DRAFT IVD SOW.pdf

PURCHASE DESCRIPTION FOR THE ACQUISITION OF AN

UPGRADE TO A IVD SYSTEM AT FLEET READINESS CENTER

SOUTHWEST (FRCSW), BLDG. 472

1.0 SCOPE.

1.1 Scope. The content of this specification describes the minimum requirements for the complete upgrade of an existing Ion Vapor Deposition (IVD) Chamber at Fleet Readiness

Center Southwest (FRCSW). This upgrade shall include a complete installation of all new components provided in this specification to make the current system fully functional for coating metal. The installation provided by the contractor shall include delivery, off-loading equipment, necessary rigging, transportation (including any hotel arrangements for contractor personnel), artisans/skilled labor for completing the work, start-up, and verification testing.

2.0 APPLICABLE DOCUMENTS. The documents listed in this section are cited in sections 3 and 4 of this specification. This section does not include documents cited in other sections of this specification or recommended for additional information or as examples. While every effort has been made to ensure the completeness of this list, document users are cautioned that they must meet all requirements of documents cited in sections 3 and 4 of this specification, whether or not they are listed in section 2.

Unless otherwise specified, the documents listed in the solicitation or contract shall be the current edition at time of solicitation.

2.1 Government Documents.

2.1.1 Specifications, Standards, and Handbooks. The following specifications, standards and handbooks form a part of this document to the extent specified herein.

29 CFR 1910: General Industry, OSHA Safety and Health Standards

(Application for copies should be addressed to the OSHA Publications

Superintendent of Documents P.O. Box 37535 Washington, D.C. 20013-7535)

MILITARY STANDARDS

MIL-STD-130N w/Change 1: Identification Marking of U.S. Military Property

Item Unique Identification Marking (IUID)

MIL-DTL-83488D – Coating, Aluminum, High Purity (1999 edition)

(Applications for copies should be addressed to the Superintendent of

Documents, Government Printing Office, Washington, DC 20402.)

2.1.2 Other Government Documents, Drawings, and Publications. The following other

Government documents, drawings, and publications form a part of this document to the extent specified herein. Unless otherwise specified, the documents listed in the solicitation or contract shall be the current edition at time of solicitation.

LOCAL FACILITY DOCUMENTS

FRCSW North Island Layout Drawings of Facility Engineering Layout Showing designated area for EMAS identified with adequate utility Facility/Aircraft power.

FRCSW 5100/19 Rev D (or latest revision) – Plant Maintenance Energy Control

Procedure (ECP) Form

Applications for these documents shall be addressed to the Technical Point of

Contact (TPOC)

2.2 Non-Government Publications, Specifications, Standards, and Handbooks. The following documents form a part of this document to the extent specified herein. Unless otherwise specified, the documents listed in the solicitation or contract shall be the current edition at time of solicitation.

International Organization for Standardization (ISO)

ISO 4414: Pneumatic Power-General rules and safety requirements for systems and their components

(Application for copies should be addressed to the International Organization for

Standardization (ISO) 1 rue de Varembé, Casepostale56, CH211Geneva 20, Switzerland)

National Electrical Manufacturers Association (NEMA)

NEMA 250: Enclosures for Electrical Equipment (1000 V Maximum)

NEMA MG 1: Motors and Generators

(Application for copies should be addressed to the National Electrical

Manufacturers Association, 1300 N 17th Street, Rosslyn, VA 22209)

National Fire Protection Association (NFPA)

NFPA 70: National Electrical Code

NFPA 79: Electrical Standard for Industrial Machinery

(Applications for copies should be addressed to the National Fire Protection

Association, ATTN: Support Services, 11 Tracy Drive, Avon, MA 02322)

2.3 Order of Precedence. In the event of a conflict between the text of this document and the references cited herein, the text of this document takes precedence. Nothing in this document, however, supersedes applicable laws and regulation unless a specific exemption has been obtained.

3.0 REQUIREMENTS.

3.1 Design. The components offered for the upgrade shall be new and currently commercially available models. A current model is defined as the manufacturer’s currently produced model which, on the date this solicitation is issued, has been designed, engineered, sold or is being offered for sale through advertisements or manufacturer’s published catalogue or brochures. Products such as a prototype unit, pre-production model, or experimental unit do not qualify as meeting the requirements specified herein. The upgrade shall include all components, parts, and features necessary to meet the performance requirements specified herein. All parts subject to wear, breakage or distortion shall be accessible for adjustment, replacement, and repair.

