Replacement_of_Circulating_Annealing_Furnaces-SOW-Draft.pdf

UNITED STATES MINT

United States Mint-Philadelphia

Replacement of Circulating Annealing Furnaces at Philadelphia and Denver

STATEMENT OF WORK (SOW)

Replacement of Circulating Annealing Furnaces at Philadelphia and Denver

1. Background

The United States Mint is a bureau within the United States Treasury Department that manufactures the nation’s supply of coins, sells numismatic products, and secures the nation’s treasury of gold bullion. It operates 6 facilities throughout the country: West Point, NY; Philadelphia, PA; Denver, CO; San Francisco, CA; Washington, DC; and Fort Knox, KY.

The Circulating Furnaces function is to anneal all circulating coin denominations and are an integral part of the overall coin production process. The United States Mints at Denver and Philadelphia both utilize five (5) rotary hearth furnaces at each location to perform all circulating annealing operations. The existing furnace lines are at the end of life cycle and are in need of replacement. Currently Philadelphia utilizes five (5) Seco- Warwick furnaces while Denver utilizes two (2) Rogers and three (3) AGF furnaces due to footprint constraints. Additionally, the United States Mint has partnered with Fraunhofer USA to develop a study and recommendation regarding the furnace atmosphere composition. This information will be shared at the conclusion of the study.

2. Purpose

The purpose of this SOW is to obtain a Technical Quote (proposal) that identifies the offerors’ specific, approach to completing each of the tasks specified at Section #4 of this SOW The Technical Quote must describe the offerors’ approach through the use of narrative, charts, diagrams, video, etc. Additionally, the purpose of this SOW is to obtain a price quote from offerors’ that identifies the prices per CLIN structure and option year over the life of this entire project.

3. Scope

The general scope of this project is to design, build and install blank annealing furnace lines (furnace, washer, dryer, conveyors, atmosphere equipment, electronic controls, etc.) for circulating coin production at the United States Mint at Philadelphia and Denver. The scope of this project encompasses the following specific tasks (each described in detail in Section #4 of this SOW). Please note that the Contractor may be required to perform some of these simultaneously.

1. Preliminary Design

2. Design review with United States Mint team

3. Demolition and removal of existing furnace

4. Delivery and installation of replacement furnace to Denver or Philadelphia

5. Integration of all electronic controls and systems

6. Start-up and testing

7. On-site training for Mint personnel

8. Documentation

9. On site service and maintenance

4. Specific Tasks

The United States Mint Manufacturing Directorate requires that the offeror independently complete each of the following specific tasks. Offerors’ Technical Quotes must identify their step-by-step approach to performing these tasks, indicating the estimated amount of time required to complete each.

Task 1 (Preliminary Design)

The contractor shall submit proposed design and statement of capabilities for review and approval. The design shall be inclusive of the furnace and all subcomponents (such as: furnace, washer, dryer, conveyors, atmosphere equipment, electronic controls, etc.) in order to fully anneal blanks to the criteria below. The contractor shall identify all governing standards and codes in their proposal. All codes and standards shall be the latest version or publication.

Throughput and footprint requirements: The proposed design shall meet or exceed the desired throughput rate while not exceeding the available footprint given below:

Philadelphia:

Desired Throughput (lbs/hr): 6000 Available footprint (L’ x W’): 272 x 94

Denver (Rogers):

Desired throughput (lbs/hr): 4000 Available footprint (L’ x W’): 80 x 15 Height: 14’ to hook, 17’ to I-beam

Denver (AGF):

Desired throughput (lbs/hr): 2400 Available footprint (L’ x W’): 60 x 14 Height: 17’ to hook, 20’ to I-beam

If the desired throughput rates are not feasible, the design shall maximize throughput while not exceeding the available footprint.

This design is inclusive of the furnace feed operation. The contractor shall identify the proposed method of blank delivery to the furnace line.

Annealing atmosphere composition shall be recommended by the offeror and shall consider available footprint, cost of implementation, safety and code compliance. The atmosphere shall protect against oxidation during the annealing process. The current annealing requirements are as follows:

Hardness:

Strip Hardness (HR15T) 1c 5c 10c 25c 50c G$

Max 92 92 92 92 92 92 Min 80 85 85 85 85 85

Annealed Hardness (HR15T) 1c 5c 10c 25c 50c G$

Upper 72 60 60 60 68 68 Lower, but may be softer 62 50 50 50 60 60

Temperature and Composition:

1c 5c 10c 25c 50c G$

Annealing Temp (F) N/A 1600 1245 1315 1350-

1370 1370

Alloy Copper Plated

Zinc

Cupro- Nickel

Cupro- Nickel

Cupro- Nickel

Cupro- Nickel

Manganese - Brass

Composition 2.5% Cu balance Zn

25% Ni balance

Cu

8.33% Ni Balance Cu

8.33% Ni Balance Cu

8.33% Ni Balance Cu

88.5% Cu 6% Zn 3.5% Mn 2% Ni

The furnace shall be required to hold a maximum temperature of 1600F for 30 minutes during the annealing process.

Task 1 (Color):

The requirement for all denominations is a shiny metal finish without discoloration of any type after being washed and dried. However, the Golden Dollar shall drive the atmosphere selection as that composition is the most susceptible to oxidation. The requirements for the CIELAB color space test on the Golden Dollar denomination are:

L≥81, but does not exceed 95, a≤6, but does not fall below 3.5 b≤19.5, but does not fall below 16

The furnace shall be a simply supported structure as opposed to a cantilevered beam type design which has historically caused issues.

