Attachment 6 - Ink Mill Test Plan.pdf

ACCEPTANCE TEST PLAN

FOR INK MILL

I – Introduction

This document specifies the testing procedures for the Bureau Acceptance Test (BAT) for the Ink Mill. Testing shall be performed in accordance with section C of contract NO.

The BAT will occur at the BEP’s facility, after installation and startup of the equipment.

The purpose of the BAT is for complete demonstration of all requirements by the vendor for acceptance by the BEP. The BEP will furnish all items listed as inputs that the government will provide for the operation of the equipment. The BEP will provide sheets of test or live currency for the performance of the BAT.

During the contractor’s presence within the BEP, the contractor’s personnel shall comply with all requirements and regulations of the BEP’s Office of Security and Office of Environment, Health and Safety.

II – Test Plan

The contractor shall demonstrate equipment conformance with all requirements during BAT. The testing of the requirements shall be divided into three parts: Certification, Static Demonstration/Inspection, and Dynamic Inspection.

1) Certification:

Written documentation for design elements or any other requirements that cannot be reasonably tested or demonstrated during the performance of test shall be provided. Certifications shall be supplied on company letterhead, signed by officer with responsibility for the design of the equipment.

2) Static Demonstration/Inspection:

Static Demonstration/Inspection applies to any requirement that can only be verified while the equipment is not in operational mode or for which demonstration during operational mode would interfere with the operation of the equipment.

3) Dynamic Inspection:

Dynamic Inspection/Demonstration applies to any requirement that can be demonstrated or witnessed while the equipment is in an operational mode and does not impact the performance of the equipment.

An Excel Spreadsheet referencing each and every requirement in the contract shall be created. Within the spreadsheet, for each requirement the following shall be specified:

- Methodology of demonstration

- How compliance will be demonstrated

BAT TEST PLAN

INK MILL

- During which session will compliance be demonstrated

The spreadsheet will be used to track all requirements.

Certification document(s) shall be supplied to BEP on or prior to conducting any testing.

A universal certification document for all systems is acceptable.

All sampling of performance measurements shall be demonstrated in accordance with the type of ink being processed and the corresponding specifications of viscosity, tack and grain size. The sampling plan shall be sufficient to provide an appropriate confidence that the equipment operates as specified.

For complex systems, overall reliability can be verified to the Bureau by certification(s) and/or demonstration(s) of the reliability of individual system components. This approach is recommended in the case of highly restrictive requirements or for systems that demonstration of the entire system reliability would require testing far beyond the intended testing time frame.

The production run on the equipment required the production of a specific quantity of Ink within a specific time period. During the production run, the Ink will be sampled for analysis.

Prior to the testing, the contractor will process ink to ensure the machine is ready for the performance of the test. Contractor will notify the COR when testing is to begin.

If for reasons beyond the control of the Bureau and contractor testing cannot occur on a given day; testing will be arranged to be performed on the next available day.

The test plan shall specify how testing will be performed. The test plan can be changed by mutual agreement between the Bureau and contractor.

During production runs all panels shall be closed and no test equipment shall be permitted to be connected to the Mill. There shall no more than two operators controlling the system.

All production runs shall be conducted as if they were actual production runs occurring.

BEP will supply ink, pigments and any other additive require. BEP will not interfere with the continuous operation of the machine during the production runs. However, Ink Samples may be requested. If the BEP notices an issue with the system or operation of the system that would void the testing results, the BEP will notify the contractor’s representative to stop operation.

III – Bureau Acceptance Test (BAT)

The purpose of the BAT is for complete demonstration of all requirements by the vendor for acceptance by the BEP. The Ink Mill shall be configured for regular production. The BEP will coordinate with the vendor on the type of Ink for the production of the BAT.

Materials: The BEP will provide the ink and additives for the performance of the BAT.

The contractor shall provide any other materials required for the performance of the

BAT.

BAT TEST PLAN

INK MILL

Duration: The BAT is anticipated to require two (2) days for the vendor to successfully demonstrate all requirements. One (1) day will require the operation of the system in production mode.

Tests: During the performance of the BAT, the vendor will be required to demonstrate the following in addition to the production running of the Mill for one (1) days:

- Individual roll cooling Temperature Control

- Hydrodynamic roll pressing system Control

- Speed Control

- Production data entering for fully automatically operation.

- Operation of all protective devices for safe feeding and colleting processed ink.

- Any other input require for operation

V – Final Acceptance

Final acceptance of the Ink will occur after the following:

1. Successful completion of the BAT

2. Successful Training of all BEP personnel

3. Successful Production Validation (PV) by the BEP

4. Successful operation by BEP personnel of the equipment in production for at least twenty (20) days on one (1) shift or 160 hours without any problems or failures in full compliance with the requirements within this contract.

During the Extended Run, the BEP will operate the Ink Mill as instructed. The BEP will monitor and report on the compliance of the Ink Mill with the specified performance requirements.