SOURCES SOUGHT
22 -- Golden Spike NHS Locomotive Wheel Replacement
- Notice Date
- 12/26/2013
- Notice Type
- Sources Sought
- NAICS
- 336510
— Railroad Rolling Stock Manufacturing
- Contracting Office
- NPS, IMR - Northern Rockies MABOPO Box 168Mammoth Supply Building #34Yellowstone NPWY82190US
- ZIP Code
- 00000
- Solicitation Number
- P14PS00191
- Response Due
- 1/24/2014
- Archive Date
- 2/23/2014
- Point of Contact
- MARTIN HAUCH
- Small Business Set-Aside
- N/A
- Description
- The Department of Interior, National Park Service, Golden Spike National Historical Site, located in Box Elder County, Utah 32 miles west of Brigham City, is looking for interested sources to manufacture four replacement wheels for one of its historical steam locomotives, the Jupiter. The Jupiter has three sets of wheels, the first is the engine truck wheels, the second is the driving wheels and the third is the tender wheels. The engine truck wheels are the leading wheels that help guide the locomotive along the tracks and support the weight of the front of the locomotive. One wheel out of a set of four has what is believed to be a casting imperfection which has created a flat spot. The flat spot has not been significant enough to impair the locomotives operation until recently. After 33 years however, the wheels flat spot has begun deteriorating at an accelerated rate. This is causing a pounding action as the locomotive moves along the track which is a detriment to the locomotive and could cause the wheel to fracture, rendering the locomotive immovable. There are also indications of similar damage areas to the other engine truck wheels. The Jupiter wheels are approximately 27 inches in diameter and weigh 600 pounds each. The National Park Service conducted an assessment of the wheels. The investigation reported that the likely cause of the surface flaws (indentures) was due to defect in casting in the form of soft spots (more in the flattened wheel and less in the other wheels) and surface crack. The soft spot would generate indentation (there is an indention next to the gouge). The surface flaws expanded due to two possible causes. Moisture penetrated the indention and corroded the material leading to the gouge. Also, motion of the locomotive generates heat in the wheels at the interface with rails, and causes the edges of the surface flaw to chip off. The flattened spot was most likely due to impulsive load and creep - the weight of the locomotive bearing on the soft spot. The investigations recommendation on material of casting, method of heat treatment and quality control procedures after replacement wheels are cast. The estimated weight of the locomotive with water, fuel and people is 60,000 lbf. Assume the four truck wheels together carrying half the locomotive weight in equal proportion. So when the locomotive is stationary, the weight acting through any truck wheel is 7500 lbf including the weight of the wheel. The required design service goal (DSG) life of the wheel is 100 years. The Wheel Replacement Program consists of the following tasks: TASK1: PERFORM A STRESS ANALYSIS TO SHOW WHEEL DESIGN MEETS STRENGTH AND LIFE REQUIREMENTS Accordingly, perform an analysis using - Material of wheel to be one of the following o AAR-M-208-74 Class C cast carbon steel from Reference 1, o AISI 4130 carbon Steel, o AISI 8620 carbon steel, - Dimensions of wheel to be from Reference 1, - Material properties from public source, - A casting factor no less than 1.5, - A material factor of safety of no less than 1.1. Perform the following: A. With approval from the government, select the appropriate material for the wheel. B. Determine the stresses in wheel from press fit per AAR standard to an axle of AISI 1045 carbon steel from Reference 4. C. Determine Margin of Safety (MS) of the wheel design under static load (from operation and press fit) and check for plastic deformation at rail and axle interface. D. Estimate the dynamic magnification factor (DMF) to be applied to static load on a wheel (with no defect) based on the operating speed of locomotive and estimate its occurrence rate.E. Generate a load spectrum over one design life from D. F. Determine Margin of Safety (MS) of the wheel design under dynamic load and check for plastic deformation. G. Identify the critical (i.e. high stress) locations and the rational for choosing the critical locations. H. Perform a fatigue analysis at critical locations identified in G to determine the life of the wheel using the loads spectrum of E and material fatigue data from public domain taking into account porosity of casting. If fatigue data for the exact material is not available, justify the data used. I. Estimate