3.1.1 Measuring and Indicating Device Graduations. All measuring and indicating devices on the machine shall be graduated in the inch/pound.

3.1.2 Safety and Health Requirements. All machine parts, components, mechanisms, and assemblies furnished on the machine, whether or not specifically required herein, shall comply with all of the requirements of OSHA 29 CFR 1910.

3.1.3 Audible Noise Level. Audible noise emitted by the components shall not exceed 84 decibels (dB), measured on the “A” weighted scale of a standard Type II sound level meter, at the operator's work position or any point at a distance of three (3) feet from the equipment. Noise generated by the work piece shall be excluded in determining compliance of the equipment with the 84 dB requirements.

3.1.4 Hazardous Material Exclusions. Supplies or materials being provided as part of the equipment shall be free of known hazardous materials. These materials shall not be brought on site without prior approval of the Government. Radioactive materials or instruments capable of producing ionizing radiation as well as materials which contain asbestos, mercury, lithium, methylene chloride, lead (= or >0.06%), or polychlorinated biphenyls

(PCB’s) are prohibited. Definitions of hazardous materials are specified in the latest version, including revisions adopted during the term of the contract, of FED-STD-313F.

Nickel Metal Hydride and lithium batteries are permissible for memory backup. Class I

Ozone Depleting Substances as defined in 40 CFR 82 shall not be used in the performance of this contract or be provided as part of the equipment. Exceptions to the prohibition of these materials must be referred to the Contracting Officer in writing, for consideration, not later than 60 calendar days after effective date of contract and prior to any work being performed.

3.1.5 Environmental Protection. Under the operating, service, transportation, and storage conditions described herein, the machine shall not emit materials hazardous to the ecological system as prohibited by Federal, state, or local statutes in effect at the point of installation.

3.1.6 Lubrication. Means shall be provided to ensure proper lubrication (oil, grease, coolant, etc.) for all moving parts in accordance with manufacturer requirements. Each lubricant reservoir shall have at least a 24-hour capacity. Means shall be provided to indicate a low lubrication condition. All oil holes, grease fittings, and filler caps shall be easily accessible.

3.1.7 Replacement Parts. All parts subject to replacement shall be manufactured to definite dimensions and tolerances. Replacement parts shall be interchangeable without requiring modification. Replacement parts are those that are subject to wear or failure such as gears, bearings, shafts, feed screws, drive belts, pumps, and seals. Electrical replacement parts shall include but not be limited to motors, relays, fuses, switches, magnetics, pushbuttons, light bulbs, braking mechanisms, and solid-state devices. Tooling and accessories normally supplied as standard items shall be considered replacement parts.

Foreign-sourced replacement parts shall either be interchangeable with domestically supplied components or be readily available from a domestic source.

3.2 Components for the Upgrade. The IVD System that is being upgraded shall consist of the following components:

3.2.1 Diffusion Pump, 32 inches. Remove and replace existing diffusion pump with a new 32-inch diffusion pump. The new diffusion pump replacement shall include the following:

1. New seals

2. New water-cooling lines

3. New wiring from the pump to the switch box

4. Thermocouple inside of the pump for monitoring the system.

5. New holding pump with oil mist separator and new connecting clamps and hoses

3.2.2 IVD Chamber Rack. The contractor shall provide a rack that is flat for loading parts into the chamber. The flat rack shall be designed to use the entire chamber working area.

3.2.3 Water System Manifold. The contractor shall remove the exiting water-cooling manifold, water lines, solenoids, flow and pressure gauges, valves, and fittings. All components shall be replaced with new components. This upgrade shall include a water manifold, water lines, and fittings. An alarm feedback panel shall be provided and include all new pressure and flow water cooling gauges.

3.2.4 Poly Cold Cryogenic Coil. The contractor shall install a new Poly Cold Cryogenic system with This upgrade shall be integrated into the control panel. This shall include the pass thru port on chamber modification. The system shall be designed with a 4,000 W unit able cool down up to -98°C with a typical cold trap area of 2.2 m2.

