14424-20-001 Upgrade Controllers for M2 and M3 Load Commutated Inverters SOW.pdf

14424-20-001

SOW NO. 14424-20-01

24 January 2020

STATEMENT OF WORK

TO

UPGRADE CONTROLLERS FOR

M2 AND M3 LOAD COMMUTATED INVERTERS

ARNOLD ENGINEERING DEVELOPMENT COMPLEX

ARNOLD AIR FORCE BASE, TENNESSEE 37389-9998

NOT SENSITIVE

IRA-4868

IRA-4868 Page-1

1. SCOPE

1.1 The Contractor shall provide design and installation for two new ABB AC800 PEC controllers to replace the existing PSR2 controllers in the ABB MEAGADRIVE-LCI Load Commutated Inverters (LCI) servicing M2 and M3 motors in Propulsion Wind Tunnel’s (PWT) Main Drive. ABB controllers shall be used without substitution. Replacement shall include the engineering and technical services needed to provide a system tailored to the M2 and M3 drive system. The replacement system shall increase Main Drive performance, safety, reliability and maintainability. Work shall be performed at Arnold Air Force Base, Tennessee.

1.2 Background: M2 and M3 are 60,000 Horsepower (HP), 44.7 Megawatt (MW) motors. Each motor stator has two sets of three-phase windings which are displaced by 30 degrees. These motors are always powered by the two independent ABB MEGADRIVE LCI converters. The power hardware for these converters will remain in place. The existing control system is an ABB PSR2 (with ArcNet and light firing).

When the converter outputs are connected to a synchronous motor, the system can start, accelerate, and operate the motor at any desired speed within the limits of 6 to 60 hertz motor frequency. Assignment switchgear is included such that the two converters can serve as a backup to the other motor if needed.

1.3 The existing system interfaces heavily with AEDC’s Main Drive Control System (MDCS). Speed control is done in the MDCS which passes torques commands to the ABB system. Communication between the LCI Control System and MDCS takes place via MODBUS to transmit diagnostics, status information, and commands to the drive.

2. APPLICABLE DOCUMENTS

2.1 Government Documents:

A. AEDC Environmental Policy:

http://www.arnold.af.mil/Portals/49/documents/AFD-160204-029.pdf

B. AEDC Safety, Health, and Environmental (SHE) Standards latest version, available upon request from the Government.

A. A6 with Supplement User and Subcontractor Safety

(Mandatory Documents/Submittals).

B. A10 Job Safety Analysis.

C. B1 Master Work Permit.

D. B2 Lockout Tagout (LOTO).

E. B4 High Voltage Electrical Work.

F. D10 Scaffolds.

IRA-4868 Page-2

G. E18 Managing Wastes Containing Chemical or Petroleum Products.

H. F2 Personal Protection Equipment

(PPE).

C. Air Force Federal Acquisition Regulation:

A. AFFARS 2.101 Definitions of Words and Terms.

B. AFFARS 23.401 Use of Recovered Materials

Definition.

C. AFFARS 52.223-9 Estimate of Percentage of

Recovered Material Content for EPA-Designated Items.

D. AFFARS 5352.223-9000 Elimination of Use of Class I Ozone Depleting Substances

(ODS).

D. Code of Federal Regulations, latest version:

A. 7 CFR 2902 Subpart B Guidelines for Designating

Biobased Products for Federal Procurement, Designated Items.

B. 29 CFR 1926.1101 Asbestos.

C. 40 CFR 261 Identification and Listing of

Hazardous Waste.

D. 40 CFR 370 EPA Hazardous Chemical

Reporting and Community Right to Know Requirement.

2.1.2 Department of Defense Standard Practice:

A. MIL-STD-882-12 System Safety.

2.2 Non-Government Documents:

2.2.1 National Electrical Manufacturers Association:

A. NEMA ICS 3-10 Standard Industrial Control and Systems Medium Voltage.

3. REQUIREMENTS

3.1 Contractor shall:

3.1.1 Remove the two existing ABB PSR2 control systems including all associated hardware in the existing control cubicles. Remove all associated hardware outside of the control cubicles up to but not including the thyristors. The remaining empty cubicles shall be used to install the two new ABB AC800 PEC control systems and associated hardware. The replacement systems shall be configured as required to be fully

IRA-4868 Page-3 compatible with the existing ABB MEGADRIVE-LCI hardware and shall perform all functions as well or better than the ABB PSR2’s as currently installed in PWT – including sequences, signal handling, and communication with the MDCS. After installation and commissioning, there shall be no degradation in the operation or performance of the M2 and M3 drive system including start, speed control, synchronization, and dynamic braking.

