Statement_of_Need_Delta_H_Oven.pdf

STATEMENT OF NEED

ALUMINIUM HEAT TREAT FURNACE

Date: 18 Apr 2016

PREPARED BY: TSgt Shawn Walters, 436 MXS/MXMFA

STATEMENT OF WORK (SOW)

ALUMINIUM HEAT TREAT FURNACE

C-1 SCOPE. This specification sets forth the minimum requirements for the procurement of one (1) Aluminium Heat treat Furnace, to include all components and equipment specified herein.

C-2 APPLICABLE DOCUMENTS

C-2.1 Government Documents.

TECHNICAL ORDER (T.O.) 1-1A-9 CHANGE 12, Aug 2014 - Aerospace

Metals-General Data and Usage Factors.

COMMERCIAL ITEM DESCRIPTION A-A-59375, June 2000 – Furnaces, Heat-

Treating, Electrical, Natural, Atmosphere, Box Type

C-2.1.1 Specifications and Standards. The following specifications and standards form a part of this purchase description to the extent specified herein.

STANDARDS – FEDERAL

FED-STD-H28 - Screw Thread Standards for Federal Service

SPECIFICATIONS – MILITARY

DOD-STD-100E - Engineering Drawing Practices

MIL-STD-130 - Identification Marking of U.S. Military

Property

C-2.1.2 Other Government Documents and Publications. The following other Government documents and publications form a part of this purchase description to the extent specified herein.

U.S. DEPARTMENT OF LABOR

29 CFR 1910 - Occupational Safety and Health Standard (OSHA).

(Application for copies should be addressed to the Superintendent of

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

C-2.2 Other Publications. The following documents form a part of this purchase description to the extent specified herein.

NATIONAL ELECTRICAL MANUFACTURERS' ASSOCIATION (NEMA)

NEMA ICS-1 - Standards for Industrial Controls

NEMA ICS-2 - Industrial Control Devices, Controllers &

Assemblies

NEMA ICS-6 - Enclosures for Industrial Controls

(Application for copies should be addressed to the National Electrical

Manufacturers' Association, 2101 L Street, N.W., Washington, DC 20037-

1580.)

NATIONAL FIRE PROTECTION ASSOCIATION (NFPA)

NFPA 86 - Standard for Ovens and Furnaces 2015 Edition

NFPA 79 - Electrical Standard for Industrial Machinery.

(Application for copies should be addressed to the National Fire

Protection Association, Batterymarch Park, Quincy, MA 02269-101.)

SOCIETY OF AUTOMOTIVE ENGINEERS (SAE)

AMS 2750E – Pyrometry

AMS 2770N – Heat Treatment of Wrought Aluminum Alloy Parts

(Application for copies should be addressed to SAE International, 755 W. Big Beaver, Suite 1600, Troy MI 48084)

C-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 regulations unless a specific exemption is obtained.

C-3 REQUIREMENTS

C-3.1 Design. IAW A-A-59375, Section 3.1, the equipment shall be new and unused, capable of performing its intended function in accordance with the operation and performance requirements specified herein. The equipment shall be specifically built for use in aerospace heat treating and not a modified version of a standard heat treating furnace. The equipment shall be complete, so that when connected to the utilities identified herein, it can be used for any function for which it is designed and constructed. The equipment shall be one of the manufacturer's current, production models which, on the date this solicitation is issued, has been designed, engineered and sold, or is being offered for sale through advertisements or manufacturer's published catalogs or brochures. Products such as a prototype unit, pre-production model, or experimental unit do not qualify as meeting the requirements specified in Section C-3. Nor do products that are a modified version of a standard production model.

C-3.1.1 New Development. If, during the contract period, any new developments are generated that would improve the efficiency, accuracy or productivity of the furnace and its related equipment or decrease its operation costs, the contractor shall notify the Contracting

Officer and the Program Manager.

C-3.1.2 Safety and Health Requirements. Covers, guards, or other safety devices shall be provided for all parts of the furnace that present safety hazards. The safety devices shall not interfere with the operation of the furnace. The safety devices shall prevent unintentional contact with the guarded part, and shall be removable to facilitate inspection, maintenance, and repair of the parts. An energy isolation device shall be installed on the machine designed to accept a lockout device. All furnace parts, components, mechanisms, and assemblies furnished on with the machine, whether or not specifically required herein, shall comply with all of the requirements of OSHA

Safety and Health Standards (29CFR 1910).

C-3.1.2.1 Audible Noise Levels. Audible noise emitted by the equipment shall not exceed 84dba at the operator's work position nor at any other point at a distance of three (3) feet from the equipment, as measured on the "A" weighted scale of a standard Type II sound level meter. All measurements shall be taken with the equipment under a fully operational condition. The points of monitor shall be determined by the inspecting Quality Assurance Official at time of inspection.