3.2.5 Vacuum Pump Replacement. The contractor shall provide a new roughing and vacuum booster pump. This pump replacement shall include the following:

a. Roughing vacuum pump mounted over anti-vibration pads.

b. Oil mist separator.

c. Replace existing vacuum exhaust system with new to include a low pint drain valve.

3.2.6 Control System Upgrade. The contractor shall incorporate new software called

Pregl Aluminum Ion Vapor Deposition (AIVD) into the control system. This package shall include a Micro-Logix Programmable Logic Controller (PLC) rack with all hardware and software necessary for the complete installation and shall incorporate a voltage and amperage feedback to ensure consistency and repeatability of the parts processed.

Uninterrupted power supply shall be provided to protect computer and PLC from power outages or a hard shutdown of the chamber.

3.2.7 Pneumatic System. The system shall be complete, including all pumps, valves, piping, cylinders, and pressure controls, and comply with ISO 4414.

3.2.8 Electrical System. The machine shall conform to NFPA 79. The existing power available at the facility is 460 volt, 3-phase, 60 Hertz (Hz). The electrical system shall be complete, including any electrical transformer(s) that may be required to modify the existing source voltage to the proper operating voltage of the equipment. A properly rated and fused, single disconnect device shall be utilized on the machine with means of lockout in the off position only.

3.2.8.1 Electrical Enclosures. Construction of the electrical enclosures shall be in accordance with NEMA 250 type 12 or current equivalent ISO/EN/DIN/JIS/IEC standards and shall provide for ventilation of components and shall be designed for an indoor non-hazardous location. All electrical components shall conform to NFPA 79 or equivalent

ISO/EN/DIN/JIS standards. The machine shall be provided with interlocks on its electronic cabinet that shall instantly remove power from the equipment when the door is opened in accordance with NFPA 79 or current equivalent ISO/EN/DIN/JIS/IEC standards.

3.2.8.2 Arc Flash Protection. The machine enclosures shall be marked for arc flash in accordance with NFPA 79 Paragraph 16.2.3 “Safety Signs for Electrical Enclosures” or current equivalent ISO/EN/DIN/JIS/IEC standards for arc flash safety.

3.2.8.3 Solid-State Components. Electrical devices used to power electrical motors of control voltage delivered to solid-state electrical components shall be solid-state devices.

Such devices shall be equipped to handle the electrical load imposed by operation of the machine to its maximum potential. The use of selenium in solid-state components shall be restricted to those devices that protect other solid-state components from voltage surge.

3.2.9 Motors. Motors shall be rated for continuous duty. Alternating-current (AC) motors shall be designed to operate on 60-Hz and each motor enclosure shall meet the requirements for a drip-proof enclosure. All motors shall meet the requirements of NEMA

MG-1 or current equivalent ISO/EN/DIN/JIS/IEC standards. Each motor shall have an identification plate in accordance with paragraph 3.4.2 to identify manufacturer, model number, serial number, voltage, amperage, horsepower, phase, frequency, and frame number. Motor horsepower shall be the manufacturer’s standard or standard optional horsepower as indicated on the manufacturer's design and construction drawing(s).

3.3 Standard Tooling and Equipment. All standard tooling and equipment required for proper operation and maintenance of the machine shall be provided.

3.4 Preventive Maintenance. The Contractor shall provide a Preventative Maintenance

(PM) service plan with the ability to provide maintenance for an additional four years of service to maintain two Aluminum Ion Vapor Deposition (IVD) chambers manufactured by

Pregl Inc. model Pro-coat with S/N’s 5629 and McDonald Douglas S/N 27 with PEMA #

65888016316 in Building 472 – FRCSW.

The Preventative maintenance (PM) contract shall be performed biannually and must include the OEM PM schedule for the following components

Mechanical, Diffusion, Holding and Cryogenic Pumps

Vacuum Booster

Hi-Vac, Main, Roughing, Foreline and Holding Valves

Drive and Power Feeds

Nitrogen and Argon System

Miscellaneous Ports

Leak Checks

Cooling Water System

Remove and Inspect all Chamber Shields

Wire Feed Drives

3.4.1. The Contractor shall provide 3 copies of manuals, publications, software, or consumables by electronic means or hard copies that are needed for the continued operation of the IVD equipment, if applicable.

