Attachment 0001 - Statement of Work.pdf

Scope of Work (SOW) for

Pyrotechnics Equipment System April 2024

1.0 BACKGROUND

Crane Army Ammunition Activity (CAAA) is an Army tenant at Naval Support Activity, Crane approximately 40 miles southwest of Bloomington, Indiana. One of CAAA’s missions is manufacturing various pyrotechnic devices in support of the warfighter.

Some of the pyrotechnic production process steps at CAAA include drying, pulverizing, weighing, pressing, and data collecting. The specific existing equipment specifically related to this modernization project is as follows:

• Many chemicals used in pyro production require drying, as moisture content has a significant impact on the proper performance of pyrotechnic items. Steam ovens are currently used for this purpose.

• Some chemicals used in pyrotechnic production must be processed to a specific micron size. The equipment used for this process is a pulverizer. The chemicals are currently manually loaded into the pulverizer by an operator. The speed and feed of the pulverizer are then adjusted by the operator to process the material to the required micron size. The speed and feed are manually recorded in a logbook.

• Materials used in production also need to be accurately weighed per the formula and batch size. Digital scales are used for this purpose.

• Hydraulic presses consolidate the mix into the vessel. There is currently no data able to be captured for this cyclic process (hydraulic pressure, cylinder travel distance and speed, etc.). Three times per day the quality inspector manually records the data shown on the screen; a calibrated load cell is used at the beginning and end of the shifts to ensure the press is consolidating correctly. This information is also recorded by the quality inspector.

To improve the operation’s efficiency, quality, and reliability CAAA desires to modernize portions of the existing equipment system with this project to include incorporation of an automatic data collection system to record and maintain data that is currently recorded manually.

2.0 PROJECT SCOPE

This project’s scope of work includes all necessary work for a turn-key equipment system including finalization of the design/layout of the system as well as exiting equipment demolition/removal, new equipment procurement, full installation, prove-out, and any necessary operator and maintenance personnel training.

The contractor shall furnish all the necessary engineering, labor, technical support, documentation services, and materials for the equipment. Other project-specific requirements:

• This contractor is responsible for running power from existing panels/disconnects to the equipment provided in this contract. See Encl 1 for a facility drawing including equipment locations and available power.

• Contractor shall ensure no significant building modifications will be necessary for equipment incorporation (foundations, larger openings, etc.). Existing floor slab is 6” reinforced concrete. Door dimensions are listed below.

• Contractor shall provide all documentation required to operate and maintain the equipment and system (operations and maintenance manuals, lock-out/tag-out procedures, preventative maintenance plans, recommended spare parts lists, PLC programs, equipment drawings and schematics, etc.)

• The contractor shall comply with all the federal and state laws and regulations including OSHA and other applicable safety, explosives safety and environmental regulations.

Examples include, but are not limited to:

o NFPA 70E Electrical Code o NAVSEA OP5 Ammunition and Explosives Safety Ashore o DA PAM 385-64 Ammunition and Explosives Safety Standards

• All controllers/computers designed into the system must include stand-alone software (cannot be networked).

Equipment included in the scope of this project includes the following:

2.10 Removal of (7) existing steam ovens and pulverizer. Set in location outside onsite and

CAAA will decontaminate/excess. Existing steam lines shall be removed and capped at entry point to room.

2.11 Seven (7) Non-Sparking Electric Blower Friction Ovens (2 large and 5 small)

2.10.1 Oven sizes to be determined by the following:

Unit Location Room Door Size

Room Height

Approx.

interior oven dimensions

1 (Large) A-wing oven room

72”x96” 120” 48”x48”x64”

2 (Large) A-wing oven room

72”x96” 120” 48”x48”x64”

3 (Small) A-wing oven room

72”x96” 120” 60”x24”x48”

4 (Small) A1 39”x82” 120” 60”x24”x48” 5 (Small) A1 39”x82” 120” 60”x24”x48” 6 (Small) A2 39”x82” 120” 60”x24”x48” 7 (Small) B14 39”x82” 120” 60”x24”x48”

2.10.1 Ovens shall be electrically rated for operation in the following environments:

2.10.1.1 Class 1 Div 1 Group D

2.10.1.2 Class II Div 1 Groups E, F, and G

2.10.2 Ovens shall be designed to safely dry a variety of hazardous chemicals (powdered oxidizers and metals) and class I explosive powders, some of which contain solvents. Materials will be loaded on trays made of non-sparking material and placed into oven for drying. Shelving/trays shall be included.