C-3.1.2.2 Caution - Warning Plates. Corrosion resistant "Caution" or

"Warning" plates shall be securely attached to the equipment in visible locations, with any safety precautions to be observed by the operator or maintenance personnel permanently marked on the plates.

C-3.1.2.3 Prohibited Materials. Asbestos, mercury, lead, or polychlorinated biphenyl (PCB) shall not be used in any part or component of the machine.

C-3.1.3 Measuring and Indicating Devices. All measuring and indicating devices such as scales, dial indicators, pressure gages, temperature indicators, and other similar devices used on the machine shall be graduated in dual, inch-pound and metric units. Marking on all measuring and indicating devices shall be permanently and legibly engraved or etched on a non-glare background. All dials and other type indicating devices shall be securely mounted in place. Such devices shall be located so as to allow reading from the operator's normal work station.

C-3.1.4 Interchangeability. All replaceable parts shall be manufactured to definite standards, tolerances and clearances in order that any such parts of a particular type or model can be replaced or adjusted without modification of the equipment.

C-3.1.5 Maintainability. The equipment shall be designed and constructed to permit maintenance personnel to easily and effectively service the equipment using a minimal number of tools. Consistent with required maintenance and design of the equipment, the contractor shall provide any special tools required to service the unit. Additionally, the equipment shall be equipped with access covers to facilitate inspection, cleaning and repair or replacement of parts.

C-3.1.6 Construction. The machine shall be constructed of parts which are new, without defects, and free of repairs. The structure shall withstand all forces encountered during operation of the machine to its maximum rating and capacity without permanent distortion or failure.

C-3.1.6.1 Reclaimed Materials. The machine may contain reclaimed materials to the maximum extent possible provided such materials will not jeopardize the intended use, performance, or design life of the machine. Reclaimed materials shall have been collected or recovered from solid waste and reprocessed to become a source of raw materials, as opposed to virgin raw materials. None of the above shall be interpreted to mean that the use of used, rebuilt or remanufactured end products is allowed under this purchase description.

C-3.1.6.2 Welding, Brazing and Soldering. Welding, brazing or soldering shall be employed only where those operations are included in fabrication of the original design. These operations shall not be employed as repair measures for defective parts. Weldments shall be in compliance with ANSI/AWS D14.2-93.

C-3.1.6.3 Fastening Devices. All screws, pins, bolts, and similar parts shall be installed in such a manner as to prevent change of tightness. Those subject to removal or adjustment shall not be swaged, peened, staked or otherwise permanently deformed.

C-3.1.6.4 Threads. Inch-series threaded parts, and metric series threaded parts where used shall conform to FED-STD-H28.

C-3.1.6.5 Castings and Forgings. All casting and forgings shall be free from defects such as scale and mismatching. Processes such as welding, peening, plugging, or filling with solders or pastes shall not be used on castings or forgings to reclaim any defective components for use on the machine. Such processes may be used only for enhancing surface finish and appearance.

C-3.1.6.6 Painting. The equipment shall be painted in accordance with the manufacturer's standard commercial practice. Prior to painting, surfaces shall be properly prepared and primed. Manufacturer's standard color shall be provided.

C-3.1.6.7 Surfaces. All surfaces shall be clean and free of harmful or extraneous materials. All edges shall be either rounded or beveled unless sharpness is required to perform a necessary function. The condition and finish of all surfaces shall be in accordance with the manufacturer’s standard commercial practice.

C-3.1.6.8 Gears. Any gears and pinions contained in the design shall be designed and manufactured of a suitable ferrous material to meet or exceed the requirements of AGMA 2000-A88, AGMA 2001-B88, and AGMA

390.03A for the English (US) system or ISO 54 for the metric (SI) system.

C-3.1.6.9 Ventilation. The equipment shall be adequately cooled or ventilated to preclude premature deterioration of the equipment or any component thereof when utilized under the ambient and operating conditions specified herein.

C-3.1.7 Marking on Instruments, Control Panels, Charts, and Plates.

All words on instruments, control panels, charts, and plates shall be in the English language. Characters shall be permanently marked in boldface on a contrasting background and shall be clearly and legibly marked for function and identification. All plates shall be corrosion resistant.

C-3.1.7.1 Manufacturer's Data. A metal nameplate, or other identifying means, shall be permanently attached to the machine, in a conspicuous location, legibly marked in the English Language with following information:

a. Manufacturer's Name or Trademark

b. Manufacturer's Nomenclature

c. Manufacturer's Model and/or serial number

d. Contract Number or Order Number

e. Date of Manufacture

f. National Stock Number

C-3.1.7.2 Lubrication Chart or Plate. A lubrication chart or plate shall be permanently and securely attached to the machine. The following information shall be furnished on the chart or plate.