3.1.2 Provide ABB’s Advanced Power Factor Improvement (APFI) and Advance Power Factor Optimization (APFO) software to reduce Main Drive reactive power usage and increase its power output. The software provided shall be fully parametrized to optimize the performance of the government’s current M2 and M3 drive system. Contractor shall perform a system study to determine optimum parameters and evaluate the resultant harmonic mitigation and power factor correction performance of the filter banks. The contractor shall provide ability to disable the APFI/APFO and MPTC software should complications be encountered.

3.1.3 Replace the excitation SCR power controller with a standard ABB DCS800 field current power controller. The field contactor shall be replaced as well as the power electronic fuses. All other hardware associated with the excitation shall be tested for functionality. The rotor shall have ground fault protection associated with the excitation system.

3.1.4 Provide ABB’s Arc Guard, Earth Fault Supervision, Motor Protection software, and Failure Mode Analysis. These added features shall include all necessary engineering, sensors, software and hardware (including installation and checkout) required to make them fully functional as advertised and in support of the existing ABB MEGADRIVE-LCI hardware.

3.1.5 Performed all work in accordance with applicable state and local safety, health, and environmental standards, and OSHA, including AEDC SHE Stds. A6, B1, B2, B4 and MIL-STD-882E Sections 3 & 4.

3.1.6 Contractor shall conduct 30 percent, 60 percent, and 90 percent design reviews. Design review packages shall include all demolition and installation work to be performed as well as all planned configuration changes (sequences, logic, components, parameters, signal handling and other functional changes), a training plan, and work activity scheduling.

Documentation shall be provided at least 14 days before the design review meetings.

3.1.7 Submit as-built final drawings to the Government.

3.1.8 Provide all controller code documentation associated with the new AC800 controllers as property of the Government at the completion of the project.

IRA-4868 Page-4

3.2 Verification and Validation:

3.2.1 Contractor shall perform a factory acceptance test. Submit test results to the Government.

3.2.2 After installation, Contractor shall perform an onsite test demonstrating that all requirements are met and system is functioning as specified.

3.2.3 Verification Plan. A thorough written test plan shall be completed and submitted. The verification plan shall include all testing criteria, procedural information, and target pass/fail values. All criteria/recommendations that differ from the requirements set herein this SOW shall be delineated for discussion, understanding and approval by the Government prior to fabrication.

3.2.4 Acceptance. The Government will accept the M2 and M3 LCI control system and all related components upon satisfactory verification and operation at AEDC including but not limited to demonstration of the stated improvement due to the new APFI and APFO.

3.3 Submittals: Provide all submittals in accordance with Appendix B.

3.3.1 The Contractor shall provide a proposed implementation plan that minimizes the overall impact to the test facility. All outage coordination will be approved through coordination with the Government. The upgrade shall be performed in no more than 10 calendar days.

3.3.2 The Contractor shall provide an operations and maintenance (O&M) manual for the proposed design solution including preventative and predictive maintenance schemes and operating procedures. The operating procedures shall include the new scheme for filter control with the APFI/APFO. Include a list of proposed spare parts and consumables anticipated as part of a maintenance plan.

3.3.3 Required submittal summary table:

Table I. Required submittal.

No. Section Submittal Description Due

1 3.1.6 30 percent design submittal

14 days prior to design review meeting

2 3.1.6 60 percent design submittal

14 days prior to design review meeting

IRA-4868 Page-5

No. Section Submittal Description Due

3 3.1.6 90 percent design submittal

14 days prior to design review meeting

4 3.1.7 As-built drawings Prior to final acceptance

5 3.1.8 Controller Code Documentation

Prior to final acceptance

6 3.2.1 Factory test results Within 7 days after test

7 3.2.3 Verification Plan Prior to verification and acceptance

8 3.3.1 Implementation Plan including schedule and outages

Prior to on-site work

9 3.3.2 O&M Manual Prior to final acceptance

10 Appendix A para 1.3.D

Outage Request 2 weeks prior to outage

11 Appendix A para 1.3.M

Proposed Scaffolding Before beginning work

12 Appendix A para 1.3.N

Record As-Built Drawings

Before final inspection

13 Appendix A para 1.3.B

Existing Conditions Report Which could be Construed as Damage Resulting from Work

Before beginning work

14 Appendix A para 1.5A

Safety and Health Plan 10 days after contract award

15 Appendix A para 1.6.A

Special Material Turn in Material Form

Prior to disposal

16 Appendix A para 1.10.A.2

Percentage of Recovered Material Content

Before final inspection

IRA-4868 Page-6

No. Section Submittal Description Due

17 Appendix A para 1.12.A

Disallowed Products Locations

Before final inspection

18 Appendix A para 1.13.A

Asbestos Locations Before final inspection

19 Appendix A para 1.14.A

Waste Identification (WIF) and Chemical Waste Data Sheet

(CWDS

Before final inspection

20 Appendix A para 1.5.A

Hazardous Material Info Before beginning on-site work

21 Appendix B para 1.2B

Summarized submittal listing with delivery dates

14 days after contract award

IRA-4868 Appendix A-1

APPENDIX A

JOB CONDITIONS AT AEDC

PART 1 GENERAL1

1.1 DEFINITIONS

A. Certain terms used in the contract documents are defined below. Definitions and explanations contained in this section are not complete, but are general for the work to the extent that they are not stated more explicitly in another element of the contract documents.

