Attachment One Performance Work Statement.pdf

PURCHASE DESCRIPTION

FOR

MOTOR CONTROL CENTER (MCC) HOUSING UPGRADE

FOR THE

AIR FREIGHT TERMINAL

AT

JOINT BASE PEARL HARBOR HICKAM (JBPHH), HAWAII

CSN BHC717

THIS PAGE INTENTIONALLY LEFT BLANK

Hickam Cover Purchase Description - Page i

TABLE OF CONTENTS

1. SCOPE

1.1. GENERAL SCOPE

1.2. DEFINITIONS

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1.2.1. ACRONYMS

1.2.2. INBOUND

1.2.3. OUTBOUND

2. APPLICABLE DOCUMENTS

2.1. GOVERNMENT DOCUMENTS

2.2. NON-GOVERNMENT DOCUMENTS

3. REQUIREMENTS

3.1. SYSTEM DESCRIPTION

3.2. CHARACTERISTICS

3.2.1. NOISE LEVELS

3.2.2. ELECTRICAL CHARACTERISTICS

3.2.2.1. INSTALLATION CODE

3.2.2.2. CONDUIT

3.2.2.3. GROUNDING

3.2.2.4. FLEXIBLE CONNECTIONS

3.2.2.5. WIRING

3.2.2.6. OVERCURRENT PROTECTION

3.2.2.7. ENVIRONMENTAL PROTECTION

3.2.2.8. DIAGRAMS, CODES, AND DOCUMENTATION

3.3. DESIGN AND FABRICATION

3.3.1. DESIGN CRITERIA

3.3.1.1. RELIABILITY AND AVAILABILITY

3.3.1.2. MAINTAINABILITY

3.3.1.3. ENVIRONMENTAL CONDITIONS

3.3.1.4. STANDARD, COMMERCIAL COMPONENTS

3.3.1.5. STANDARDIZATION

3.3.1.6. SPECIAL TOOLS

3.3.1.7. STRUCTURAL AND SEISMIC REQUIREMENTS

3.3.1.8. OZONE DEPLETING SUBSTANCES (ODS)

3.3.1.9. SAFETY

3.3.1.9.1. OCCUPATIONAL SAFETY AND HEALTH ADMINISTRATION

3.3.1.9.2. PROTECTION AGAINST MOVING PARTS

3.3.1.9.3. PLACARDS

3.3.1.9.4. FAIL-SAFE CONTROLS

3.3.2. WELDING

3.3.2.1. WELDING PROCEDURE QUALIFICATION

3.3.2.2. WELDER PERFORMANCE QUALIFICATION

3.3.3. FIRE PROTECTION

3.3.4. NAMEPLATES

3.3.5. AIRFIELD REQUIREMENTS

Hickam Cover Purchase Description - Page ii

3.3.5.1. VEHICLE ACCESS

3.3.5.2. EAR PROTECTION

3.3.5.3. NIGHT OPERATIONS

3.3.5.4. PROHIBITED AREAS

3.3.5.5. TEMPORARY AIRFIELD CONSTRUCTION WAIVER

3.3.5.6. EMERGENCY EVACUATIONS

3.3.6. PRECEDENCE

3.4. DOCUMENTATION

3.4.1. MANAGEMENT REPORTS

3.4.2. SHOP DRAWINGS

3.4.3. EQUIPMENT MANUALS

3.4.3.1. MAINTENANCE MANUALS

3.4.3.2. ILLUSTRATED PARTS BREAKDOWN MANUALS

3.4.4. CERTIFICATIONS

3.4.5. AS-BUILT DRAWINGS

3.4.6. REFERENCE MATERIAL

3.5. INSTALLATION IMPACT ON, ON GOING AFT OPERATIONS

3.6. CONTRACTOR EXPERIENCE

3.6.1. EXPERIENCE DOCUMENTATION WITH PROPOSAL

3.7. SECURITY REQUIREMENTS

3.7.1. REQUIRED SECURITY INFORMATION

3.7.2. SECURITY TERMS AND CONDITIONS

3.7.2.1. DISQUALIFYING FACTORS FOR UNESCORTED INSTALLATION

ACCESS

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3.7.2.2. CRIMINAL RECORDS/SEX OFFENDER CHECK

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4. QUALITY ASSURANCE PROVISIONS

4.1. GENERAL

4.2. ACCEPTANCE TESTS

4.2.1. SYSTEM CHECKOUT TEST

4.2.2. QUALITY CONFORMANCE TEST

4.2.3. RELIABILITY DEMONSTRATION TEST

4.2.4. MAINTENANCE SUPPORT DURING TESTING

4.3. INSPECTIONS, TESTS, AND CERTIFICATIONS

4.3.1. INSPECTIONS

4.3.2. TESTS

4.3.3. CERTIFICATIONS

JBPHH MCC Housing Replacement - Page 1

1. SCOPE

1.1. GENERAL SCOPE

This purchase description (PD) establishes the minimum performance, design, fabrication, installation, orientation, and test requirements for Motor Control Center (MCC) replacement housings for the Air Freight Terminal (AFT) complex at Joint Base Pearl Harbor Hickam (JBPHH), Hawaii. This PD covers all equipment, materials, and labor necessary to complete installation of the system. It also includes performing tests and making adjustments to the system.

1.2. ACRONYMS

AFT - Air Freight Terminal CO – Contracting Officer COTR - Contracting Officer's Technical Representative DPTV – Dual Pallet Transfer Vehicle ETV – Elevating Transfer Vehicle LSDC – Long Staging Dock Conveyor MPBUC – Multi-pallet Build Up Conveyor MTBF - Mean Time Between Failures MTTR - Mean Time To Repair NEL – Narrow Edge Leading PD - Purchase Description PLC - Programmable Logic Controller SDC - Staging Dock Conveyor SSDC – Short Staging Dock Conveyor SPRTV – Single Pallet Rotating Transfer Vehicle TV – Transfer Vehicle WEL – Wide Edge Leading

1.3. DEFINITIONS

1.3.1. PALLETS

The system shall handle 463L pallets and multi-pallet trains (463L pallets attached together). References to pallets shall refer to 463L pallets. References to pallet trains or trains shall refer to 463L multi-pallet trains.