The contractor shall design and furnish fully electronic controls and include operator HMI, system monitoring and allow for integration in the building automation system (BAS) at each facility. The furnace shall have a standby mode that will allow the furnace to function unmanned during periods of downtime.

Design documentation shall be provided in original and .pdf formats. All documentation shall be in the English language. Dimensions and weights shall be in the English system of measurement

Task 2 (Design review with United States Mint team):

Once a preliminary design is selected, the contractor will conduct preliminary and critical design reviews with the United States Mint project team.

a) Design reviews will be used to review and confirm design criteria, constraints and other design factors in order to finalize the design for construction and implementation.

b) The contractor shall provide detailed design and documentation of (but not limited to):

a. Demolition plan

b. Construction materials and methods

c. Control and automation logic, parts, programming and integration

d. Points list

e. Integration plan

f. Development of testing plans - Factory Acceptance Test (FAT) and Site

Acceptance Test (SAT)

g. Safety plan

c) This task is not meant to be whole design phase, since the major requirements have been identified in this statement of work.

d) A minimum of five (5) review sessions shall be held with the United States Mint project team.

e) The contractor shall track all submittals, RFI’s, open issues and maintain minutes for this task

f) The United States Mint shall approve the design which will be used in factory acceptance testing (FAT)

g) The United States Mint shall approve the FAT after being performed at the contractor’s facility. Upon successful completion of the FAT, the United States Mint will approve the design for initial implementation at Philadelphia.

Task 3 (Demolition and removal of existing furnace):

Target timeframe for this task is one month. The contractor shall provide all labor, equipment, tools and materials to perform demolition of existing furnace after final acceptance of the FAT.

a) The contractor shall demolish and remove the selected existing furnace.

b) The contractor shall utilize qualified demolition personnel and riggers to remove the existing equipment and perform any hazardous material abatement (if necessary). The contractor shall assume responsibility for cleanup of disposal of all materials associated with demolition.

c) The contractor shall clean up the job site daily to reduce impact on ongoing operations and to minimize visual impact to the tour route.

d) During demolition, no interruptions to ongoing production shall occur. All utilities shall be isolated by the contractor before demolition begins.

e) No United States Mint equipment or tools shall be provided. Use of the overhead crane will be permitted with an approved lift plan and certified operators. A laydown area for dumpsters and tools shall be provided which shall be coordinated through the site manager. All debris collections shall be coordinated with the site manager.

f) Due to the secure nature of the facility, the United States Mint Police reserve the right to inspect all debris prior to final removal from the facility.

g) The contractor shall track all submittals, RFI’s, open issues and maintain minutes for this task

Task 4 (Delivery and installation of replacement furnace):

Target timeframe for this task is two months. The contractor shall provide all labor, equipment, tools and materials to perform installation of new furnace.

a) Following the removal of the existing furnace, the contractor shall make any necessary repairs to the concrete, epoxy or other surfaces associated with the footprint of the existing furnace line.

b) The contractor shall deliver equipment to the United States Mint prior to installation using qualified personnel and riggers.

c) The contractor shall install the new furnace and all associated support equipment. All installation work shall be performed by the contractor and the installation shall be turn key.

d) A phased approach shall be utilized to minimize disruption to ongoing production activities

e) The contractor shall track all submittals, RFI’s, open issues and maintain minutes for this task

Task 5 (Integration of electronic controls and systems):

The Contractor shall perform the following to ensure integration of the furnaces into the United States Mint’s building automation system. This task can be performed concurrently with installation.

a) Integrate the replacement furnace equipment into the existing Building

Automation System.

b) Run all required conduit and wiring per approved design.

c) Integrate all control points per approved design.

d) Install new control panels and HMI per approved design.

e) Provide engineering to program, perform front end setup and configuration, functional testing, Task 6 (Start up and testing):

Target timeframe for this task is one month. The Contractor shall provide all labor, equipment, tools and materials, testing equipment etc. to perform SAT test developed and approved during task 2. Site Acceptance Testing will be approved by the United States Mint Contracting Officer Representative (COR). Contractor will submit two copies (1 .pdf format, 1 hard copy) of the test report to the COR and to the site manager.

Task 7 (On-site training for Mint personnel):

The Contractor shall provide on-site training to Philadelphia and Denver Mint personnel on all aspects of the furnace and associated equipment. Training shall include all training materials, classroom and hands-on training to include theory of operation, operational adjustments, service, maintenance, repair, recommended parts replacement, adjustment procedures, troubleshooting methods. One training session per shift is required. The Contractor shall coordinate with the COR and/or Site Manager to schedule training. Training shall occur after the installation of each furnace.

Task 8 (Documentation):

The contractor shall provide via a full set (3 hardcopies, 1 .pdf and CAD files via CD) of as-built drawings, spare parts lists, O&M manuals and any other applicable documentation to the United States Mint COR and site manager after successful acceptance of furnace line.

Task 9 (Service and Maintenance):

The contractor shall provide a list of all preventative maintenance work and maintenance intervals. The price proposal shall include a maintenance schedule along with proposed cost for a factory technician to perform maintenance at the required intervals. The price proposal shall include a breakdown of hours and labor cost per hour for each option year.