1. Furnish. The term "furnish" means to supply and deliver to the project site, ready for unloading, unpacking, assembly, installation, and similar operations.

2. Install. The term "install" describes operations at the project site, including the actual unloading, unpacking, assembly, erection, placing, anchoring, applying, working to dimensions, finishing, curing, protecting, cleaning, and similar operations.

3. Provide. The term "provide" means "provide complete in place"; that is, "furnish and install.”

4. Indicated. Where "as indicated" or words of similar import are used, it shall be understood that the reference is made to the drawings accompanying this contract unless stated otherwise.

5. Postconsumer material (AFFARS 52.223-9): a material or finished product that has served its intended use and has been discarded for disposal or recover, having completed its life as a consumer item.

Postconsumer material is a part of the broader category of “recovered materials”.

6. Recovered material (AFFARS 2.101): waste materials and by-products recovered or diverted from solid waste. The term does not include those materials and by-products generated from, and commonly reused within, an original manufacturing process.

7. Biobased product (AFFARS 2.101): a product determined by the U.S. Department of Agriculture (USDA) to be a commercial or industrial product (other than food or feed) that is composed, in whole or in significant part, of biological products, including renewable domestic agricultural materials (including plant, animal, and marine materials) or forestry materials.

8. USDA-designated item (AFFARS 23.401): a generic grouping of products that are or can be made with Biobased materials (1) that is listed by USDA in a procurement guideline (7 CFR 2902, Subpart B);

and (2) for which USDA has provided purchasing recommendations.

1.2 CODES AND STANDARDS

A. AEDC Environmental Policy:

http://www.arnold.af.mil/Portals/49/documents/AFD-160204-029.pdf

IRA-4868 Appendix A-2

B. AEDC Safety, Health, and Environmental (SHE) Standards latest version, available upon request from the Government.

1. A6 with Supplement User and Subcontractor Safety

(Mandatory Documents/Submittals).

2. A10 Job Safety Analysis.

3. B1 Master Work Permit.

4. B2 Lockout Tagout (LOTO).

5. B4 High Voltage Electrical Work.

6. D10 Scaffolds.

7. E18 Managing Wastes Containing Chemical or Petroleum Products.

8. F2 Personal Protection Equipment (PPE).

C. Air Force Federal Acquisition Regulation:

1. AFFARS 2.101 Definitions of Words and Terms.

2. AFFARS 23.401 Use of Recovered Materials Definition.

3. AFFARS 52.223-9 Estimate of Percentage of Recovered

Material Content for EPA-Designated Items.

4. AFFARS 5352.223-9000 Elimination of Use of Class I Ozone Depleting Substances (ODS).

D. Code of Federal Regulations, latest version:

1. 7 CFR 2902 Subpart B Guidelines for Designating Biobased

Products for Federal Procurement, Designated Items.

2. 29 CFR 1926.1101 Asbestos.

3. 40 CFR 261 Identification and Listing of Hazardous

Waste.

4. 40 CFR 370 EPA Hazardous Chemical Reporting and

Community Right to Know Requirement.

1.3 JOB CONDITIONS

A. Plan and execute this project in a manner to minimize downtime. Schedule all work in advance with the Government Representative.

B. Work may require coordination with test schedule. Coordinate with Government Representative.

C. Furnish new components and devices, complete, with all necessary materials for installation to meet this objective.

D. Do not interrupt existing utilities or commence power outages without signed authorization from the Government Representative. Submit each utility outage request for Government approval at least two weeks prior to

IRA-4868 Appendix A-3 each requested outage date. Outages may be granted depending upon the Government’s schedule for facility use, and may occur on weekends and/or holidays.

E. Keep work area clean and free from waste and debris. Dispose of waste as directed by the Government Representative.

F. Do not close or obstruct egress width to any building or site exit without written permission from the Government Representative.

G. Do not disable or disrupt building fire or life safety systems without written permission from the Government Representative.

H. Conform to applicable procedures when any hazardous or contaminated materials are discovered.

I. Cease operations immediately for any unsafe conditions and notify the Government Representative. Do not resume operations until authorized by the Government Representative.