1.3.1.1. 463L PALLET

The 463L pallet is used to transport air cargo on military aircraft. The 463L pallet consists of an end-grain balsa-wood or redwood core sandwiched between two sheets of aluminum with frames on all sides consisting of extruded aluminum edge rails.

Steel tie-down rings are distributed around the perimeter of the

JBPHH MCC Housing Replacement - Page 2 pallet to secure nets and to facilitate handling. The entire pallet measures 108 inches wide by 88 inches long by 2.25 inches thick. Cargo on 463L pallets is normally no higher than 96 inches, but overweight pallets may be stacked up to 156 inches high for transport on C-5 aircraft. The pallet has a rated capacity of 10,000 pounds and weighs approximately 290 pounds.

Nets and straps add an average of 65 pounds to each single pallet for a total pallet tare weight of 355 pounds. The 463L pallet can be transferred with either the 108-inch edge leading (wide-edge leading or WEL) or the 88-inch edge leading (narrow-edge leading or NEL).

1.3.1.2. MULTI-PALLET TRAIN

A multi-pallet train is used to palletize cargo too long to fit on a single pallet. A multi-pallet train consists of two to six 463L pallets attached together in series. Trains can have either the 88-inch edge leading or the 108-inch edge leading. The 463L pallets are attached together with two to four connectors. A two-inch gap will exist between the attached pallets except for the connectors. The load capacity of a multi-pallet train is the capacity of the 463L pallet multiplied by the number of pallets in the train. The load on each individual 463L pallet in the train will not exceed 10,000 pounds. Cargo on a multi-pallet train may be stacked up to 156 inches high.

1.3.2. INBOUND

In general, inbound is the direction of pallet movement from the air side of the facility toward the truck side of the facility.

1.3.3. OUTBOUND

In general, outbound is the direction of pallet movement from the truck side of the facility to the air side of the facility.

2. APPLICABLE DOCUMENTS

The following documents form a part of this PD to the extent specified herein. The issue in effect on the date the solicitation is issued shall apply.

2.1. GOVERNMENT DOCUMENTS

AIR FORCE INSTRUCTION (AFI)

AFI 91-203

Air Force Consolidated Occupational Safety Instruction

JBPHH MCC Housing Replacement - Page 3

OCCUPATIONAL SAFETY AND HEALTH ADMINISTRATION (OSHA) STANDARDS

29 CFR 1910 Occupational Safety and Health

Standards

29 CFR 1926 Safety and Health Regulations for Construction

UNIFIED FACILITIES CRITERIA (UFC)

UFC 3-310-04 Seismic Design for Buildings

UFC 3-600-01 Design: Fire Protection Engineering for

Facilities

2.2. NON-GOVERNMENT DOCUMENTS

AMERICAN NATIONAL STANDARDS INSTITUTE (ANSI)

ANSI B15.1 Safety Standard for Mechanical Power

Transmission Apparatus

AMERICAN WELDING SOCIETY (AWS)

AWS B2.1 Specification for Welding Procedure and

Performance Qualification

AWS D1.1 Structural Welding Code – Steel

AWS D14.1 Specification for Welding of Industrial and Mill Cranes and Other Material Handling Equipment

AWS Z49.1 Safety in Welding, Cutting, and Allied Processes

(Applications for copies shall be addressed to the American Welding Society, Inc, 550 NW Lejeune Road, P.O.Box 35140, Miami

FL 33135)

NATIONAL ELECTRICAL MANUFACTURER'S ASSOCIATION (NEMA)

NEMA ICS 6 Industrial Controls and Systems:

Enclosures

(Applications for copies shall be addressed to the National

JBPHH MCC Housing Replacement - Page 4

Electrical Manufacturers Association, 2101 L Street, NW, Washington DC 20037)

NATIONAL FIRE PROTECTION ASSOCIATION (NFPA)

NFPA 70 National Electrical Code

(Applications for copies shall be addressed to the National Fire Protection Association, One Batterymarch Park, P.O. Box 9101, Quincy MA 02269-9101)

3. REQUIREMENTS

3.1. SYSTEM DESCRIPTION

Twelve existing steel MCC housings shall be replaced with twelve stainless steel MCC housings meeting the requirements of NEMA ICS 6, Type 4X. In addition a new MCC shall be provided for the existing refrigerated storage area. MCCs house motor controllers, communications, and control wiring, LAN and programmable logic controller (PLC) processor interfaces. When the installation of the new MCC housing replacements are completed the operational capabilities of the current equipment controlled by the twelve MCCs shall be the same as before the installation of the MCC housings. The locks of all MCCs shall be keyed alike and the Contractor shall provide two keys per lockset. Control wiring diagrams shall be provided as part of all drawing submittals, with an extra as-built copy mounted in a plastic case inside the panel door. All components inside the cabinet shall be clearly labeled and shall match the drawings.

The function of the MCCs shall be clearly labeled on the outside of the MCC.

3.1.1. INSTALLATION OF NEW MCC FOR REFRIGERATED STORAGE AREA

The existing MCC for the refrigerated storage area is old and out dated. An updated MCC shall be designed and installed to replace the existing MCC. As a minimum the new refrigerated MCC shall control the four conveyors inside the refrigerated area, the overhead doors, and the existing refrigeration system. Any auxiliary equipment required to make the existing system compatible with the new MCC is the responsibility of the contractor. After installation of the new refrigerated MCC the conveyors inside the refrigerated area, the overhead doors, and the refrigeration system shall operate as they presently do.

