****31 MAR 2016 UPDATE**** ADDITIONAL QUESTIONS AND ANSWERS POSTED BELOW Q: Section C, Scope of Work (SOW) section 3.8.1; requirement states, "Product level drawings are necessary to enable the Government to competitively purchase all end items, and support logistic activities of fielded items." Is it the government's intent that the supplier creates a part drawing for every component within the system regardless if the part needs to be replaced? Example, creation of sheet metal drawings for the entire structure even though sheet metal parts may not be replaced as part of the capital reset. A: It is the government's intent to buy a complete system TDP drawing package which will include all drawings for both the C and D model units Q: Section C, SOW section 3.8.2; Drawing Submittal Requirements, is it necessary to recreate drawings that exist from the previous equipment if they do not meet all of the requirements of this section? A: Drawings need to meet the requirements outline in the SOW Q: DD254 RECAP V2; clarification that it is necessary for the prime contractor to have "secret" level clearance [MIL-STD 2169]? A: Contractor must meet the requirements outlined in the contract. Q: SOW 3.1.1 First Articles. "The vendor will apply the MWO and return the recapitalized PPUs to the government's possession." Who pays for the return transportation costs? A: It is the Governments intent to ship units. Q: SOW 3.1.4 Upgrade Control Components. There are two Feeder Outputs and one Tie Output in the PDC. It is our understanding that the feeder circuit is no long used since the Primary Switch is part of the system. What is the purpose of the feeder in the system now? A: The PD and SOW has been updated to outline the Governments requirements. Q: Can the feeder circuit components be removed? A: Same as above, Documents have been updated. Q: If a feeder output is still required, can one of the two be removed? A: Same as above, Documents have been updated. Q: SOW 3.9.3.2 Pre-Production Examination, para. 8) Utility paralleling demonstration. Who is responsible for making the arrangements with the utility company and cable connections? A: Contractor is responsible to demonstrate the capability Q: SOW 3.9.4 Production Commissioning Inspection Test (PCIT) (Production Phase). The Government will conduct a PCIT on each individual recapitalized PPU IAW PD 6115- 0132, Table I, and this SOW. The test will include but not limited to: a. Maximum Power Test; Volt/frequency transients Test b. Safety Warning and Shutdown Test c. Paralleling of eight (8) engine generator units (PPU) Test d. Overload Test; 50 Hertz Test e. Economizing Function Test - Should this be Table II of both the /1 and /2 PD cut sheets? Since the tests listed do not specify a particular test or requirement, is the contractor responsible to meet? If so, what are the parameters A: Test will replicate the functions outlined in the PD 3.5.12.1.6. Q: Purchase Description Summary (PDS), Section 3.5.1.10 Fuel consumption; "Fuel consumption using JP-8 shall be no greater than 30 gals per hour (GPH) per engine at full load (60 GPH, 100% load two engines) (Objective 10% reduction). Primary 521 fuel shall be JP-8/F-24." The current Caterpillar 3456 consumption is in excess of this requirements when running JP-8 fuel thus current fielded units will not meet this requirement. As a capital reset of current assets is this 30 GPH the intended requirement? A: The system shall meet the requirements outlined in the PD and SOW. Q: PDS, 3.5.4 Cranking system. The cranking system shall be 24 volts direct current (DC), negative ground. The set shall not be damaged (see 6.4.2) in the event that the polarity of the battery cables is reversed. It shall not be possible to crank the set with the battery polarity reversed. Does the Government have a solution in mind for battery polarity sensing? Almost all generator sets and vehicles used on the nation's highways lack this feature. This will be an added special or unique feature. A: Fielded E2S2 systems have this capability currently, TQG, LAMPS and AMMPS. Q: PDS, 3.5.7.1 Standard starting aids (ether or glow plugs). For temperatures between - 6C (20F) and 32C (-25F) standard starting aids shall be used. If ether is selected, the starting aid system shall be automated to inject a measured shot of ether based on ambient temperature and cranking conditions. The systems shall be compatible with the ether tank depicted on drawing 30554-69-77776 and ether bottle bracket depicted on drawing 30554-69-777. They shall be permanently installed in each set in a location that permits installation and removal of the ether tank without