J. Provide temporary barricades and other forms of protection as required to protect Government personnel and the general public from injury due to the work. Provide temporary signage as needed or directed in accordance with AEDC SHE Standard B3.

K. Remove protections at the completion of work.

L. Do not close, block, or otherwise obstruct streets, walks, or other occupied or used facilities without written permission from the Contracting officer.

M. Submit sketches of proposed scaffolding, if utilized. All scaffolding shall be in accordance with AEDC SHE Standard D10 and shall be inspected, approved, and tagged by the Contractor’s scaffold competent person after it has been erected and prior to use.

N. Submit record as-built drawings.

1.4 PROTECTION OF EXISTING IMPROVEMENTS:

A. Protection of the grounds, walkways and structures from deterioration due to excessive vehicular traffic, equipment disturbance, and material staging is critical to maintaining the quality appearance of AEDC. The Contractor shall protect against damage incurred by service vehicles, construction activities, maintenance and repair, and all other work that detracts from the overall appearance of the grounds and increases the costs of grounds maintenance.

IRA-4868 Appendix A-4

B. Prior to commencement of work, inspect areas in which work will be performed. Submit a report with the Contracting Officer listing existing conditions which could be construed as damage resulting from the work.

The Government Representative may also photograph or video tape areas or improvements susceptible to damage to document conditions prior to the start of work.

C. The activity of vehicles and equipment on the grounds shall be limited to only that which is essential and required for completing the work. The Government Representative will approve all access and haul routes required for the work prior to any on site operations to preclude damage to sensitive utilities or improvements which may not be readily apparent.

D. Minimize travel paths and staging areas to limit the impact and damage to work areas. Lay out the work site, material and equipment staging, and vehicle and equipment activity to minimize visibility and aesthetic impact of activities to surrounding areas.

E. Protect above and below grade utilities, plant life, lawns, and other features or improvements to remain.

F. Protect benchmarks, existing structures, sidewalks, curbs, and pavements from excavation equipment and vehicular traffic.

G. Use protective materials, such as sheeting, steel plating, rigger pads, to protect grounds and pavement from heavy equipment activity and damage.

H. Protect existing facilities from falling debris during construction such as roof materials, ductwork scraps, or other materials, by use of protective materials such as sheeting, steel plates, netting, or other materials.

I. Provide temporary weather protection during any interval between demolition and removal of existing construction on exterior surfaces and installation of new construction to ensure no water leakage or damage occurs to the structure, interior areas, or contents of the existing facility.

J. Implement a daily procedure for area clean up and organized parking of vehicles and equipment.

K. Provide temporary barricades, shoring, bracing, supports or other forms of protection as required to protect all existing improvements not scheduled to be demolished for both above and below ground improvements and to prevent movement, settlement, collapse or damage of any kind.

L. Maintain personnel and vehicular access and existing utilities to all buildings and other structures during the course of the work. Any changes or interruptions shall be coordinated and approved by the Government

IRA-4868 Appendix A-5

Representative well in advance. Temporary protections or services may be required as a condition of approval of any such change or interruption.

M. The Contractor shall be responsible for damage caused by the work and shall repair or replace same to the satisfaction of the Government. Obtain Government Representative’s approval of methods, materials, equipment or products for repair or replacement prior to use. All such repair or replacement shall be performed promptly at no additional cost to the Government. The Government will place special emphasis and requirements for repair or replacement of damage to underground utilities, lawns, grassed areas, existing structures, sidewalks, curbing, railings and pavements.

N. Remove all temporary barricades, shoring, bracing, supports or other forms of protection at completion of work. Restore all adjacent structures and surfaces to conditions existing prior to construction. Clean up all stockpiles and spoil areas, and restore all surrounding areas to conditions existing prior to construction.

1.5 SAFETY REQUIREMENTS:

A. All work shall be accomplished in compliance with AEDC SHE Standards A6 with supplement, A10, B1, B2, B4, D10, E18, and F2. Submit a safety and health plan in accordance with AEDC SHE Standard A6.

1.6 DISPOSAL OF CONTAMINATED EQUIPMENT

A. The Contractor shall clean equipment or material of contaminants prior to disposal at the AEDC Salvage Yard (with the exception of lead paint, unless the paint is flaking in which case the flaking paint shall be removed prior to transport to prevent contamination during transport). If cleaned equipment is to be turned-in to the Government for storage or excessing, a Special Material Turn-in Certification, shall be completed and submitted to the Government with the equipment or material prior to disposal. The Government Representative will assist the Contractor in filling out the form and in coordinating with Industrial Hygiene and Environmental Quality.

1.7 CONNECTIONS TO POTABLE WATER

A. Contractor shall not make any connections to an AEDC potable water system without specific approval from the Government Representative.

B. Notify Government Representative if connections to hose bibs are needed.

Do not connect to any hose bibs without Government-supplied backflow preventer and specific approval from Government Representative.