3.1.2. REMOVAL AND DISPOSAL OF EXISTING EQUIPMENT

Removal and disposal of existing equipment to complete installation of new MCC housings and the refrigerated storage MCC

JBPHH MCC Housing Replacement - Page 5 shall be the responsibility of the Contractor. All equipment disposed of by the Contractor shall be in accordance with all Federal, State, and local laws and codes.

3.2. CHARACTERISTICS

3.2.1. NOISE LEVELS

The Contractor shall consider noise levels in the design of the equipment. Hazardous noise shall not exceed 85 decibels A-weighted sound pressure level (dB(A)) for 8 hours in any 24-hour period or equivalent in accordance with AFI 91-203. Noise level measurements will be taken at a three-foot distance from the equipment producing the noise and at a level of five feet above the surrounding surface in all locations where personnel may be present during normal operations. Noise level measurements shall also be taken one foot from the front of all control consoles at a level of five feet above the surrounding surface where the operator stands. If noise levels of installed equipment exceed this requirement, then noise shall be reduced through engineering controls; i.e., insulation, dampening, and isolation.

3.2.2. ELECTRICAL CHARACTERISTICS

The electrical characteristics shall be as follows unless specified otherwise:

3.2.2.1. INSTALLATION CODE

The installation shall, at a minimum, conform to applicable rules of NFPA 70 (the National Electrical Code).

3.2.2.2. CONDUIT

All wiring shall be encased in rigid metal conduit conforming to Article 346 of NFPA 70 or cable trays as approved by the Contracting Officer’s Technical Representative (COTR). Changes in direction of conduit shall be made with symmetrical bends or cast metal fittings. Field made bends shall be made with the proper hickey or conduit-bending machine. Crushed or deformed conduit shall not be accepted. Conduit shall be rigidly fastened in place at intervals of not more than 5 feet.

3.2.2.3. GROUNDING

Each component of the system shall be properly grounded to ensure safe working conditions. This shall include adequate ground against static charges that may be generated. Grounding shall conform to Article 250 of NFPA 70.

JBPHH MCC Housing Replacement - Page 6

3.2.2.4. FLEXIBLE CONNECTIONS

Flexible connections of short length shall be provided for all motors and for other equipment subject to vibration or movement.

Liquid-tight, flexible conduit shall be used in wet and outdoor locations. A separate ground conductor shall be provided across all flexible connections.

3.2.2.5. WIRING

Conductors shall be copper. Wire connectors of insulating material or solderless pressure connectors properly taped shall be utilized for all splices where possible. Soldered mechanical joints shall not be accepted. All wiring shall be color coded, uniquely tagged, or uniquely numbered for identification.

Marking shall be applied in such a manner so as to facilitate tracing of wires (circuits) during repairs and maintenance.

Minimum control wire size shall be Number 14 AWG. All other wire sizes shall be minimum Number 12 AWG. Wiring and wiring installation shall conform to Article 300 of NFPA 70. All circuits shall be checked for grounds or poor connections prior to being energized.

3.2.2.6. OVERCURRENT PROTECTION

The power distribution panel shall be equipped with circuit breakers and fuses in compliance with Article 240 of NFPA 70.

Motors shall be equipped with disconnect switches and thermal overload devices.

3.2.2.7. ENVIRONMENTAL PROTECTION

All enclosures and controls shall be in accordance with NEMA ICS 6, Type 4X. Moisture shall not enter electrical enclosures. All boxes and fittings shall connect through rainproof fittings, Mars Hubs, or equivalent as approved by the COTR. MCCs shall be oriented vertically such that the cover axis is perpendicular to the ground. MCCs shall have no conduit entry or other holes on the top surface unless a stainless steel protective shield is provided on top of the panel to deflect water away. All electrical enclosures and components installed shall be sealed with no openings, holes, or gaps. No electrical components shall be installed directly on the floor or ground.

3.2.2.8. DIAGRAMS, CODES, AND DOCUMENTATION

The Contractor shall provide flow charts for the refrigerated storage area that clearly illustrate control and operation logic.

The flow charts shall be submitted with shop drawings. Ladder diagrams, flow charts, all variable control settings, and disks

JBPHH MCC Housing Replacement - Page 7 containing source code for all control programs. The MCC for the refrigerated storage area shall be added to the existing maintenance manuals along with any changes made to the other twelve MCCs.

3.3. DESIGN AND FABRICATION

3.3.1. DESIGN CRITERIA

3.3.1.1. RELIABILITY AND AVAILABILITY

Each component of the system shall demonstrate a mean time between failure (MTBF) and availability greater than or equal to that listed in Table 1. A failure is defined as any condition that does not conform to the specification or any interruption that causes corrective maintenance to be made to the system that is deemed as the result of the installation of the MCC housings.

Failures also include situations requiring the use of maintenance personnel, and situations requiring the resetting or restarting of any component. The operating time shall be based on the hours listed in Table 1 or the actual hours read from the hour meter.

Each individual component shall meet the MTBF and availability requirements specified (i.e., each staging dock conveyor must meet the MTBF and availability requirements). The following formulas will be used to calculate MTBF and availability.

TABLE 1 - RELIABILITY AND AVAILABILITY TABLE

Equipment* Operating Time

(Hours)

MTBF

(Hours) Availability

Multi-pallet Build Up Conveyor

720 360 99

Staging dock conveyor

720 360 99

ALOC conveyor 720 360 99 Rolling Stock Lift

720 240 99

MTBF =

Operating Time

Total Failures

Mean Time to Repair (MTTR) = Total Repair Time

Total Failures

Availability = MTBF

(MTBF + MTTR)

JBPHH MCC Housing Replacement - Page 8

*Each component includes all controls and electrical connections for that component.