2.10.3 Ovens shall utilize Rockwell Automation PLC and software for unit control and communication.

2.10.4 Oven shall have an operating temperature of 120-200° F be able to maintain a temperature of ±5° F from setpoint.

2.10.5 Ovens shall have programmable high temp alarms and automatic shut-off.

2.10.6 System shall have the capability to notify designated personnel when ovens have faulted or fallen outside of desired parameters. See details in Data Logging section below.

2.10.7 Individual disconnects shall be provided for each oven to allow isolation of power.

2.10.8 Ovens shall be capable to continually record production information to be incorporated into the project’s localized network. See details in Data Logging section below.

2.11 Nineteen (19) Electric Scales with power supplies per the table below:

Quantity Capacity Accuracy (meet or exceed) 5 60 lb (30kg) 0.1g 7 30lb (15 kg) 0.1g 7 6 lb (3 ig) 0.001g

2.11.1 Scales shall be capable of digitally recording production information and transferring data, for incorporation into the project’s localized network. See details in Data Logging section below.

2.11.2 Scale shall also be capable of storing or receiving pre-programmed required weights based on the “recipe” for various items.

2.11.3 Scales shall include a clear digital weight readout as well as a secondary visual (over/under) display for operators to reduce operator weighing errors.

2.11.4 Scales shall be electrically rated for operation in the following environments:

2.11.4.1 Class 1 Div 1 Group D

2.11.4.2 Class II Div 1 Groups E, F, and G

*Note: Class II Div 1 Group E scales may not be commercially available with 0.001g accuracy. If scales meeting Group E are not commercially available, contractor shall provide scale meeting all other requirements and GOV will mitigate risk of group E hazards by another means.

2.11.5 Scales shall have NIST-traceable long form certification of calibration.

2.12 One (1) Pulverizer with Automatic Loading and Dust Collector

2.12.1 New Pulverizer needs to meet or exceed performance of current Bldg 126 1SH Mikropulverizer Hammer Mill.

2.12.2 Materials pulverized are oxidizers such as Sodium Nitrate, Barium Nitrate and Potassium Nitrate. Material will be required to be pulverized to an average particle diameter (APD) that ranges from 10-20 microns. T-type swinging hammer is preferable method of pulverizing.

2.12.3 Material hopper capacity needs to be a minimum of 50lbs.

2.12.4 Processed material barrel must hold a minimum of 50lbs of processed material.

2.12.5 Dust collector must be able to handle all dust made during pulverizing cycles.

2.12.6 Pulverizer must have interchangeable screens for flexibility between products and must provide easy assembly/disassembly and cleaning to prevent cross contamination between products.

2.12.7 Pulverizer shall be fabricated out of non-sparking materials such as 300 series stainless steel.

2.12.8 Pulverizer shall be capable of recording production information and transferring data, for incorporation into the project’s localized network. See details in Data Logging section below.

2.12.9 All above equipment shall be electrically rated for operation in the following environments:

2.12.9.1 Class 1 Div 1 Group D

2.12.9.2 Class II Div 1 Groups E, F, and G

2.13 Overall Data Logging System including a minimum of thirty-one (31) data logging stations tied back to a central server / computer workstation in the building’s main office. See Encl 2 for a drawing of room designators.

2.13.1 Data logging station locations and required logged information is as follows:

Location Quantity Logged Information Big Oven Room 1 Amount of chemicals in ovens, PA #, time in oven/time out of oven, Oven temp, ability to alert system when temp is out of range, etc.

Tie to HMI from Ovens

A1 1 Amount of chemicals in ovens, PA #, time in oven/time out of oven, Oven temp, ability to alert system when temp is out of range, etc.

Tie to HMI from Ovens

A2 (TNC Oven) 1 Amount of chemicals in ovens, PA #, time in oven/time out of oven, Oven temp, ability to alert system when temp is out of range, etc.

Tie to HMI from Oven

A4 (QA Room) 1 Inspector Name, Batch/PA #, Fisher Data, MicroTrak data, etc.

A6, A8, A11, A12, A14

5 Operators, Batch#, Formula #, Weights from scales, etc.

A15 (Walk-in Oven)

1 Oven temp, Qty. in oven, date and time in oven, ability to alert system when temp is out of range, etc.

Mix Wing (A19- A24)

6 Batch #, screening, PA #, Operators, Mix Time, Formula, etc. records

North Press Line 1 Batch #, Operators, Batch start and finish times, batch quantities, increment weights (collected from scales at each station), press pressure each increment, load cell reading, etc.