Point of lubrication

Service interval

Type of lubricant

Viscosity

C-3.1.8 Electrical System and Control Panel. The electrical system shall conform to all applicable NFPA 79, NEMA MG-1 and 7 standards.

The electrical system shall be designed to operate on 230/480 VAC, 3 phase, 60 hertz power, and shall be initially wired for operation on

480 VAC, 3 phase, 60 hertz. The system including all components shall be designed to operate with a +/- 10% variation in power source voltage. A surge protection shall be provided to protect the controller. The electrical system shall be complete. This shall include any heater element circuit protectors, circuit breakers, switches, relays, starters and 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.

C-3.1.8.1 Enclosures. Construction of the enclosure shall conform to

NEMA ICS 6 standards. The enclosure shall be a NEMA type 12 and shall provide for ventilation of components and shall be designed for an indoor nonhazardous location. All electrical components shall conform to applicable NEMA ICS 1 and 2 standards.

C-3.1.8.2 Motors. Motors shall be rated for continuous duty and shall have ball or roller bearings of the sealed and permanently lubricated type. All motors shall be totally enclosed and fan cooled.

C-3.1.8.3 Worklight. A work light shall be provided for any enclosed maintenance access areas large enough for personnel access, or inside which maintenance must be done on site (such as inside large electrical panels). The light shall have a protective shield, an on-off switch, and shall be adjustable to reflect maximum light on the work area. If a built-in lighting system is provided, the adjustable light described above shall not be required.

C-3.1.9 Hydraulic System. If the design of the furnace requires hydraulics the system shall conform to ISO 4413, and shall be complete, including all pumps, valves, piping, cylinders, and pressure controls.

Overpressure protection shall be provided in the high pressure line to prevent damage to components. A filter system shall be provided to ensure delivery of clean fluid. The hydraulic reservoir shall have means for determining fluid level, a provision for draining, and a clean out access plate if the reservoir is not removable.

C-3.1.10 Pneumatic System. If the design of the furnace requires

Pneumatics the system shall conform to ISO 4414, and shall be complete, including all pumps, valves, piping, cylinders, and pressure controls.

Overpressure protection shall be provided in the high pressure line to prevent damage to components. A filter system shall be provided to ensure delivery of clean air.

C-3.2 Components. The system shall be designed to meet or exceed the requirements for the initial and periodic inspections, calibration and certification standards for temperature uniformity, loaded heating recovery, and temperature control specification requirements as stated in USAF T.O. 1-1A-9, Boeing Process Specifications BAC 5602 and 5621K, McDonnell Douglas Corporation - Douglas Process Standard DPS 1.700, Airbus 80-T-36-1010, and the Society of Automotive Engineers, Inc. -

Aerospace Material Specification AMS 2750E and AMS 2770N. The system also needs to include all necessary equipment for NADCAP certification and full compliance with USAF T.O. 1-1A-9.

The system shall consist of a dual chamber furnace in a stacked (one on top of the other) configuration. The Bottom furnace chamber shall be a solution heat treat furnace. The top chamber shall be an aging furnace.

The system shall include a stainless steel rollaway water quench tank.

The system shall include a furnace temperature controller and temperature recorder sufficient to meet the annotated specifications while operating both chambers independently.

The system shall include a quench delay timing system.

The system shall include all consumables (thermocouples, recommend spares, etc.) and replacement items necessary to operate the system for one year. All supplied thermocouples must be certified to special limits of error as per AMS-2750E and include certificates – traceable to NIST covering the necessary temperature ranges.

C-3.2.1 Solution Heat Treat/Aging Furnace. The furnace and its related systems shall conform to T.O. 1-1A-9 as well as AMS 2750E with respect to pyrometry and to AMS 2770N with respect to the heat treatment of Aluminum. The Furnace and its associated systems shall be capable of achieving NADCAP certification for heat treating Aluminum for aerospace applications. The system must be a standard production model designed for aerospace with proven / documented successful performance in the aviation industry.

The bottom chamber shall be designed for solution heat treating of

Aluminum. The working envelope of the chamber shall be at least 24 inches wide, 16 inches tall and 48. The chamber shall be capable, inherently, of meeting all pyrometry capabilities of a Class 2 furnace from 500F to 1200F according to AMS 2750E. Temperature Uniformity

Survey High / Low locations monitoring must be provided with SAT capability.

The top Chamber shall be designed for aging age-hardenable Aluminum.