3.3.1.2. MAINTAINABILITY

The system shall be designed, fabricated, and installed to facilitate maintainability and ensure a minimum service life of 30 years. The design shall provide for modular assembly of components and subassemblies where feasible to permit repair or replacement of parts in a minimum of time. This shall include plug-in electrical connections for major electrical subassemblies.

3.3.1.3. ENVIRONMENTAL CONDITIONS

All system components shall operate in a temperature range of 40 to 100 degrees Fahrenheit with up to 99 percent relative humidity. All system components shall be constructed for year-round outdoor use, operating in an environment consisting of sun, rain, fog, high humidity, and wind. All system components shall be designed to not trap precipitation.

3.3.1.4. STANDARD, COMMERCIAL COMPONENTS

Standard, commercial components which have been for sale and available for purchase to the general public or government agencies for at least one year shall be used to the maximum extent possible. If requested by the COTR, the Contractor shall furnish evidence that equipment of approximately the same design as that proposed to be installed has been tested and successfully operated. Where two or more units of the same type of equipment are required, these units shall be products of the same manufacturer. All equipment and materials shall be new.

3.3.1.5. STANDARDIZATION

Mechanical and electrical interchangeability shall exist between like assemblies, subassemblies, and replaceable parts regardless of the manufacturer's supplier. Interchangeability does not necessarily mean complete identity, but requires that a substitution of such like-assemblies and replacement parts be easily effected without physical or electrical modifications, including cabling, wiring, and mounting.

3.3.1.6. SPECIAL TOOLS

Use of special tools shall be minimized and, where required for operational adjustments, shall be securely mounted within the equipment in a readily accessible location. Standard tools, JBPHH MCC Housing Replacement - Page 9 fittings, lubricants, and fluids shall be used to the maximum practicable extent.

3.3.1.7. STRUCTURAL AND SEISMIC REQUIREMENTS

The system shall be designed and constructed in accordance with applicable seismic design codes and UFC 3-310-04. All mechanical and electrical components shall be designed and installed to withstand seismic activity. Vibration isolation devices and bracing shall be used as necessary to meet this requirement.

3.3.1.8. OZONE DEPLETING SUBSTANCES (ODS)

The Contractor shall not use or prescribe to the greatest extent possible any ODS in the installation and maintenance of the system. ODS includes, but is not limited to aerosol cans, certain cleaning solvents, refrigerants, and certain lubricants.

If there is a question pertaining to the applicability of a substance, submit the name of the substance to the Contracting Officer for verification.

3.3.1.9. SAFETY

The Contractor shall consider the safety of personnel and equipment when designing and installing the system. Safety provisions shall be incorporated to the maximum extent possible.

When possible, hazards shall be eliminated through design. When this is not possible, safety devices such as guards, interlocks, and barriers shall be installed. If this does not eliminate the hazard, warning devices such as warning signs, indicator lights, and audio devices shall be installed. Safety requirements shall include, but are not limited to, the following:

3.3.1.9.1. OCCUPATIONAL SAFETY AND HEALTH ADMINISTRATION

The system installation practices and completed system shall meet all applicable requirements of OSHA 29 CFR 1910 and OSHA 29 CFR 1926.

3.3.1.9.2. PROTECTION AGAINST MOVING PARTS

Moving parts shall be provided with guards to protect personnel from possible injury. Guards shall be in accordance with ANSI B15.1.

3.3.1.9.3. PLACARDS

Conspicuous placards shall be mounted adjacent to areas where hazards may exist (i.e., high voltage, pinch points, and tripping hazards). Placards shall also be used to identify operating

JBPHH MCC Housing Replacement - Page 10 limits (i.e., capacity, speed, and incline) in a conspicuous location for operators' use. All areas with operating controls shall be identified by placards as “No Drinking, Eating or Smoking” areas.

3.3.1.9.4. FAIL-SAFE CONTROLS

No controls shall cause false operation or endanger personnel if a part should fail. No damage or destruction of any component shall result from reduced voltage or complete loss of power.

3.3.2. WELDING

Dimensional tolerances for welded construction, details of welds, and quality of welds shall be in accordance with the applicable requirements of AWS B2.1, AWS D1.1, and AWS D14.1. The Government reserves the right to perform supplemental nondestructive and destructive tests to determine compliance.

Safety precautions during welding shall conform to ANSI Z49.1.

3.3.2.1. WELDING PROCEDURE QUALIFICATION

Qualification of welding procedures shall conform to the applicable requirements of AWS B2.1, AWS D1.1, and AWS D14.1.

The Government reserves the right to request copies of Welding Procedure Specifications for any welding procedure followed in the fabrication of this system.

3.3.2.2. WELDER PERFORMANCE QUALIFICATION

Each welder, welding operator, and tack welder assigned to work on this system shall be qualified in accordance with the applicable requirements of AWS B2.1, AWS D1.1, and AWS D14.1.

The Government reserves the right to request certification (Performance Qualification Test Record) that each welder, welding operator, or tack welder is qualified as specified.

3.3.3. FIRE PROTECTION

Fire protection requirements shall be as specified in the building requirements and shall conform to UFC 3-600-01 and AFI 91-203.

3.3.4. NAMEPLATES

The Contractor shall provide and install one corrosion resistant metal nameplate for each MCC. Nameplates shall last the life of the equipment and shall be capable of withstanding local environmental conditions. Nameplates shall be stamped, engraved, or etched in a print type not less than 0.5 inch tall.

JBPHH MCC Housing Replacement - Page 11

3.3.5. AIRFIELD REQUIREMENTS

The following requirements apply to all on-site work:

3.3.5.1. VEHICLE ACCESS

If driving on the airfield side of the AFT the Contractor shall ensure all vehicle operators, including subcontractors and delivery agencies, are qualified flight line drivers or are escorted by a qualified operator at all times. All contractor vehicles require a temporary vehicle pass to operate on the flight line. Vehicle operations on the flight line shall be kept to the absolute minimum required to conduct the work.