Tie into GOV-furnished Human-Machine Interface (HMI) control at press

South Press Line (Flare Press/ Smoke Press)

1 Batch #, Batch start and finish times, batch quantities, load cell reading, operators, increments weights, etc.

Big Weigh Room 1 Batch #, Batch Quantities, increment weights, # of increments per candle, etc.

Pulverizer 1 Speed and feed, average particle diameter, magnehelic monitoring, drum #, operator, material lot #, etc.

This will tie into new Pulverizer HMI that will be purchased as part of this Contract.

Distributing Room B

3 Operators, PA #, Batch#, Formula #, Weights from scales, etc.

Staking Machine 1 Operator, Lot # of parts used, Assy completed.

Tie into GOV-furnished Human-Machine Interface (HMI) control at press

B9/B10 2 Operators, Increments Weights pulled form scales, quantities pressed, batch #, comp batches, etc.

B14 1 Operators, number of delays packed, lot number of delays, etc.

B15 (Walk-in Oven)

1 Oven temp, Qty. in oven, date and time in oven, ability to alert system when temp is out of range, etc.

B16 1 Amount of chemicals in ovens, PA #, time in oven/time out of oven, Oven temp, ability to alert system when temp is out of range, etc.

Tie to HMI from Oven

Inspector (Mobile) 2 Replaces daily production inspection sheets B11, B12, B13, B17, B18

1 Data drops into each cell for future additions to data collecting systems.

2.13.2 The system shall be capable of notifying operators if a value captured in the data logging is out of the specified range for that particular product.

2.10.2 Contractor shall supply the server and computer station necessary to view and store logged information (cannot be networked to CAAA’s network). The system shall be capable of being backed up external to the computer and physically stored.

2.10.3 System redundancy, including a backup server, shall be built into the system to avoid data loss.

2.10.4 All cabling/wiring for data collecting system must be ran in conduit thru main corridor and penetrate walls to equipment in cells when necessary.

2.13.3 All data logging equipment (with exception to servers placed in non-hazardous environments) shall be electrically rated for operation in the following environments:

2.13.3.1 Class 1 Div 1 Group D

2.13.3.2 Class II Div 1 Groups E, F, and G

3.0 EQUIPMENT DESIGN

3.10 The equipment should be of a type previously placed in successful operation and it should embody proven principles of design. Standalone computer system cannot be networked to Army system. The contractor shall furnish finalized details of the equipment to the government for review/ acceptance prior to procuring the equipment. Design information includes (but is not limited to):

3.10.1 A detailed description of the ovens with proposed features including the following at a minimum:

3.10.1.1 Safety features

3.10.1.2 Electrical Hazard Classification

3.10.1.3 Operating temperature

3.10.1.4 Maintenance features and requirements of the equipment

3.10.1.5 External and internal dimensions

3.10.1.6 Materials of construction

3.10.1.7 Power requirements

3.10.1.8 Material drying load capacities

3.10.1.9 Heating system description

3.10.1.10 Air circulation and exhaust system description

3.10.1.11 Control system details

3.10.1.12 Data recording and communication capabilities

3.10.2 A detailed description of the scales with proposed features including the following at a minimum:

3.10.2.1 Electrical Hazard Classification

3.10.2.2 Capacity

3.10.2.3 Accuracy

3.10.2.4 Overall size

3.10.2.5 Data receiving and recording capabilities

3.10.2.6 Communication capabilities

3.10.2.7 Display/readout details

3.10.3 A detailed description of the pulverizer and dust collector with proposed features including the following at a minimum:

3.10.3.1 General size

3.10.3.2 Materials of construction

3.10.3.3 Electrical Hazard Classification

3.10.3.4 Auger speed and hammer feed ranges

3.10.3.5 Hopper design details

3.10.4 A detailed description of the data collection system with proposed features including the following at a minimum:

3.10.4.1 Data collection station details

3.10.4.2 Server capabilities

3.10.4.3 Software overview

3.10.4.4 General facility layout including data drop locations, data collection station locations, and communication lines schematic.

4.0 MEETINGS AND DELIVERABLES

4.10 The following site Visits/meetings shall be incorporated into the project:

4.10.1 Design kickoff and existing plating facility visit (requirements gathering meeting)

4.10.2 Monthly progress meeting (virtual)

4.10.3 Final acceptance (onsite) and government equipment turnover

4.10.4 Training for technical staff and maintenance personnel

4.10.5 Any other onsite or virtual meetings the contractor deems necessary to complete the contract

4.11 Project Deliverables: The following deliverables are required for this project:

4.11.1 Pre-Final Design / Equipment information noted in above section.

4.11.1.1 All equipment information for approval is expected to be submitted as one full package. However, if long lead items necessitate earlier submittal reviews the GOV may review and approve individual submittals ahead of the full package submission.