IRA-4868 Appendix A-6

1.8 DELIVERY, STORAGE, AND HANDLING

A. Deliver all equipment properly packaged in factory containers and/or mounted on shipping skids.

B. Provide and store all equipment in a clean, dry space, and protect from dirt, fumes, moisture, construction debris, and traffic. Ensure that all equipment is prepared for anticipated storage conditions.

C. Where equipment is stored outdoors, ensure electrical components are stored above grade and enclosed with watertight wrapping. Provide 120V temporary power to space heaters or provide temporary heat if required to protect equipment.

D. Notify Government Representative a minimum of two weeks prior to delivery of large equipment being stored on-site. Contractor shall offload equipment at a location designated by the Government Representative.

E. All handling, loading, and offloading of all equipment shall be done by the Contractor.

F. Handle and store all equipment in accordance with manufacturer’s instructions.

1.9 TOOL CONTROL: Coordinate tool control with the Government Representative.

1.10 EPA-DESIGNATED ITEMS

A. (For solicitations and contracts exceeding $150,000 only) (If applicable) The Contractor, on completion of this contract in accordance with AFFARS 52.223-9, shall:

1. Estimate the percentage of the total recovered material content for

EPA-designated item(s) delivered and/or used in contract performance, including, if applicable, the percentage of post-consumer material content; and

2. Submit this estimate to the Contracting Officer.

1.11 ELIMINATION OF ODS CHEMICALS

A. The use of Class I ozone depleting substances (ODS) is prohibited.

Reference text of AFFARS clause 5352.223-9000.

1.12 DISALLOWED PRODUCTS

A. Do not use products or materials that contain lead, chromium, mercury, cadmium, silver, barium, selenium, beryllium, or arsenic on this project except as expressly authorized by the Contracting Officer. If no substitutes for products containing the listed materials are available, and the

IRA-4868 Appendix A-7

Contracting Officer approves the use of products containing the listed materials, highlight and detail their exact location on the drawings.

1.13 ASBESTOS PRODUCTS

A. Do not use products or materials that contain asbestos on this project except as expressly authorized by the Contracting Officer. If no substitutes for asbestos products are available, and the Contracting Officer approves the use of asbestos products, highlight and detail their exact location on the drawings and identify their location in the field following 29 CFR 1926.1101 guidelines.

1.14 HAZARDOUS WASTE

A. Where hazardous waste (as identified in 40 CFR 261) is generated, follow the procedures in AEDC SHE Standard E18, Chemical and Petroleum Products Waste Management, for storing and turning in hazardous waste.

These procedures include the requirement to the Waste Identification Form (WIF) and, if applicable, the Chemical Waste Data Sheet (CWDS), which will be furnished by the Government Representative.

1.15 HAZARDOUS MATERIAL IDENTIFICATION AND MATERIAL SAFETY DATA

A. The following procedures shall be followed to meet 40 CFR 370, EPA Hazardous Chemical Reporting and Community Right to Know Requirement.

1. Procedures:

a. The Contractor shall furnish information on the hazardous materials he brings on AEDC property prior to beginning on-site work. Hazardous materials may include solvents, paints, adhesives, acids, or any other substance which could be included within the definitions in paragraph 2.

b. The information required is:

1) Company name, point of contact, and phone number.

2) Brief statement indicating how the hazardous material will be used within the scope of the contract.

3) List of all hazardous materials to be used (product name, manufacturer’s name, and address).

4) Amount of each material to be stored on site and where it will be stored.

5) Where the product Safety Data Sheet (SDS) will be maintained.

c. All unused product is the responsibility of the Contractor and shall be removed from AEDC property at the completion of the project.

IRA-4868 Appendix A-8

d. The Contractor shall coordinate with the Government Representative and the Hazardous Waste Operations Group (454-3628) if any hazardous waste is to be generated.

2. Definitions

a. Hazard communication standard. A chemical right-to-know law under OSHA that requires chemical manufacturers and importers to assess the hazards of chemicals they make or import and to distribute this information to inform workers of the hazards associated with these chemicals. This written information is a Safety Data Sheet (SDS).

b. Hazard classes. Hazardous materials that have been grouped into classes by the Department of Transportation (DOT).

These classes include explosives, flammables, oxidizers and organic peroxides, compressed gases, corrosives, and poisons.

c. Hazardous material. Any substance that may be harmful when used. Specific substances have been designated as hazardous under the Clean Water Act, the Resource and Conservation and Recovery Act, and the hazardous air pollutants under the Clean Air Act.

d. Hazardous waste. Any waste that may cause or significantly contribute to serious illness or death or that may pose a substantial threat to human health or the environment, if not properly managed. Hazardous wastes may be solids, liquids, semi-solids, or compressed gases.