The working envelope shall have the same physical dimensions of the bottom chamber. It shall be able, inherently, to meet Class 1 capabilities from 200F to 500F as defined by AMS 2750E. Class 1 is necessary IAW AMS 2770N for the aging of certain 7000 series alloys.

Temperature Uniformity Survey High / Low locations monitoring must be provided with SAT capability.

Steel Construction and Refractory: The outside casing of the furnace should be designed for rugged industrial applications and constructed of a minimum of 3/16 inch plate steel. Structural reinforcement should be integrated within the casing. There should be an air gap between the upper and lower chambers to minimize heat transfer. Refractory insulation materials in the both chambers must be sufficient so as not to allow the surface temperatures to be greater than ambient +60 degrees F.

Re-circulation Air Fans and Baffling System: Each chamber shall incorporate a high volume re-circulating air fan. The fans need to be designed to allow sufficient air changes per minute at the maximum designed operating temperature to achieve the necessary temperature uniformity with no overshoot for each chamber or slow heating locations. The design of the internal duct work must be consistent with allowing only convection heat transfer.

Heating Elements and Power Control: Power control needs to be controlled by Solid State Relays (SSRs) for each chamber.

Each chamber shall include a port adjacent to each of its control and recording thermocouples for the passage of the SAT (system accuracy test) thermocouples. A TUS frame will be provided with the unit that is compatible with high temperatures. A manual, back-up TUS capability shall be included to be used in the event a recorder is not available for the TUS.

Each chamber will have an elevated setting area raised 1-1/2 to 3 inches above the floor/hearth for the placement of parts and centered in the chamber so that parts are not set directly on the floor of the chamber.

Each chamber will have a door limit safety switch which will remove power to the blower and heaters when the door is not closed.

Additionally a timed interlock means of shutting off the fan prior to loading or unloading either chamber is required.

C-3.2.2 Temperature Controller. The primary temperature controller / programmer needs to be capable of up to 40 separate programs with multiple ramp and soak segments, guaranteed soak function, temperature deviation alarms, event alarms, and enhanced auto-tune with the required 0.1% accuracy, and control features. This controller, and control system shall also include audible alarms, indicator lights, and switches, which enhance process repeatability and quality during operation by providing precise duplication of heating cycles, while having the capability to notify operators of any alarm conditions and of the completion of the heating cycle. Must be certified AMS2750E compliant. Controller must come pre-programmed for heat treating common tempers of all standard aerospace Aluminum alloys.

C-3.2.3 Automated Temperature Recorder. Sufficient recording channels are required for a recorder or data acquisition system to comply with

AMS2750E for both chambers simultaneously including the oven control or display temperature, the TUS High / TUS Low positions and the additional quench tank thermocouple. Compliance to AMS2750E is required for NADCAP certification. The recorder and provided software must include the AMS2750E features to track SAT, TUS, and calibration times to alert the operator to potential deviations to AMS2750E compliance. The recorder also provides an overview of T/C usage for all survey T/C’s providing a color coded for early warning screen (5 day expiration and past due). All instrumentation needs to comply with

Type “C” per AMS2750E. Batch software must be included to order to provide a secure record of any parts heat treated. Batch records must be readily retrievable and include all temperature and time stamps to prove proper heat treatment – including quench time delay. Software must be included for network monitoring of the heat treatment process, including remote viewing and records printing. The provided software must enable the operators to easily print out a record of the heat treating profile and include all pertinent information to prove a proper cycle.

C-3.2.4 Quench Tank. The quench tank shall be a stainless steel tank that is located at floor level immediately under the solution heat-treating furnace. The quench tank shall be fitted with locking wheels such that it can be moved underneath the furnace when not in service.

Fill and drain ports and valve shall be provided for simplistic management of the water level. The tank shall be capable of being fitted with a high capacity submersible pump of the manufacturer’s design, or as provided by the manufacturer as a normal optional item.

This shall be an offered option for agitation and maintaining uniform temperature. Operation of the pump must have both a manual and automatic mode. An additional thermocouple shall be installed and capable of communication with the temperature recorder for water temperature monitoring.

C-3.2.5 Quench Timing System. As required per NADCAP certification, the system will have the capability of measuring and recording to the

Temperature Recorder the time elapsed between the chamber opening and the metal entering the quench tank. This system shall be automated and secure.

C-3.2.6 Thermocouples. Each of the two chambers shall have five thermocouples for use in production; the primary temperature controller's, the high limit controller’s, and the recorder’s – chamber temperature and high/low TUS. For compliance to AMS-2750E, provisions shall be made to mount the two additional (High/low TUS) thermocouples to monitor the highest and lowest temperature locations of the most recent TUS. Each chamber shall include provisions to mount the SAT thermocouples. A TUS frame will be provided with the unit that is compatible with high temperatures.