3.3.5.2. EAR PROTECTION

The Contractor shall provide personnel working on-site with ear protection against noise.

3.3.5.3. NIGHT OPERATIONS

During night operations, the Contractor shall provide sufficient lighting for work to be conducted safely.

3.3.5.4. PROHIBITED AREAS

No personnel, vehicles, or equipment shall enter the runway, overruns, helipads, or taxiways at any time.

3.3.5.5. TEMPORARY AIRFIELD CONSTRUCTION WAIVER

A temporary airfield construction waiver, if required, shall be obtained prior to the start of on-site work.

3.3.5.6. EMERGENCY EVACUATIONS

The Contractor shall be able to evacuate all workers and portable equipment to a designated area within 3 minutes in the event of an in-flight or aircraft ground emergency.

3.3.6. PRECEDENCE

Where local codes and standards conflict with the contents of this PD, the more stringent requirement shall prevail.

3.4. DOCUMENTATION

The Contractor shall provide documentation (data) as described below and in accordance with Table 1 below. Where possible, the

JBPHH MCC Housing Replacement - Page 12

Contractor shall print on recycled paper. Also, the Contractor shall not require the use of any Class I ozone-depleting substance in any submittal.

3.4.1. MANAGEMENT REPORTS

The Contractor shall provide a monthly status report complete with schedule. The report shall be either Microsoft word document or a PDF file. The monthly status report shall be submitted in accordance with Table 1. Contractor format is acceptable as long as it provides the following information as a minimum;

A) A front cover sheet which includes the title of report, the contractor’s name and address, the base name, the contract number, and the date.

B) A schedule showing actual progress to date against current contract schedule through contract completion is required. In addition, forecasted delivery and other significant project milestones should address/include, at a minimum: CLIN deliveries, submission of all data items, post award site visit (if applicable), shipping of deliverables, installation, training/orientation (if required), system checkout test, quality conformance test, reliability demonstration test, etc."

C) The body of the report shall provide a summary of the progress to date. It shall identify any problem areas, any changes in schedule or contract equipment, any engineering change proposals, all significant trips, emails, or telephone calls affecting the performance or scope of the contract.

3.4.2. SHOP DRAWINGS

The Contractor shall provide shop drawings, which include as minimum; electrical and electrical schematics. Items manufactured by the contractor, contractor maintains control of the design, rather than supplied, shall contain a Bill of Materials with the shop drawings for these items. Shop drawing package shall be submitted in accordance with Table 1. Hard copy size of drawing shall be dependent on clarity of drawing, but as a minimum shall be B size. Shop drawings shall be submitted in a time frame, which meets the contract schedule. Government shall have two weeks to review shop drawings. Any resubmittals required shall be resubmitted within one week.

3.4.3. EQUIPMENT MANUALS

The Contractor shall update the existing maintenance and Illustrated Parts Breakdown (IPB) manuals to add the refrigerated storage area MCC and any changes to the existing MMCs.

JBPHH MCC Housing Replacement - Page 13

3.4.3.1. MAINTENANCE MANUALS

Maintenance manuals shall provide step-by-step instructions for the replacement of all commercial parts. The maintenance manuals shall provide instructions for all maintenance tools provided.

3.4.3.2. ILLUSTRATED PARTS BREAKDOWN MANUALS

The IPB shall provide illustrated breakdown for disassembly of all commercial parts as well as the breakdown of major assemblies. The IPB shall include all commercial part numbers for commercial items whether or not they have been modified by the Contractor.

3.4.4. CERTIFICATIONS

After installation of all equipment the contractor shall certify the system meets or exceeds the requirements listed in paragraph

4.3.3. of this Cover Purchase Description. A general statement that the delivered system meets or exceeds all system requirements is not acceptable i.e. the contractor shall certify each requirement one-by-one. With these certifications the contractor shall also certify the tests in paragraph 4.3.2. of this Cover Purchase Description and of all appendices have been performed and the system is ready for Government inspection.

3.4.5. AS-BUILT DRAWINGS

The Contractor shall provide as-built drawings of all drawings submitted as part of the shop-drawing package. As-built drawings shall be submitted in accordance with Table 1.

Table 1 – Data Requirements

SUBMITTAL DUE DATE DISTRIBUTION LIST

Ron Parsons Ronald.parso ns@us.af.mil

Buyer identified at time of award

POC

identified at time of award

Management Reports (3.4.1)

1st business day of each month starting after the month the contract is awarded email with attachment of report email with attachment of report email with attachment of report

JBPHH MCC Housing Replacement - Page 14

Shop Drawings (3.4.2)

Due date is same as CLIN

Email with attachment of drawings (AutoCAD and PDF) (and one set of B size hard copies)

Email with attachment of drawings

(PDF)

Email with attachment of drawings (AutoCAD and PDF) and one set of hard copies (D size)

Manuals (3.4.3.)

With delivery of equipment

Email with attachment of manuals

(PDF)

Email indicating delivery of manuals completed

Email with attachment of manuals (PDF) and 2 sets of hard copies

Certifications (3.4.4)

Due upon system installation completion

Email with attachment of certificatio ns (Word Document or

PDF)

Email with attachment of certificati ons (Word Document or

PDF)

Email with attachment of certificati ons (Word Document or

PDF)

As-built Drawings (3.4.5)

30 days after Government acceptance of system

Email with attachment of drawings (AutoCAD and PDF) (and one set of B size hard copies)

Email with attachment of drawings

(PDF)

Email with attachment of drawings (AutoCAD and PDF) and one set of hard copies (D size)

3.4.6. REFERENCE MATERIAL

Schematics of the system and its major components shall be provided in two formats; they shall be printed on separate sheets of paper and laminated so the schematics can be used while performing maintenance and then wiped clean afterwards and submitted on two sets of CDs in a PDF format or equivalent.