the use of tools. The measured shot of ether shall be as recommended by the engine manufacturer. An electrical interlock shall be provided such that the ether starting aid will be inoperative unless its switch is automatically activated concurrently with cranking of the engine. The ether tank shall not be a component of the set and shall be furnished only on Test Articles (see 3.2). Production sets shall be furnished without ether tanks. Clarification that it is the government's expectation the supplier does not supply cold weather starting feature on production units? A: All units will have winterization kits per PD 3.5.7.2. Q: PDS, Appendix A, Apparatus. Will the required M17 Lightweight Decontamination System NSN 4230-01-251-8702 be provided as Government Furnished Equipment for use on the program? A: The Government will not be providing M17 decontamination system as GFE. Q: PDS, 6115-0132 Lines 21-22. Will droop paralleling be a satisfactory method for paralleling new units with legacy MEP-PU-810A/B sets? A: Droop is an acceptable method. Q: PDS, 6115-0132 Lines 394-395. When stating that "Each PPU contains two independently controlled generator sets that can operate independently or in parallel, in isochronous speed and voltage droop modes", does this imply that each generator can be loaded independently? The present electrical configuration would prevent this. A: There is no requirement that states the units be loaded independently. Units can be operated independently and paralleled to a common buss. Q: PDS, 6115-0132 Lines 889-900. Is it safe to have automatic start and stop features such as "Economizing" mode active by default when in auto, or should there be provisions to have a user confirm this operation upon switching to auto mode? A: The requirements for the Economizing mode are outlined in PD 3.5.12.1.6. Q: PDS, 6115-0132 Lines 889-900. What type of control should be used to enable/disable the automatic starting/stopping feature, i.e. unit will no longer start based on load demand, either through enabled or disabled economizing? A: The ability to isolate a unit is up the offerer/contractor to determine, depends on which control system is selected by the offerer. Q: PDS, 6115-0132 Lines 1032-1934. What is expected of self-diagnosis on all system line replaceable units (LRUs) during startup? A: The system shall identify any faults within the LRU's Q: PDS, 6115-0132 Lines 1026-1030. Is the unit required to parallel to live sources, utility or other PPUs, through either of the feeders? A: There is no requirement in the PD to allow for paralleling through the feeders. Q: PDS, 6115-0132 Lines 1026-1030. What is the intended operation when paralleling to a utility? a. Control the amount of utility power used b. Base load the generator sets on the system to support utility c. Use the generator sets to back up utility in case of present or imminent failure. A: Yes to all above Q: PDS, 6115-0132 Lines 1026-1030. Will a signal be present to indicate the position of the utility contactor? A: Depends on system but usually No. Breakers/switches will be controlled by the assigned operators. Q: PDS, 6115-0132 Lines 1026-1030. Will testing the transient response be performed at unit (2 generators) or individual generator level? A: Single and two unit operation. Q: PDS, 6115-0132 Paragraphs 2.2.1. There was a revision listed for each specification in the previous draft. There is no revision listed in the current draft. The revision level is important to know what revision is being used and can have an effect on the cost to comply. Will the revision level be re-inserted in the final PD? A: The latest versions will apply, Revisions will not be added to the PD. The current revision at time of award is the revision that should be used. Q: PDS, 6115-0132 Paragraph 3.5.12.3.2 Automatic paralleling. Each generator set (GENSET) shall ... Paralleling cables, if required, shall be provided with each PPU and shall be 50 feet in length. Paragraph 3.7.2.1 calls for the cable to be 25 feet. Which is correct? A: The PD has been updated to reflect the correct length. Q: PDS, 6115-0132 4.7.22.1 Permissive paralleling test. PPU (see 3.1) shall be parallel tested IAW 630.1 of MIL-STD-705 with the following changes: b. Verify that two or more generator sets of the same mode will not parallel until the voltage difference of the same phase is less than 8 volts [an acceptable meter error of plus or minus 1% on a 4160 volt machine that is equivalent to 41 volts]. In order to meet 8 volts, the meter would have to be +/- 0.2%. Is this the intent? A: The PD has been updated to reflect the requirement. Q: PDS, 6115-0132 