1.16 PROPRIETARY AND BRAND NAMES: Proprietary and brand names used in this document are meant to describe physical, performance, and quality characteristics of items and materials, and are not meant to limit competition or exclude Contractors, Vendors, or Manufacturers from submitting like products to the Contracting Officer for approval.

END OF APPENDIX A

IRA-4868 Appendix B-1

APPENDIX B

SUBMITTAL PROCEDURE

PART 1 GENERAL

1.1 DESCRIPTION OF REQUIREMENTS. This section specifies procedural requirements for non-administrative submittals, including but not limited to shop drawings, product data, manufacturer’s certificate, design data, calculations, and verifications, manufacturer’s instructions, manufacturer’s field service reports, samples, operation and maintenance manuals, and other miscellaneous work-related submittals. These submittals are required to amplify, expand, and coordinate other information contained in the contract. This section describes the type and content of submittals that may be required for this work. The required submittals are included in the Statement of Work or Specification.

Non-work-related submittals are addressed elsewhere in the contract rather than in the specification and may include items such as: contract progress schedule, permits, payment applications, performance and payment bonds, insurance certificates, and progress reports.

The Contracting Officer may request submittals in addition to those specified when deemed necessary to adequately describe the work covered in the respective sections of the Specification or Statement of Work.

1.2 SUBMITTAL PROCEDURE

A. Definition: For the purposes of this section, the term “Contractor” denotes the prime Contractor.

B. Listing: At the end of this section is a summarized listing of item submittals requiring approval for the work. The listing is included for the convenience of users of the contract documents. The listing may not be all inclusive and additional item submittals may be required. Within 14 calendar days after receiving contract award, Contractor shall submit a copy of the summarized submittal listing with calendar dates assigned to each item submittal indicating when submittal will be received by the Government. If contract requires a pre-construction conference, Contractor may submit completed submittal listing at the conference.

C. Risk: Do not proceed with the part of the work covered by an item submittal including purchasing, fabricating, and delivering until approval is received.

Machinery, equipment, material, and articles that do not have the required approval shall be installed or used at the risk of subsequent rejection. Any fabrication or other work performed in advance of the receipt of accepted item submittals and approvals shall be entirely at the Contractor’s risk and expense.

IRA-4868 Appendix B-2

D. Transmittal Timing: Coordinate the preparation and processing of item submittals with the performance of the work. Prepare and transmit each item submittal to the Contracting Officer sufficiently in advance of the performance of related work and other applicable activities. Transmit related item submittals for the same unit of work so that processing will not be delayed by the Government's need to review submittals concurrently for coordination. No delay damages or time extensions will be allowed for time lost in late submittals.

E. Content: Each submittal shall be complete and in sufficient detail to allow ready determination of compliance with contract requirements. All submittals which are generic and list more information than is specifically required shall be marked to identify required information. Complete AF Form 3000 and attach as cover sheet for each submittal. Contractor may include multiple item numbers on an AF Form 3000.

F. Language: All item submittals shall be written in English, including documents, notes on drawings, sketches, and/or samples, calculations, manuals, and all other instances of written text and communication.

G. Units: All item submittals shall be marked or show dimensions and values in the same units as specified in the contract documents.

H. Review Time: Allow sufficient time so that contract performance will not be delayed as a result of the time required to properly process submittals, including time for re-submittals, if necessary. Allow 14 calendar days for initial Government processing of each submittal. No extension of time will be authorized because of the Contractor's failure to transmit submittals to the Government sufficiently in advance of the work.

I. Contractor Certification: All submittals shall be carefully reviewed by an authorized representative of the Contractor prior to submission to the Government. Each submittal shall be dated, signed, and certified by the Contractor as being correct and in strict conformance with the contract documents. No consideration for review by the Government of any Contractor’s submittal will be made for any items which have not been so certified by the Contractor. All noncertified submittals will be returned to the Contractor without action taken by the Government, and any delays caused thereby shall be the total responsibility of the Contractor.

J. Deviations: Should any item submittals required by the contract documents show deviations from the contract requirement, the Contractor shall make specific mention of such deviations in the letter of transmittal, including stating cost effects, and product and system limitations which may adversely affect the work, in order that if acceptable, suitable action may be taken for proper adjustment of the contract; otherwise the Contractor will not be relieved of the responsibility for executing the work in accordance

IRA-4868 Appendix B-3 with the contract documents and the approved submittals. Contractor shall clearly mark the proposed variation in all documentation and specifically point out deviations from contract requirements in transmittal letters. Failure to point out deviations may result in the Government requiring rejection and removal of such work at no additional cost to the Government. Deviations from contract requirements require Government approval and will only be considered when advantageous to the Government. When proposing deviations, deliver written request to the Contracting Officer, with documentation of the nature and features of the deviation and why the deviation is desirable and beneficial to the Government. If lower cost is a benefit, include an estimate of the cost savings. In addition to documentation required for deviation, include the submittal information required for the item. Allow an additional 14 calendar days beyond normal submittal review period for consideration by the Government of submittals with deviations.