the life of the wheel based on the operating schedule (5 months of usage per year at maximum speed of 15 mph) and locomotive breaking rate (provided by park services). A design speed of 30 mph is to be used even if the locomotive is to be operated at 15 mph. The operating speed may be decided per park guidelines. J. If the wheel does not have sufficient strength, rigidity, or life determine the design changes required: a. The required MS is minimum 0.0, b. The required fatigue life is 3 DSG, c. The required crack size to be less than critical after 1 DSG, d. The allowed design changes with approval from authorities are: i. Material of casting and heat treatment, ii. Thickness of 5/8 stiffener plates, iii. Thickness of rim, iv. Radius of (concave and convex) corners. TASK2: PREPARE A STRESS REPORT - This report must be in sufficient detail to meet requirements of Reference 2. The report at minimum:- Document the approach, - Identify any software used, - Identify any assumptions, simplifications and approximations, - Sources of data, - Plots for clarity, - Must be acceptable to authorities providing certification and approval. TASK 3: GENERATE DRAWINGS, A. Generate drawings of wheel castings before machining. B. Generate drawings of castings after machining. The drawings must be in details with minimum: a. All units per Reference 2, b. Tolerances per Reference 2, c. Identify material and heat treatment, d. Surface finish per Reference 2.e. Identify critical locations from stress report f. Identify no repair of critical locations, g. All testing to be performed at locations per Reference 2. C. Submit the drawings to the government for approval, D. Incorporate or address the comments from the government and get final approval. TASK 4: MANUFACTURE FOUR (4) WHEELS AND PERFORM INSPECTION AND TESTING, A. The contractor or its sub-contractor will make the castings. The castings will be per drawings from TASK 3 and meet Reference 2 requirements.B. The casting material for each lot will be tested for strength, porosity and grain size.C. All inspections will be performed per Reference 2. D. The machined parts will each be tested for porosity, surface cracks and surface flaws. E. Defects in non-critical locations may be repaired per Reference 2. F. The inspection and testing reports will be provided to the government for approval. G. The heat treatment must meet the requirements of Reference 2 and the detailed heat treatment of Reference 3 is to be used as a guideline. TASK 5: MANUFACTURE ONE (1) AXLE AND INSTALL THE AXLE TO A PAIR OF WHEELS (2 WHEELS) USING PRESS FIT. A. The wheels must be press fit using the manufactures selected method that meets AAR standard. B. The allowance, tolerance, heating conditions must agree with those used in stress analysis in TASK 1 and reported in TASK 2 stress report. Any disagreements to be brought to the attention of the government before press fitting and resolved. TASK 6: DELIVERY OF WHEELS mounted on AXLE AND INSTALLATION SUPPORT, A. Once the government gives acceptance approval of the wheels mounted on axle, they will be delivered to the government site by contractor. B. The contractor will assist the government and provide support in the installation of the wheels. C. Deliver the other two wheel castings to the government after all testing, machining and heat treatment are completed and approved. D. Deliver copies of all drawings produced in the following formats:a. PDF, b. CAD, c. Hard copy (two sets). The NAICS code for this procurement is 336510, with a size standard of 1,000 employees. Contractors having capabilities necessary to meet or exceed the stated requirements are invited to provide company information in the format of a narrative that demonstrates technical understanding, past performance and experience to Martin Hauch, Contract Specialist at: martin_hauch@nps.gov, phone number 307-739-3448. Responses should include the following information: company name, address, point of contact, phone number, socio-economic status (Service Disabled, 8(a), etc), provide DUNS number, state if/if not registered in SAM. All relevant input is encouraged. This synopsis is for information and planning purposes only and is not to be construed as a commitment by the Government nor will the Government pay for information solicited; no basis for claim against the Government shall arise as a result from a response to this Sources Sought or Government use of any information provided. The Government reserves the right to consider a small business, 8(a) or any other set aside arrangement as deemed appropriate based on the response for this notice.
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