Along with the five production thermocouples, all necessary thermocouples, of the correct types, to perform the TUS and SAT shall be provided along with the necessary cabling and junctions. All thermocouples shall be provided with current N.I.S.T. certified calibrations.

C-3.2.7 Spare parts/consumables. The System shall come with enough spare parts/sets for each component that is regularly consumed in the course of one year. If the part is required to be changed on a

Preventative Maintenance (PM) schedule, the spare parts shall be of sufficient quantity to supply one year of PMs. These would be items such as any necessary spare thermocouples, cabling, junctions etc. All consumable material such as lubricants, quench water conditioners, desiccants, etc. shall be supplied and installed. All spare thermocouples shall be provided with N.I.S.T. certification.

C-3.3 ASSOCIATED EQUIPMENT REQUIREMENTS:

C-3.3.1 Utility Metering. The contractor shall supply a means for monitoring hours in operation, such as a Hobbes meter, or electronic metering which displays on the HMI and/or can be transmitted via network connections.

C-3.3.2 Utilities Interconnection. The GOV shall route and connect required utilities to a contractor specified single location near the equipment. Compressed air, electricity, water, and breaker box(es) shall be located near the system. Contractor shall specify the location of the specific utility that is needed at the 25% review. Once the

Government has approved the location and the requirements any changes thereafter shall be at the contractors own risk, cost(s) of change shall require the contractor to absorb cost(s) making the necessary modifications. This location shall not be changed without written authorization from the Government. The following is the specifics for the utilities available within B9001 (all numbers are typical values):

Air: 80-120 psig

Potable Water: 80F-90F

Chilled Water: 50F-60F 350 GPM – 6000 GPM at the 18” diameter line

Power: 480V and 120V

The contractor shall install an electric power disconnect switch which shall be located about 4 feet above the floor near the equipment. If there are no stanchions near the equipment, the disconnect junction box may be mounted on the outside of the equipment in an easily accessible location. All machine mains for the system shall be routed through the electric disconnect switch. All equipment shall utilize surge protection provided by the contractor with GOV approval. The contractor shall install and put into operation an electric power meter to track power usage on the system. The readout for electricity usage shall be

KWH.

The contractor shall provide any equipment including but not limited to pressure regulators, check valves, shut off valves, in-line filters, water traps, etc necessary to supply the quality of air if the equipment requires shop compressed air. The contractor shall install an emergency compressed air shutoff valve and shall be located about 4 feet above the floor in a Government approved location. All air hoses shall use band-it clamps instead of screw clamps.

C-4 QUALITY ASSURANCE TESTING

C-4.1 Responsibility for Inspection. The contractor shall be responsible for the performance of all inspection requirements specified herein. The contractor may use their, or any other, facility suitable for the performance of the inspection requirements specified herein. All testing shall be done on site after installation. The

Government reserves the right to perform any inspection set forth in the specification where such inspections are deemed necessary to assure supplies and services conform to the prescribed requirements.

C-4.2 Responsibility for Compliance. The furnace shall meet all requirements of sections C-3 and C-4. All instruments, test programs, materials, and tools required to perform and evaluate these tests shall be furnished by the contractor. The test programs and computer printouts shall become the property of the Government.

C-4.3 Quality Conformance Inspection. Quality conformance inspection may be conducted at the point of origin or after installation and shall consist of the examinations in paragraph C-4.5.2. Failure of the furnace to pass this inspection shall be cause for rejection.

C-4.4 Final Inspection and Acceptance. Final inspection and acceptance shall be after installation. Acceptance shall be determined by examination, inspection and tests as specified in paragraph C-4.5 thru C-4.5.5.

C-4.5 Tests. The furnace shall be subjected to the following tests.

All instruments, programs, materials, and tools required to perform and evaluate these tests shall be furnished by the contractor. Any measuring instruments shall have evidence of calibration traceable to the National Institute of Standards and Technology. The test parameters used and results shall be printed and shall become the property of the Government.

C-4.5.1 Test Conditions. All tests shall be performed in an indoor facility with ambient conditions of 41 to 104 degrees Fahrenheit and 20 percent to 95 percent relative humidity.

C-4.5.2 Examination. The equipment shall be examined for design, dimensions, construction, materials, components, electrical equipment, and workmanship to determine compliance with the requirements of

Section C-3 of the contract.

C-4.5.3 Operational Test. The furnace and its control and recording systems shall be operated in accordance with the manufacturer's standard operating test procedure for warm-up (if necessary) and operational checks. A System Accuracy Test (SAT) shall be performed according to AMS 2750E. Afterwards, a Temperature Uniformity Survey

(TUS) shall be performed according to AMS 2750E. All parameters tested shall conform to those standards and shall be in compliance with the necessary standards such that the furnace could be classified as a

Class 1 furnace according to the specifications.