3.4.2. Field Service Report (FSR) (CDRL A001). Upon completion of the PM services, the Contractor shall provide the TPOC a detailed Field Service Report (FSR) (CDRL

A001). The report shall include the name of the technician(s), the date(s), services provided, model and serial numbers of all the equipment serviced, replaced, and/or installed, a detailed report of the work performed. Any discrepancies shall be noted along with a list of parts and/or services suggested to return or keep the equipment fully operational and shall include an estimate of repair time and cost. The FSR shall be provided to the TPOC within five (5) Business days of completing service.

*NOTE: FRCSW personnel are not authorized to direct either verbally or in writing contractor technician/personnel to perform any additional labor services or furnish any additional parts/components outside the scope of this SOW. To do so may constitute an unauthorized commitment. The Contractor company administrator shall instruct their personnel on the work limitations of this SOW and any resultant contract awarded regarding funding limitations.

3.5 Marking on Instruments, Control Panels, and Plates. All words on plates shall be in the English language. Characters shall be engraved, etched, embossed, or stamped in boldface on a contrasting background. All plates shall be corrosion resistant.

3.5.1 Lubrication Plate. A lubrication plate shall be permanently and securely attached to each machine. The plate shall contain the following information:

Points of Lubricant Application

Servicing Interval

Type of Lubricant

Viscosity

Military or Federal Specification for Each Lubricant (If available)

Size and Type of Each Lubricant Filter

3.5.2 Nameplate. A nameplate shall be permanently and securely attached to each machine. The nameplate shall contain the information listed below. If the machine is a special model, the model designation shall include the model number of the basic standard machine and a suffix identified in the manufacturer's permanent records.

Nomenclature

Manufacturer’s Name

Manufacturer’s Model Designation

Manufacturer’s Serial Number

Power Input (Volts, Total Amps, Phase, Frequency)

Contract Number

Date of Manufacture

3.5.3 Identification Marking of Military Property. An Item Unique Identification

Marking (IUID) shall be provided in accordance with MIL-STD-130N and all applicable documents within the standard with Machine Readable Information (MRI) for item identification marking and automatic data capture. The application of Human Readable

Information (HRI) shall be used in combination with MRI and free text. At a minimum this tag shall contain the information listed in paragraph 3.7.2 Nameplate.

3.6 Technical Data. Three (3) hard copies and one (1) electronic copy of technical data shall be provided with the machine. Technical data shall contain specifications, instructions for the operation, maintenance of the machine and recommended spare parts list. All copies of technical data shall be legible and written in the English language.

3.6.1 Manuals (CDRL A002) / Drawings / (CDRL A002). The contractor shall furnish three (3) hard copies of all technical and maintenance manuals and drawings containing all information in compliance with modifications of the system. The manuals shall provide the data necessary for the programming, operation, and maintenance of the machine and ancillary equipment. The contractor shall furnish one (1) digital copy of the above technical manuals and drawings in PDF file format or Excel on CD-ROM(s), as appropriate. The digital manuals and drawings shall be organized, indexed and referenced similar to the equivalent hardcopy format (i.e. volume, manual, section, etc.).

3.6.2 Maintenance Manuals (CDRL A002). The maintenance manuals shall properly identify in detail the extent of preventive maintenance, repair, and/or troubleshooting of equipment. A complete list of all materials, chemicals, substances, and parts used for the maintenance and operation of the equipment shall be provided to the government.

3.6.3 Onsite Adjustment (CDRL A002). Any upgrades or part replacements made to the equipment shall be under warranty for no less than a year. An updated manual with all adjustments, updates, or changes made to the system shall be provided to the Government via electronic copy.

3.6.4 Plan of Action and Milestones (POA&M) (CDRL A003). The contractor shall provide a POA&M to identify contractor performance dates of all major events from contract award to completion of all contract requirements. The initial POA&M shall be provided during the Post Award Conference (PAC). The PAC shall be held no later than 30 calendar days after contract award. The milestones shall be prepared using a recognized project management technique (preferably Microsoft Project). The Government and the contractor shall review the POA&M on a monthly basis. The contractor shall notify the

Government one day prior to making any changes to the POA&M. The POA&M shall contain such items as engineering, procurement of major hardware, assembly, operational debug, factory acceptance, shipment lead times, installation, training, and final acceptance test.