Approval of the specific schematics necessary for lamination shall be obtained from the COTR. The reference materials shall be submitted with the maintenance manuals.

3.5. INSTALLATION IMPACT ON ONGOING AFT OPERATIONS

The Air Freight Terminal (AFT) shall remain operational during the entire installation period. The Contractor shall conduct operations to cause the least possible interference with normal operations. The work shall be completed in a manner that

JBPHH MCC Housing Replacement - Page 15 minimizes interruptions and delays. The Contractor shall notify the Government a minimum of 14 calendar days prior to the commencement of on-site work, including delivery of materials.

The Contractor shall not be allowed access to the site to begin work until all design work (including the Engineering Plan and all shop drawings) for that portion of the work has been completed and accepted by the Government and there are no outstanding issues that would delay completion of that portion of the work. The system shall not be considered fully operational if work-around procedures or special procedures that do not conform to the specification are required for operation, or if operational deficiencies not conforming to the specification exist. A critical or major defect as defined in 4.3. shall mean the system is not fully operational. The COTR shall determine whether or not minor defects as defined in 4.3. interfere with operational use of the system, and at what point the system is considered fully operational.

3.6. CONTRACTOR EXPERIENCE

Demonstrated experience, to the satisfaction of the Contracting Officer, during the past five years in the design, manufacture, software development, installation, acceptance and current customer operation of AFT operations, shall be required.

3.6.1. EXPERIENCE DOCUMENTATION WITH PROPOSAL

The offeror shall provide a summary of experience in providing AFTs with the proposal. An offeror who cannot demonstrate such experience, verifiable through contacting and/or visiting the offeror's past customers to determine the success of these systems, shall be deemed technically unacceptable. As a minimum, the summary shall include the following information for the projects proposed as relevant experience:

Customer Company Name Installation Location Date of Customer Acceptance Is the System Still in Use?

Equipment furnished with the System Include all major components Specify capacity and speed for TVs or ETVs

Specify positioning system of TVs or ETVs Specify capacity for the conveyors and lifts

Name of Customer Contact Telephone and Email Address of Customer Contact

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The Government reserves the right to contact additional customers to obtain information that will be used to evaluate the offeror’s experience.

3.7. SECURITY REQUIREMENTS

The contractor shall ensure each employee obtains required pass and identification items for access to JBPHH. All contractor employees must have in their possession and present upon request, personnel and vehicle passes issued by the government.

Contractor and employees shall return identification cards to Security Forces within 24 hours of termination. All other government identification for terminated employees shall be returned to the Contracting Officer (CO) within 24 hours of termination.

3.7.1. REQUIRED SECURITY INFORMATION

The contractor shall provide a complete list of all personnel, including the contract manager and alternate(s), to the CO no later than 30 days prior to start of installation. The listing must include name, address, telephone number, and social security or pass port number of all employees. Contractor shall maintain a current listing of all employees, providing updates to the CO within 3 days of change.

3.7.2. SECURITY TERMS AND CONDITIONS

The Contractor shall perform Background, Sex Offender and Criminal Record Checks on all selected personnel requiring access onto the JBPHH. The Contractor shall arrange, conduct, and absorb all expenses of the background checks. The background checks must be current as of 120 calendar days from the start of the contract to receive access onto JBPHH. For Non-U.S. Citizen Applicants, background checks will be verified with the Department of Homeland Security/Immigrations and Customs Enforcement)

4. QUALITY ASSURANCE PROVISIONS

4.1. GENERAL

The COTR will monitor the installation of the system. The system delivery dates shall not be extended because of work stoppages caused by unacceptable practices or test failures. For all inspections and tests, the Contractor shall provide all test apparatus (i.e., tape measures, levels, calipers, micrometers, stop watches). All test apparatus will be returned to Contractor upon completion of all tests. The Government will provide all test loads. The Contractor shall be responsible for performing

JBPHH MCC Housing Replacement - Page 17 all inspections and tests. The Contractor shall provide a knowledgeable and authoritative representative on site during the entire acceptance tests.

4.2. ACCEPTANCE TESTS

Three tests must be successfully completed prior to the Government accepting the system. These tests are the system checkout test, the quality conformance test, and the reliability demonstration test.

4.2.1. SYSTEM CHECKOUT TEST

Upon completion of installation, the system shall be checked out by the Contractor using loads of the type specified. The Contractor shall inspect the system to assure that the system meets all the requirements of 4.3.1. The Contractor shall also test the system in accordance with the tests defined in 4.3.2.

All inspections and tests shall be repeated until all modifications and adjustments are complete and the system passes all inspections and tests. The Contractor shall submit written certification to the Contracting Officer that the system has passed the requirements of this paragraph. The COTR will schedule the quality conformance test to start within 10 days following the receipt of the written certification from the Contractor.

4.2.2. QUALITY CONFORMANCE TEST

All work shall be scheduled so only one quality conformance test is required. The Contractor shall provide the requirements certification and the system checkout certification prior to the start of the quality conformance test. The Contractor, in the presence of the COTR, shall inspect the system to confirm that the system meets all the requirements of 4.3.1. The Contractor, in the presence of the COTR, shall also test the system in accordance with the tests defined in 4.3.2. Upon successful completion of all tests and inspections and the receipt of all certifications, the reliability demonstration test shall start.