C-4.5.4 Program Verification Test. While using one or more test set-ups devised by the contractor, a Furnace test program shall be run on the Furnace to verify its ability to receive and perform all program functions without malfunction or error.

C-4.5.5 Performance Test at Destination. The performance tests require three parts. Part 1 shall be the Heat treatment of a coupon of

2024 Aluminum sheet to W temper. Part 2 shall be the heat treatment of a coupon of 7075 Aluminum sheet to W temper. Part 3 will require the aging of the 7075 coupon to a T76 temper. These tempers will be verified via conductivity and hardness testing within 10 minutes of quenching for the initial W tempers and after aging for the T76 temper.

The Performance Test can be combined with the Program verification test at the contractor’s request.

C-4.5.6 Documentation. The contractor shall provide three (3) sets of the following documentation in the English language: Operators, programming, electrical maintenance, mechanical maintenance, parts lists, electrical schematics and ladder logic diagrams. One (1) set of subject documentation shall be furnished to the government 10 days after government approval of 100% design review and the balance of two

(2) documentation sets shipped with the machining cell. Further, all

NIST traceable calibration certifications, as well as documentation from all final inspection and acceptance testing shall be furnished to the government upon completion of the acceptance process.

C-4.5.7 Software/Firmware. The contractor shall provide one (1) copy of all software and/or firmware loaded onto any computer, controller, PLC, e-prom or other data storage device. Any pre-programming or preloaded code shall likewise be provided to the US government as a backup copy. This requirement can be provided on a CD, thumb drive, dongle, or any means necessary to re-load the particular device upon which it was originally loaded. Devices bought by the contractor for use as a component of the furnace, which may come with proprietary software and which the contractor has no access to is exempt from this requirement. However, any modifications or programing code utilized or loaded onto or used in conjunction with that third party software must be provided so the US government can perform recovery or reloading of that code should it become corrupted or disabled. This shall become the property of the US government to use in the performance of government objectives with perpetual license.

C-5 TRAINING

C-5.1 Operation/Programming. Within 10 days of acceptance at Dover

AFB, the contractor shall conduct a minimum of 36 hours of on-site training over five consecutive work days, during the hours of 0645 to

1530 for up to four (4) operators. The training shall include instruction and demonstration of both furnace operation and programming of the control unit, as well as use of unique features and/or accessories provided. Training shall highlight the features that lead to compliance with AMS 2750E and AMS 2770N and the importance of those standards with respect to aerospace heat treating of Aluminum.

Training shall be scheduled so as to not interfere with any Federal

Holidays.

C-5.2 Maintenance and Calibration. The contractor shall provide two

(2) separate one (1) day maintenance training courses; one course for system maintenance and one course for calibration of the furnace and associated systems. If the course material for these courses is included as a regular part of the vendor’s training program, the requirement for separate courses may be waived upon Government approval. Maintenance training shall be conducted on-site and can be conducted in conjunction with the operator training if possible.

Training shall be provided for a total of up to four personnel, two (2) each personnel per discipline. On-site maintenance training shall be conducted during the hours of 0645 - 1530. If maintenance training requires classroom facilities, contractor will alert the Government at the design review and space will be made available. Maintenance training shall be scheduled so as not to interfere with Federal

Holidays.

C-5.3 Certifications. All training will include certificates of training to certify operators are trained and authorized to heat treat

Aluminum parts for aerospace applications per required specifications.

Further certification shall include certified Quality Control and

Trainer certifications to employees trained to fulfill those roles.

C-6 DESIGN REVIEW REQUIREMENTS

C-6.1 25% Review. The 25% design review shall take place within 3 weeks of contract award. This review shall show equipment location (to include foot prints of all major pieces), any roof penetrations needed to be ready prior to installation, and utility drops and placement.

This review shall be an onsite visit unless it is deemed unnecessary by mutual consent. Contractor shall be responsible for providing a shop layout design identifying the locations of the major equipment, infrastructure requirements and obstacles that must be addressed.

Design may require modifications due to obstacles, constraints or preferences. These changes to the design shall be made at no additional expense to the Government. Also, a Work Breakdown Structure

(WBS) or timeline that shows major milestone dates, such as design reviews, fabrication dates, delivery, installation, training, design reviews, and completion of each system. The Government shall have 3 week to review and respond to the contractor regarding the proposal.