3.6.4.1 Program Scheduling (CDRL A003): The Contractor shall prepare and submit a project plan or schedule chart using Microsoft Project that delineates itemizing project tasks from contract award to install completion, to include engineering, design, manufacturing, delivery, and acceptance within the POA&M at the Post Award

Conference.

3.6.4.2 Program Review (CDRL A003): The Contractor shall be responsible to submit a program review to the TPOC.

3.6.4.2.1 Engineering Documentation

3.6.4.2.2 System Documentation.

a. Test Report (see section 4.6) (CDRL A004)

b. System User’s Manuals (CDRL A001)

c. Calibration Procedures (CDRL A001)

d. Maintenance / Corrective Maintenance Manuals (CDRL A001)

e. Provisioning Technical Documentation (CDRL A001)

f. Schematics/Drawings (if required) of the Electrical and

Mechanical (CDRL A001)

3.6.5 Post Award Conference. The contractor shall participate in a PAC which will be held 30 days after contract award. The PAC date shall be coordinated between the contractor and the PCO. The contractor shall provide the initial POAM in 3.6.4 for review during the PAC. The contractor shall include the Acceptance Test Plan, 3.6.6, for review during the PAC. The contractor shall be prepared to discuss its proposed mobilization approach with the Government team.

3.6.6 Acceptance Test Plan (ATP) (CDRL A004). The Contractor shall prepare an

Acceptance Test Plan (ATP). The ATP shall be a systematic written instruction on how to verify compliance during Contract Quality Assurance Inspection and the Final

Inspection/Acceptance Test specified in Sections 4.4 and 4.5. The Manufacture’s standard testing procedures shall be included in the ATP. Any procedures necessary for compliance with Section 4 not covered by the Manufacturer’s standard testing procedures, shall be identified and included in the ATP. The initial ATP shall be submitted thirty (30) calendar days ACA for Government review and approval. The accepted test procedures shall become part of this contract.

3.7 Installation. The contractor shall be responsible for the complete installation of the upgrade of the IVD system, to include:

1. Shipping all parts to the facility.

2. All travel and/or housing needed for contractors’ team to complete the required work.

3. All tooling and components needed to complete the upgrade.

4. Contractor is responsible for removing and disposing of all parts/components being replaced on the upgraded IVD.

5. Contractor is responsible for removing and disposing of any waste from the install of any new components stated in this SOW for the complete upgrade of the IVD system.

6. Ensuring the IVD system is fully operational.

For base access and facility related requirements, please see Base Access at the bottom of this Statement of Work (SOW).

3.7.1 Work Stoppage. For unforeseen issues that are found during installation the contractor shall notify the point of contact (POC) and PCO immediately to determine further course of action.

4.0 QUALITY ASSURANCE.

4.1 Responsibility for Inspection. The contractor shall be responsible for the performance of all inspection requirements specified herein. The Government reserves the right to witness any inspections set forth in the purchase description where such inspections are deemed necessary to assure supplies and services conform to prescribed requirements.

4.1.1 Responsibility for Compliance. All items must meet all requirements of Sections 3 and 4.

4.2 Classification of Inspections. The inspection requirements specified herein are classified as follows:

a. Final Inspection/Acceptance Test (Destination) (see 4.5).

4.3 Inspection Conditions. All inspections, tests, and examinations shall be performed in an indoor facility with ambient temperature conditions in the range of 55° F to 100° F and

10% to 95% relative humidity.

4.4 Final Inspection/Acceptance Test (Destination). Final Inspection and acceptance test shall be performed on the machine by a Government representative to ensure conformance with this purchase description. The acceptance test shall be performed only after the machine is installed at its final location. The acceptance test shall consist of the examination in 4.6 and all tests in 4.7. The machine shall pass the examination and all tests to be accepted.

4.4.1 Examination. The equipment shall be examined for design, dimensions, construction, materials, components, electrical equipment and workmanship to determine compliance with the requirements of this specification.