4.11.2 Project schedule and progress notes including an action item register, updated monthly prior to progress meeting.

4.11.3 Electronic copies of all technical manuals, operator and maintenance (O&M) manuals, etc. for all pieces of equipment.

4.12 Project Schedule: All equipment shall be fully installed and operational within 365 days of contract award. Scheduled installation time shall not exceed 90 days in order to reduce ongoing production down time. Any necessary field training shall also be complete within this timeframe. Timeframe and installation duration are estimates and may change with GOV authorization.

4.12.1 The contractor shall build in a two-week government review period of the equipment submittals for final approval into their overall schedule.

4.12.2 Submittals for items with long lead-times may be submitted ahead of overall equipment information package to expedite project.

5.0 AT Level 1 Training. All contractor employees, to include subcontractor employees, requiring access to Army installations, facilities and controlled access areas shall complete AT Level I awareness training within 15 calendar days after contract start date or effective date of incorporation of this requirement into the contract, whichever is applicable. The contractor shall submit certificates of completion for each affected contractor employee and subcontractor employee, to the COR or to the contracting officer, if a COR is not assigned, within 30 calendar days after completion of training by all employees and subcontractor personnel. AT level I training is available at the following website:

https://atlevel1.dtic.mil/at.

Access and general protection/security policy and procedures. This standard language is for contractor employees with an area of performance within Army controlled https://atlevel1.dtic.mil/at installation, facility, or area. Contractor and all associated subcontractor employees shall provide all information required for background checks to meet installation access requirements to be accomplished by installation Provost Marshal Office, Director of Emergency Services or Security Office. Contractor workforce must comply with all personal identity verification requirements (FAR clause 52.204-9, Personal Identity Verification of Contractor Personnel) as directed by DOD, HQDA and/or local policy. In addition to the changes otherwise authorized by the changes clause of this contract, should the Force Protection Condition (FPCON) at any individual facility or installation change, the Government may require changes in contractor security matters or processes.

For contractors that do not require CAC, but require access to a DoD facility or installation. Contractor and all associated sub-contractors employees shall comply with adjudication standards and procedures using the National Crime Information Center Interstate Identification Index (NCIC-III) and Terrorist Screening Database (Army Directive 2014-05/AR 190-13), applicable installation, facility and area commander installation/facility access and local security policies and procedures (provided by government representative); or, at OCONUS locations, in accordance with status of forces agreements and other theater regulations iWatch Training. This standard language is for contractor employees with an area of performance within an Army controlled installation, facility or area. The contractor and all associated sub-contractors shall brief all employees on the local iWatch program (training standards provided by the requiring activity ATO). This local developed training will be used to inform employees of the types of behavior to watch for and instruct employees to report suspicious activity to the COR. This training shall be completed within 15 calendar days of contract award and within 10 calendar days of new employees commencing performance with the results reported to the COR NLT 10 calendar days after contract award.

For contracts that require a formal OPSEC program. The contractor shall develop an OPSEC Standing Operating Procedure (SOP)/Plan within 90 calendar days of contract award, to be reviewed and approved by the responsible Government OPSEC officer. This plan will include a process to identify critical information, where it is located, who is responsible for it, how to protect it and why it needs to be protected. The contractor shall implement OPSEC measures as ordered by the commander. In addition, the contractor shall have an identified certified Level II OPSEC coordinator per AR 530-1.

For contracts that require OPSEC Training. Per AR 530-1, Operations Security, the contractor employees must complete Level I OPSEC Awareness training. New employees must be trained within 30 calendar days of their reporting for duty and annually thereafter.

Controlled Unclassified Information (CUI). Include DFARS clause 252.204-7012, which requires the contractor to comply with NIST 800-171. Also include DFARS provision 252.204-2019 into solicitations. Acquisition officials should follow procedures outlined in DFARS 204.73 and verify vendors have an adequate NIST SP 800-171 summary assessment score within the Supplier Performance Risk System (within PIEE). If the score doesn't show a medium- or high-level assessment with a score of 110 or better (as described in the "NIST SP 800-171 DoD Assessment Methodology"), include clause 252.204-7020 and obtain the vendor's "system security plan" and "plan of action" for NIST SP 800-171 verification and assurance by Army security officials.