4.2.3. RELIABILITY DEMONSTRATION TEST

After successful completion of the quality conformance test, each component of the system shall demonstrate a reliability and availability greater than or equal to that listed in the reliability and availability table in 3.3.1.1. Trained Government personnel will operate the system during the reliability demonstration test. In addition, all static components shall demonstrate compliance with the requirements of the PD. The test period shall be the 30 calendar days

JBPHH MCC Housing Replacement - Page 18 immediately following the successful completion of the quality conformance test. If the system does not demonstrate the required reliability and availability or compliance with the PD, the test will be restarted from the beginning after the Contractor has taken corrective action. The Contractor shall be allowed to restart the reliability demonstration test a maximum of 2 times. If the system fails to pass the reliability demonstration test within 3 attempts, then the system may be rejected.

4.2.4. MAINTENANCE SUPPORT DURING TESTING

The Contractor shall provide a maintenance technician on-site during the reliability demonstration test. The maintenance technician shall perform all preventive and corrective maintenance required on the system during the reliability demonstration test. The Contractor shall provide all tools, fluids, parts, and other items necessary to perform maintenance during the reliability test. The maintenance technician shall be knowledgeable in all aspects of the system and shall be able to correct all problems that arise. The maintenance technician shall provide on-going maintenance training during the reliability test. The maintenance technician shall work during normal working hours, a minimum of eight hours per day, Monday through Friday and shall be on-call during all other hours Monday through Sunday. The technician shall arrive on-site within one hour after a call is made to a Contractor-provided telephone number.

4.3. INSPECTIONS, TESTS, AND CERTIFICATIONS

This section defines all inspections and tests that must be completed as part of the system checkout test and repeated at the quality conformance test. This section also includes a list of all certifications that must be received from the Contractor on or before the start of the quality conformance test. The Contractor may add to this list, or question any requirement, by sending a letter to the Contracting Officer prior to the acceptance tests. The COTR will classify all deficiencies encountered into one of the defect classifications listed below.

Any critical or major defect found shall be cause for rejection of the system. Any minor defect shall leave the rejection of the system at the discretion of the COTR.

Critical Defect - A defect that judgment and experience indicate is likely to result in hazardous or unsafe conditions for individuals using, maintaining, working near, or depending upon the equipment.

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Major Defect - A defect other than critical, which is likely to result in failure, or reduce materially the system for its intended purpose.

Minor Defect - A defect that is not likely to reduce materially the usability of the system for its intended purpose, or is a departure from established standards having little bearing on the effective use or operation of the system.

4.3.1. INSPECTIONS

The system shall be inspected to verify that it meets all the requirements of sections 1, 2, and 3 of the Cover PD and Appendices A through F. These inspections shall be completed as part of the system checkout test and again as a part of the quality conformance test.

4.3.2. TESTS

The following tests shall be performed on the system as part of the system checkout test and again as a part of the quality conformance test.

No. Test

1. Operate all electrical components of the system.

Disconnect the transformer supplying power to the system.

After the back-up generator restores power, attempt to operate all components of the system. Restore the normal electrical power and attempt to operate all components of the system. If any component does not operate normally from the power supplied by the back-up generator, if any component does not operate properly with power supplied from the transformer, if special procedures are required to restart or otherwise operate any component during this test, or if any component requires manual initialization or recalibration, that component fails this test.

Pass: _____ Fail: _____

2. Test all continuous-contact controls in the system by using then releasing the control. If the action started by the control does not end when released, the MCC with that control fails this test.

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3. Have one person operate the controls while moving a 463L pallet over every roller in the system in both the inbound and outbound directions. The person may move to different consoles, but shall interact with the system only through the consoles. If one person is unable to transfer the pallet through the system unassisted, the controls fail this test.

4. Test the console lockout for all conveyors that can be controlled from two or more consoles. While operating the conveyor from one console, attempt to operate the same conveyor from a different console that controls the conveyor. Repeat for all consoles for all conveyors with more than one control console. If the first console used does not render the second console inoperable, the MCC with that control fails this test.

5. While operating a conveyor, depress an emergency stop button for that conveyor. Attempt to operate the conveyor from all consoles capable of operating that conveyor.

Clear the emergency stop button and operate the conveyor.

Repeat for each emergency stop button in the system. If the conveyor does not stop when the button is depressed; if any retractable pallet stops raise when an emergency stop is activated, if the TV aligned for pallet transfer with that conveyor will operate while the emergency stop button is depressed; if the conveyor or TV is not enabled by clearing the emergency stop button, the MCC controlling that emergency stop button fails this test.

6. Connect the programming terminal to each PLC in the system.

Verify the hardware and software provided enables maintenance personnel to troubleshoot and modify the PLC program. If the hardware and software do not permit the PLC program to be modified, the MCC with that PLC fails

ALL CONVEYORS CONTROLED BY MCCs WHERE HOUSINGs WERE REPLACED

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7. Attempt to access all drive chains, sprockets, bearings, motors, and all other components requiring maintenance or inspection. If access is obstructed by the MCC or sufficient room is not provided to perform maintenance functions, the MCC obstructing maintenance access fails

8. For each conveyor, activate the controls to move the pallet toward the stop and hold until the conveyor stops. Move the pallet away from the stop, then toward the stop until the conveyor stops. For all forklift interfaces, remove the pallet with a forklift and operate the conveyor towards the stop. Repeat for all conveyor controls for each conveyor. If the pallet impacts the stop, cannot be conveyed away from the stop, or if the conveyor cannot operate towards the stop after the pallet is removed by a forklift, the MCC controlling the conveyor fails this test.

9. Manually retract the pallet stops and transfer pallets across the stops in both directions from all control panels for that conveyor. Repeat for all retractable pallet stops. If the conveyor will not operate normally with the pallet stop manually retracted, the MCC controlling that conveyor fails this test.

10. Transfer an unloaded, loaded, and fully loaded WEL pallet across all conveyors in both the inbound and outbound directions. Repeat using a NEL pallet. If any conveyor fails to start, stop, support, transfer, or operate properly for any load or orientation tested, the MMC controlling that conveyor fails this test.