C-6.2 100% Review. This review shall take place within 3 weeks after

25% review is accepted by the government and shall include all details necessary for the Government to verify that any required changes have been made to meet the stated intent of this SOW. A rough draft of the user manual is due with this review. MSDS(s) for chemicals used in the system and that the contractor is planning on using at the work site shall be submitted at this review. The Government shall have 3 weeks to review and respond to the contractor regarding the proposal. This verification shall come through the contracting office. This review may be an onsite visit, or via teleconference; contractor shall be responsible for identifying the locations of the major equipment and obstacles that must be addressed. The contractor shall be responsible for placing and installation of all equipment and support equipment.

Note: variation from or modification of the design review requirements may be allowed if necessary with written approval of the contracting office.

C-7 ENVIRONMENTAL REQUIREMENTS

C-7.1 Environmental Protection & Safety. The Contractor shall be knowledgeable of and comply with all applicable federal, state and local laws, regulations, instructions and requirements regarding environmental protection and occupational safety and health. The

Contractor shall comply with any laws, instructions or regulation changes during the term of this contract.

Contractors shall be compliant in accordance with Dover AFB supplement to Air Force Instruction (AFI) 32-7086, “Hazardous Materials

Management”, Dover AFB supplement to AFI 32-7042, “Hazardous Waste

Management”, and Dover AFB supplement to AFI 32-7047, “Environmental

Compliance, Release and Inspection Reporting”. Publications are available digitally on e-Publishing website at www.e-publishing.af.mil for downloading or ordering.

C-7.2 Material Safety Data Sheet/Safety Data Sheet (MSDS/SDS). Upon

COR receipt of the “No HAZMAT Usage” certification, the requirements of this section no longer apply.

The Contractor shall not transport, ship or use any chemical, material or substance used in the performance of this SOW on Dover AFB before written approval is provided by 436 AW/CEIE, Natural Infrastructure

Management (Environmental Compliance). The Contractor shall submit to the COR, ten (10) calendar days after contract award date all Material

Safety Data Sheets (MSDSs) or Safety Data Sheets (SDSs) and a completed

MSDS/SDS Information Sheet. The Contractor shall receive approval from the COR prior to shipping any chemical, material or substance to Dover

AFB. A copy of the manufacturer MSDS/SDS shall accompany the shipment.

Contractor shall comply with the effective dates for SDS requirements

IAW the Occupational Safety and Health Administrations (OSHA) Hazardous

Communication Standard, Title 29, Code of Federal Regulation (CFR) Part

1910.1200. The COR will forward all MSDS/SDS submittals to 436 AW/CEIE for approval. A current manufacturer MSDS/SDS shall be submitted to the COR if the Contractor changes manufacturer or vendor for any chemicals that were prior approved. The Contractor shall maintain copies of manufacturer MSDSs/SDSs for all chemicals and MSDSs/SDSs shall be readily accessible at all times by Contractor personnel as well as government employees.

http://www.e-publishing.af.mil/

C-7.3 Hazardous Material (HAZMAT). If no HAZMAT will be brought on base or used in performance on this contract, the contractor shall certify “No HAZMAT will be brought on base” or “No HAZMAT Usage” in writing on company letterhead. This certification shall be provided to the COR within ten (10) days after award. Upon COR receipt of the certification, the requirements of this section no longer apply.

Appropriate penalties for the contractor, or administrative and disciplinary action for the later shall be assessed if found in violation of above certification.

The Contractor shall not store chemicals or hazardous material (HAZMAT) on Dover AFB. Contractors shall be compliant with HAZMAT management procedures per Dover AFB Supplement to AFI 32-7086, “Hazardous

Materials Management”. The Contractor shall maintain a log of all

HAZMAT that is used on base. This usage log shall be provided to the

COR monthly, the last business day of each month, or when the required work is completed. The COR will forward the records to the Unit

Environmental Coordinator (UEC) no later than the fourth (4th) day of the following month or the first (1st) subsequent business day.

C-7.4 Hazardous Waste. If no HAZWASTE will be generated during performance of this contract, the contractor shall certify “NO

Hazardous Waste Generation” in writing on company letterhead. This certification shall be provided to the COR within ten (10) days after award. Upon COR receipt of the “No Hazardous Waste Generation” certification, the requirements of this section no longer apply.

Appropriate penalties for the contractor, or administrative and disciplinary action for the later shall be assessed if found in violation of above certification.

The Contractor shall dispose of contaminated solid waste, spent or processed chemical solutions, used rags and hazardous waste in government furnished waste containers located in the shop or area the work is being performed. The Contractor shall notify the COR if the required waste containers are not available on site.

C-7.5 Discharges. Any discharges into Dover AFB Industrial Waste

Treatment Plant (IWTP) or sanitary sewer will be approved and done IAW

Dover AFB Industrial Waste Water Discharge Permit as instructed by 436

AW/CEIE, Natural Infrastructure Management (Environmental Compliance).