K. Approved Submittals: The part of the work covered by the approved item submittal may proceed provided it complies with the requirements of the contract documents. Final acceptance will depend upon that compliance.

The term “Approved” shall only indicate that there is no exception taken to the submittal. Approval of the item submittal shall not be construed as a complete check, and indicates only that the general method or other information appears to meet the contract requirements. Approval does not relieve the Contractor of the responsibility for any error which may exist.

After item submittals have been approved by the Contracting Officer, no resubmittal for the purpose of substituting materials or equipment, or changes to any other information will be considered unless accompanied by an explanation of why a substitution or change is necessary.

L. Disapproved Submittals: Contractor shall correct disapproved item submittals and resubmit for approval within timeframe noted. If no date is given, Contractor shall submit corrected submittal within 14 calendar days.

If the Contractor considers any correction or notation on the returned submittal to constitute a change to the contract drawings, specification, or statement of work the Contractor shall notify the Contracting Officer.

M. Responsibility: The Government’s review of Contractor submittals shall not relieve the Contractor of the entire responsibility for the correctness of details and dimensions and conformance to the specifications. The Contractor shall assume all responsibility and risk for any mistakes and/or costs due to any errors in submittals.

N. Inconsistencies: If a conflict or inconsistency arises between an approved item submittal and the contract documents, the contract documents shall govern.

IRA-4868 Appendix B-4

1.3 SPECIFIC SUBMITTAL DESCRIPTIONS AND REQUIREMENTS: Submittal requirements for individual units of work are specified in the applicable specification section or Statement of Work (SOW). Except as otherwise indicated in the individual specification sections or SOW, comply with the following requirements for each type of submittal.

A. Shop Drawings: These are technical drawings and data specially prepared for this contract including fabrication and installation drawings, setting and seaming diagrams, and coordination drawings (for use on-site). Shop drawings include drawings, diagrams and schedules specifically prepared to illustrate some portion of the work, diagrams and instructions from a manufacturer or fabricator for use in producing the product and as aids to the Contractor for integrating the product or system into the project, or drawings prepared by or for the Contractor to show how multiple systems and interdisciplinary work will be coordinated. Information required on shop drawings includes dimensions, identification of specific products and materials which are included in the work, compliance with specified standards, and notations of coordination requirements with other work.

Provide special notations of dimensions that have been established by field measurements. Highlight, encircle, or otherwise indicate deviations from the contract documents on the shop drawings. Furnish one hard copy and one electronic copy in AutoCAD 2007 through 2015 drawing file format (.dwg).

The only permissible text font is ROMANS. Custom fonts and shapes are prohibited. The minimum allowable font size shall be 0.125-inch. The maximum allowable font size shall be 0.25-inch.

B. Product Data: This data includes standard printed information on manufactured products that has not been specially prepared for this contract, including manufacturers' product specifications illustrating size, physical appearance and other characteristics of materials, installation instructions, standard color charts, catalog cuts, illustrations, schedules, standard wiring diagrams, standard product operating and maintenance manuals, and samples of warranty language when the contract requires extended product warranties. General information required specifically as product data includes manufacturers' standard printed recommendations for application and use, compliance with recognized standards of trade associations and testing agencies, the application of their labels and seals (if any), special notation of dimensions which have been verified by way of field measurement, and special coordination requirements for interfacing the material, product, or system with other work. Furnish three hard copies and one electronic copy.

C. Samples: These are physical examples of work, including, swatches showing color, texture, and pattern, color-range sets, and units of work to be used for independent inspection and testing. Samples include fabricated or unfabricated physical examples of materials, equipment or workmanship that illustrate functional and aesthetic characteristics of a material or product

IRA-4868 Appendix B-5 and establish standards by which the work can be judged, color samples from the manufacturer’s standard line (or custom color samples if specified) to be used in selecting or approving colors for the project, and field samples and mock-ups constructed on the project site to establish standards by which the ensuring work can be judged. This includes assemblies or portions of assemblies which are to be incorporated into the project and those which will be removed at conclusion of the work. Submit samples for the Contracting Officer's visual review of general kind, color, pattern, and texture for a final check of the coordination of these characteristics with other related elements of the work and for quality control comparison of these characteristics between the final sample submittal and the actual work as it is delivered and installed. Submit one each.

