are accepted.

SOW 5.7

(Safety

Submission of complete A-

100% compliance.

100% Safety

Review by

Work stop order;

Deliverables

A-APP &

AHA)

APP (EM 385-

1-1 App A) and

AHA covering electrical, LOTO, zero metal cutting, and SAT.

Zero on-site physical work initiated prior to formal written KO approval

SOH Office

(AMCD-CSH)

and KO/COR immediate removal from base; submittal rejected until corrected.

Technical Exhibit 2: Deliverables Schedule

Deliverable

Title

SOW

Reference

Frequency /

Mandatory

Due Date

Delivery

Format &

Media

Government

Recipient

Modernization

Design

Package &

Master I/O

Charts

Section 5.1 Within 30

Calendar Days of

Award

1 Electronic

Copy

(Searchable

PDF &

Editable Excel)

COR

Hardware

Certificate of

Authenticity

Section 5.2 &

5.3

Prior to

Delivering

Hardware to

Base

1 Electronic

Copy (PDF) with OEM

Invoices

KO & COR

Studio 5000

Converted

Logic (.ACD)

Section 5.2 14 Calendar

Days Prior to

Scheduled

Cabinet Outage

Secure

Encrypted

Digital

Transfer

(.ACD)

COR

FactoryTalk

View ME

Application

(.APA / .MER)

Section 5.3 14 Calendar

Days Prior to

Scheduled

Cabinet Outage

Secure

Encrypted

Digital

Transfer (.APA

& .MER)

COR

Cutover &

Rollback

Safety Plan

Section 1.8 &

1.9

14 Calendar

Days Prior to

Scheduled

Cabinet Outage

1 Electronic

Copy (PDF)

COR

ML1400

Verified Logic

Backups & I/O

Records (29

Units)

Section 5.4 Within 5

Working Days

Following

Controller

Flash

Secure

Electronic

Transfer (.RSS

Archive &

PDF)

COR

OT

Cybersecurity

Hardening

Report

Section 5.5 At Conclusion of SAT for

Each

Modernized

Cabinet

1 Electronic

Copy (PDF with Port Scan

Records)

COR & ISSM

Site

Acceptance

Test (SAT)

Protocol

Section 5.6 14 Calendar

Days Prior to

Scheduled

Cabinet Outage

1 Electronic

Copy (PDF)

COR

Final Verified

I/O Charts &

Closeout

Documentation

Section 5.6 Within 15

Calendar Days

Following

Final SAT

Sign-Off

3 Encrypted

USB Drives +

Secure

Electronic

Transfer

COR

Training

Records &

Attendance

Roster

Section 5.6 Within 5

Working Days

Following

Training

Completion

1 Hard Copy +

1 PDF

Electronic

Roster

COR

Abbreviated

Accident

Prevention

Plan (A-APP)

& Activity

Hazard

Analysis

(AHA)

Section 1.6.4 &

5.7

Minimum 20

Calendar Days

Prior to

Proposed On-

Site Work

(Allows 5-day

SOH review)

1 Electronic

Copy (PDF)

KO, COR, &

SOH (AMCD-

CSH)

Security

Badging, Escort

Requests, &

Training

Certificates

Section 1.6.1 –

1.6.3

Minimum 14

Calendar Days

Prior to

Scheduled Site

Arrival

1 Electronic

Package (PDF forms & certificates)

COR

Package

(DBIDS,

CCAD Escort, AT-1, OPSEC, iWatch)

0 − 32767

4000 − 20000