The COR will submit the required notice of intent documentation to the

UEC for 436 AW/CEIE approval. The Contractor shall maintain records of written approval issued by 436 AW/CEIE for discharges into IWTP and sanitary sewer.

C-7.6 Off-Site Discharge. For discharges outside of Dover AFB, the

Contractor shall ensure waste water discharges, that may contain pollutants resulting from any contracted service, go to a state or federal permitted treatment facility such as a municipal Publicly Owned

Treatment Works (POTW). The Contractor shall provide a letter ten (10) calendar days after contract award date to the COR from the POTW that states the POTW is permitted for all pollutants that the Contractor may discharge during the contracted service.

C-7.7 Spills. Upon occurrence of any spill that could enter the storm system or cause any harmful environment effects, the Contractor shall immediately call 911 to report the incident. When possible, the

Contractor shall use a base telephone to receive help from Tinker AFB

911. If using a cell phone, the Contractor shall request Tinker AFB

911. The Contractor shall immediately report all environmental violations to the COR and UEC. The Contractor shall provide five (5) copies of a typed or written report about the incident within four (4) clock hours as follows:

One (1) copy to CO, two (2) copies to the COR, a copy for UEC and one

(1) copy for record. The format of the report shall be left up to the

Contractor, but the report shall contain the following information:

1) Name and contact number of person reporting the spill

2) Date and time of incident

3) Location and source of spill

4) Substance or pollutant spilled

5) Amount spilled and rate of discharge

6) Any damages or injuries involved

7) Extent of area impacted

8) Potential hazards

9) Actions taken

10) Organizations contacted

11) Remarks Section - that addresses the cause of the spill (e.g.

human error, equipment, etc.) and whether 911 was called and which agencies responded.

C-7.8 Environmental Training. Upon COR receipt of the “No Hazardous

Waste Generation” certification, the requirements of this section no longer apply.

Contractor personnel performing duties in the service of this SOW shall have training that acquaints the person with the details of Resource

Conservation Recovery Act (RCRA) regulations in 40 CFR 260 through 279;

applicable State Laws and regulations; DoD, Air Force and local requirements. This training can be obtained through creditable training institutions or companies. All training shall be approved by

436 AW/CEIE, Natural Infrastructure Management (Environmental

Compliance).

RCRA training is available at http://www.natlenvtrainers.com/RCRA-hazardous-waste.htm;

http://www.skillsoft.com/catalog/detail.asp?CourseCode=esh_sah_a34_sh_e nus000000 and http://www.lion.com/Storing-Hazardous-Waste-for-LQGs at the

Contractor’s expense. Prior to obtaining training, the Contractor shall provide the name of the training institution or company and course description to the COR for approval within ten (10) calendar days after contract award date. Once written approval is received from the COR, the Contractor shall provide the environmental training certificates for employees performing duties in the service of this SOW to the COR, within thirty (30) calendar days after contract award date.

In addition to the required environmental training, Contractors shall be compliant with Dover AFB supplemental procedures to AFI 32-7004, “Hazardous Waste Management”.

http://www.skillsoft.com/catalog/detail.asp?CourseCode=esh_sah_a34_sh_enus000000 http://www.skillsoft.com/catalog/detail.asp?CourseCode=esh_sah_a34_sh_enus000000

INSTALLATION RESPONSIBILITIES

Government Contractor

(XX) ( ) a. Provide machine foundation in accordance with the manufacturer’s design requirements.

( ) (XX) b. Furnish labor and material handling equipment for off-loading and placing item on foundation.

( ) (XX) c. Provide and install anchor bolts and nuts.

( ) (XX) d. Set and rough level the machine on its foundation.

( ) (XX) e. Level and align machine.

( ) (XX) f. Connect machine to the provided utilities hook-up.

( ) (XX) g. Provide all necessary materials, tools, gages and instrumentation necessary to perform the required tests.

( ) (XX) h. Provide and charge all systems with fluids in accordance with manufacturer's instructions.

( ) (XX) i. Material and tooling required of the performance testing at Government facility.

GOVERNMENT RESPONSIBILITIES

(XX) Provide unobstructed utilities hook-up within 40 feet of machine.

(XX) Assign one maintenance mechanic (mechanical/hydraulic) and one

Maintenance mechanic (electrical/electronic) to provide information and limited additional materials for the contractor's representative during installation, verification, and initial start up of the machine.

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

CONTRACTOR RESPONSIBILITIES

(XX) Upon verifying and certifying the machine is correctly installed, demonstrate the operation and performance of the equipment. Verification of installation shall be included within the warranty.