D. Design Data: Design data includes design calculations, mix designs, analyses or other data pertaining to a part of work. Refer to individual sections of the specification or statement of work for required quantities, formats, and signatures or certifications required. Furnish three hard copies and one electronic copy.

E. Test Plans and Reports: Test plans shall include planned testing, including a description of the test, equipment and supplies needed, and step-by-step notation of test activities and tasks. Test reports include reports signed by an authorized official of a testing laboratory that a material, product or system identical to the material, product or system to be provided has been tested in accordance with the specified requirements. Testing shall have been within three years of date of contract award for the project. Reports also include findings of tests required to be performed by the Contractor on an actual portion of the work or prototype prepared for the project before shipment to the job site, findings of tests made at the job site or on a sample taken from the job site, investigation reports, daily logs and checklists, and final acceptance test and operational test procedures. Furnish three hard copies and one electronic copy of each such report required.

F. Certificates: These include statements printed on the manufacturer’s letterhead and signed by the responsible officials of the manufacturer of a product, system or material attesting that the product, system or material meets specification requirements. Certificates include documentation required of the Contractor, or of a manufacturer, supplier, installer or subcontractor through the Contractor, to further demonstrate the quality of orderly progressions of a portion of the work by documenting procedures, acceptability of methods or personnel qualifications. Examples include confined space entry permits, and text of posted operating instructions.

Certificates shall be dated after award of the project contract and clearly name the project. Furnish three hard copies and one electronic copy of each certificate required.

IRA-4868 Appendix B-6

G. Manufacturer’s Instructions: Preprinted material describing installation of a product, system or material, including special notices and Material Safety Data sheets concerning impedances, hazards and safety precautions.

Furnish three hard copies and one electronic copy.

H. Manufacturer’s Field Reports: Documentation of the testing and verification actions taken by a manufacturer’s representative at the job site, in the vicinity of the job site, or on a sample taken from the job site, on a portion of the work, during or after installation, to confirm compliance with the manufacturer’s standards or instructions. The documentation shall be signed by an authorized official of a testing laboratory or agency and shall state the test results, and indicate whether the material, product, or system has passed or failed the test. Furnish three hard copies and one electronic copy.

I. Operation and Maintenance Data: Data furnished by the manufacturer, or the system provider, to the equipment operating and maintenance personnel, including manufacturer’s help and product line documentation necessary to maintain and install the equipment, and needed by operating and maintenance personnel for the safe and efficient operation, maintenance, and repair of the item. The data is intended to be incorporated in an operations and maintenance manual or control system. Furnish two hard copies and one electronic copy.

J. Final Design Drawings and Documentation: Final design documentation including drawings, specifications, estimates, and other required deliverables. Electronic documentation submitted shall include every associated component file of drawings and other documentation, including raster images, jpeg, tiff, Excel, and any related items required to view, modify, or manipulate the electronic files. Furnish a CD-ROM of all final design documentation, and drawings in AutoCAD 2007 through 2015 drawing file format (.dwg), to the Contracting Officer for approval prior to applying for final payment. The drawings shall be fully editable using AutoCAD software. In addition, drawings shall be delivered to clearly show the location and arrangement of all materials and equipment. The only permissible text font is ROMANS. Custom fonts are shape files are prohibited. The minimum allowable font size shall be 0.125-inch. The maximum allowable font size shall be 0.25-inch.

K. Record (As-Built) Drawings: Record drawings showing final configuration of work accomplished. Show all changes, additions, and deviations from the original contract drawings and documentation. If no changes occur, furnish certification to that effect. Drawings shall be redlined electronic drawings, unless waived by the Government, and shall accurately show as-built conditions during the progress of the job. Furnish drawings on a CD-ROM, in AutoCAD 2007 through 2015 format, including every associated component file of the drawings, including raster images, jpeg, tiff, Excel, and

IRA-4868 Appendix B-7 any related items required to view, modify, or manipulate the electronic files.

Submit to the Contracting Officer for approval prior to applying for final payment.

L. Miscellaneous Submittals: These are work-related, non-administrative submittals that do not fit in the previous categories, including the following:

1. Maintenance agreements. Furnish one hard copy and one electronic copy.

2. Survey data and reports. Furnish one hard copy and one electronic copy.

3. Project photographs. Furnish both hard copies and digital files.

4. Keys and other security protection devices.

5. Maintenance tools, spare parts, and overrun or maintenance stock.

Refer to individual sections of the specification for required quantities of spare parts, extra and overrun stock, maintenance tools and devices, keys, and similar physical units to be submitted.

6. Qualification certificates. Furnish one hard copy and one electronic copy.

7. Employee training certificates and documentation showing successful completion of training.

8. Documentation of percentage of recovered material content used during contract.

9. Contractor safety and work plans and schedules.

10. Warranties.

END OF APPENDICES AND SOW