4.5 Tests. Unless otherwise specified within this document, all programs, instruments, materials, material handling equipment, qualified personnel, and tools required to perform and evaluate the tests shall be furnished by the contractor. All measurement tools and indicating devices shall be calibrated in accordance with NIST. Three (3) consecutive failures without completion of the test may be considered cause for rejection of the system.

For the purpose of this test, a “failure” is defined as any equipment malfunction which requires remedial action to restore the system to full operation in accordance with this specification. The contractor shall provide a test report (CRDL A003) on the below tests in section 4.6.1, 4.6.2 and 4.6.3 after the final inspection/acceptance test is completed in section 4.4. The test report shall become the property of the government.

4.5.1 Operational Test.

The IVD chamber should be evacuated to less than 9.0 x 10-5 Torr before back filling with argon in less than 2 hours. A glow discharge cycle should start after the chamber is filled with Argon gas using a high voltage potential this cycle shall take no more than 15 minutes. After the glow discharge cycle is completed all 7 wire feeds and boat racks must be moved forward and back to cover the entire rack where the parts are placed. The wire feeds and boat racks shall be operated in (Manual or Automatic) to test the machines response to the command data. After the coating cycle is completed based on a predetermined recipe the chamber must be able to undergo a Nitrogen cooling cycle that can be adjusted for a specific period of time.

4.5.2 Performance Test. The following requirements utilizing the following cited sections of MIL-DTL-83488D shall be used to ensure the IVD meets the Government’s minimum requirements:

1. Thickness: The test specimens (coupons) shall be one (1) inch by 4 inches by

0.040 inches made of Aluminum, Low Carbon Steel. Measurement of coating thickness by magnetic method for nonmagnetic coatings on magnetic base metals.

Coating thickness shall be a Class 2- 0.0005 inch thick (min) per MIL-DTL-

83488D (1.2.1). For testing aluminum, specimen integrity shall have a Rockwell B hardness change of no more than 3 points. The hardness after coating shall meet the minimum acceptance value for that alloy and temper.

a) Fifteen (15) coupons shall be tested per run. Raw stock sheet, with identifying marks will be provided by the Government.

b) Complicated Geometry components will be provided by the Government for testing.

2. Adhesion Testing: The adhesion of the coating shall not show separation from the base metal at the interface when examined at a minimum magnification of approximately four-diameters. The interface between the aluminum and the base metal is the surface of the base metal before coating. The formation of cracks in the deposit caused by rupture of the base metal but does not result in flaking, peeling or blistering of the deposit shall not be cause for rejection. A Bend or Stress Rupture test shall be utilized for acceptance determination.

3. The coupons which fail either thickness or adhesion testing shall be tested by evaluation of a cross section.

4. Aluminum Purity: Aluminum purity shall be addressed in accordance with MIL-

DTL-83488D.

5. The Subject Matter Expert, Plate Engineer, shall certify all testing on site.

6. A set of 6 steel coupons shall pass a 4-to-5-hour salt spray test per MIL-DTL-

83488D for Class 2 Type II coatings criteria. The appearance of white corrosion products on the aluminum coating during test period shall not be cause for rejection. Processor system shall be operated in the standby mode not less than two

(2) hours. Proper operation of all controls, components, functions, and calibration, adjusting mechanisms shall be checked and verified. Three (3) failed tests in a row may be cause for rejection of the entire system. After successful completion of the operational test, emergency stop devices, accessories and noise level shall be verified during the trial period.

4.5.3 Audible Noise Level Test. The equipment shall be tested for compliance with paragraph 3.1.4. “Audible Noise Level”.

CONTRACTOR RESPONSIBILITIES

a. Furnish labor and material handling equipment for off-loading and placing on IVD system

b. Connect machine to the provided utilities hook-up

c. Provide all necessary tools, gages, and instrumentation necessary to perform the required tests

d. Provide and charge all systems with fluids in accordance with manufacturer's instructions

e. Material for performance testing at Government facility

f. Material handling, Rigging equipment and Qualified Personnel for performance testing

GOVERNMENT RESPONSIBILITIES

a. Provide utilities hook-up within 20 horizontal or vertical feet of the machine.

b. No work shall be performed by customer personnel when the contractor's representative is not in the immediate work area during installation, verification, and initial start-up of the machine.