Test Schedule. The MIL-STD-705 does not address how to test when the generator set has two engine/generators within the same housing. When testing, is the contractor to: a. Test just the individual engine/generators only [two tests per trailer (test each engine/generator separately)]? A: Step C b. Test the entire trailer with both engine/generators operating together [one test with both engine/generators operating together per trailer]? A: Step C c. Test the individual engine/generators and then test the entire trailer with both engine/generators operating together [three tests per trailer]? A: The system will be tested as a single engine Gen and as a complete system. d. In addition to performing one of the configurations above, each test is conducted in 50 Hz and then 60 Hz, doubling the number of test configurations per listed test. Is this correct? A: The system will be tested at both 50 and 60 Hz as outlined in the PD and SOW. Q: PDS, 6115-0132/1 A-Model PD Paragraph 3.4 Materials. ... designed to meet all Department of Transportation (DOT) requirements for highway transport, The A-model was not designed for highway use, therefore it is does not meet DOT requirements. Does the A-model need to be redesigned to meet DOT requirements? A: Axles are DOT compliant. Intent is that the material used meets DOT specs. Does not have to be DOT Certified. Q: PDS, 6115-0132/2 B-Model PD Paragraphs 3.5.8 Landing gear. Landing gear shall support the fully loaded PPU while operating, and shall withstand, without damage, the strains imposed upon it, when coupling or uncoupling the towing vehicle, and raising or lowering the fully loaded PPU. The landing gear will retract to enable the PPU to be loaded on C-5, C-17, and C-141 military aircraft. C-141 aircraft are not called out anywhere else. Is this a requirement? A: The Government has updated the documents to reflect the change . Q: Appendix A, GFP. Will a Primary Switch be provided for PPT testing and if necessary, commissioning test acceptance? A: The Government does not intend to provide a PSC switch as GFE equipment at this time. Q: Appendix A, GFP. "Communication Cables." What cable is this, the ORT communication or the unit to unit paralleling cable? A: Communication Cable is the interconnect cable between units. Q: PDS, 6115-0132 3.5.20.5 Over/Under Voltage; Is the Over and Under voltage really supposed to be 20 and 30% for a Medium Voltage set? Present day settings in the DPGDS manual lists the settings for over and under voltage as 10 %. PD wants; warnings at 20% over and under and shutdowns at 30% over and under. The actual present day settings seem to low since they interfere with the voltage adjustment range, but 20% & 30% seems high for a MV set. Surge arrestors and M.O.V. protections will need to be that much higher for 30% Over Voltage. A: The Government has updated the documents the documents to reflect the change. The over/under voltages setpoints shall be adjustable. Q: PDS, 6115-0132 4.6 & 4.6.1 Commissioning Inspection & Tests; Question: Production tests will perform tests under column 3. Does this include: a. Maintainability Demonstration 4.7.17 b. TM 625.1 Short Circuit Mechanical strength. 3.5.9.2 (normally a Generator Only Test). c. Size and Weight 4.7.33 d. Voltage and Frequency Drift 4.7.35 e. Wet Stacking 4.7.36 A: Commissioning test will replicate some of the APG tests, not all tests will be replicated during the commissioning testing. Q: We have seen material that the EnduraSeal insulation system is a requirement. Leroy Somer was part of Reliance Electric when this technology was developed by Reliance Electric Service Centers then IPS purchased the service centers in 2007. May our insulation system will be submitted as an alternative? A: No. The SOW and PD specifically calls out the Government's requirement to use the EnduraSeal process. The original system was furnished with CAT SR4B (Leroy Somer) alternators. The system experienced significant failings in the harsh environmental conditions that these systems operate in. In response, the Government utilized the EndurSeal process on the SR4B systems; for the last five years it has proven highly reliable in the harsh, 24/7/365 environment. Q: We have also seen the water immersion test requirement. Can you tell me where this requirement initiated? A spray test is also allowed by the standard. Can you tell me if that would be acceptable? A: The water immersion test requirement will be outlined in the PD. As a result of the harsh conditions the DPGDS is required to work in, the water immersion test will be utilized to ensure that there are no voids in insulation/windings.