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11. Move a fully loaded 463L pallet inbound and outbound over every conveyor while measuring the transfer speed. The pallet should be moving at the full transfer rate when clocked (starting, speed-up, slow-down, and stopping times not included). Repeat with an unloaded pallet. If the pallet transfer speed is not 60 +/- 1 feet per minute for both loads, the MCC controlling that conveyor fails this test.

12. While transferring a pallet to an interfacing conveyor, interrupt the transfer prior to completion. Restart and complete the pallet transfer. Repeat only reverse the conveyor direction when resuming pallet transfer. Repeat, shut off the power after interrupting the transfer, then restore the power and complete the transfer. Repeat for all types of conveyors for all possible interruption points. If the pallet transfers cannot be completed or reversed to an acceptable condition (all pallet stops can rise, proper spacing between pallets, etc.) then the MCC controlling the conveyor fails this test.

STAGING DOCK CONVEYORS (SDCs)

AND THE AIR LINE OF COMMUNICATION (ALOC)

13. Align the Single Pallet Rotating Transfer Vehicle (SPRTV) with each SDC. Move the conveyor handgrip inbound and outbound. Press the extractor button to activate the SDC and transfer a pallet using the conveyor handgrip. Press the extractor button to deactivate the SDC and move the conveyor handgrip. If the SDC activates or the SPRTV conveyor does not activate when the extractor is retracted or if either conveyor fails to operate when the extractor is extended, the MCC controlling the SDC fails this test.

14. Repeat the above test using the Duel Pallet Transfer Vehicle (DPTV).

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15. Align the SPRTV for pallet transfer with a SDC. Begin pallet transfer to the SDC but stop once the pallet clears the SPRTV stop but prevents the SDC stop from rising.

Attempt to move the SPRTV. Complete the pallet transfer to the SDC and move the TV. Repeat for each SDC. If the SPRTV can travel away from the SDC when the SDC stop is not fully raised, or if the SPRTV cannot travel away from the powered conveyor when all pallet stops are fully raised, the MCC controlling the powered conveyor fails this test.

16. Repeat the above test using the DPTV.

17. Place a pallet on each SDC. Manually lower the SDC’s pallet stop at the K-loader interface. Operate the SDC outbound from the SPRTV control console and keep the pallet transfer control activated until the conveyor stops automatically. If the pallet transfers off the SDC or if the pallet prevents the SDC pallet stop at the K-loader interface from rising, the MCC controlling the SDC fails

18. Repeat the above test using the DPTV.

19. Align a SPRTV at a SDC. Depress the emergency stop button on the SDC control console. Attempt to activate the SDC from the SDC control console and the TV control console.

Reset the emergency stop button and depress the emergency stop button on the TV control console. Attempt to activate the SDC from the SDC control console and TV control console. If the TV and SDC do not stop, if any pallet stop on the TV or the SDC does not remain lowered, or if the powered conveyor and TV are not capable of normal operations after clearing the emergency stop, the MCC controlling the powered conveyor fails this test.

20. Repeat the above test using the DPTV.

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21. Begin a pallet transfer between a SDC and the SPRTV and interrupt the transfer. Restart and complete the transfer.

Repeat several times, interrupting the transfer at a different stage each time. Repeat with a fully loaded 463L pallet and an unloaded pallet in both directions. If any pallet transfer cannot be completed when interrupted at any point, the MCC controlling the conveyor fail this test.

22. Repeat test above. This time interface with the Duel Pallet Transfer Vehicle (DPTV). If any pallet transfer cannot be completed when interrupted at any point, the MCC controlling the conveyor fail this test.

23. Position a fully loaded 463L pallet on a 10K forklift.

Lower the pallet to the SDC’s forklift interface. Then convey the pallet away from and back to the forklift interface. Pick up the pallet with the forklift. If the pallet fails to transfer between the conveyor and the forklift the MMC controlling the conveyor fails this test.

24. Move a fully loaded 463L pallet with the WEL from a SDC to the SPRTV. Rotate the pallet 90 degrees so the 88-inch edge is leading. Transfer the pallet to the SDC. Transfer the pallet back to the SPRTV, rotate 90 degrees, and transfer the pallet back to the SDC. If the pallet cannot be transferred to and from the SPRTV, the MCC Controlling the conveyor fails this test.

25. Transfer a fully loaded 463L pallet with the WEL from each SDC to the DPTV and back to the SDC. If the pallet cannot be transferred to or from the DPTV the MCC controlling the conveyor fails this test.

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26. Transfer six 463L pallets with the WEL from a K-loader to each SDC to verify import K-loader indexing. The pallet stop at the K-loader interface shall rise after each pallet transfer. If six pallets cannot be transferred to the SDC without activating the SDC export, if the spacing between pallets is less than two inches, or if the pallet stop cannot rise after each pallet is transferred, the MCC controlling the SDC fails this test.

27. Transfer five 463L pallets with the NEL from a K-loader to the SDC to verify import K-loader indexing. The pallet stop at the K-loader interface shall rise after each pallet transfer. If six pallets cannot be transferred to the SDC without activating the SDC export, if the spacing between pallets is less than two inches, or if the pallet stop cannot rise after each pallet is transferred, the MCC controlling the SDC fails this test.

28. Transfer six 463L pallets with the 108-inch edge leading from the SPRTV to a SDC from the SPRTV console to verify pallet transfer to a SDC. Keep the pallet transfer control activated during each transfer until the conveyor stops automatically. Interrupt transfer during one of the pallet transfers and complete the transfer. If all six pallets cannot be transferred to the SDC, if the conveyor has to be operated inbound to accomplish the transfer, if both sets of pallet stops at the TV/SDC interface cannot rise after each pallet transfer, or if a pallet hits a pallet stop the MCC controlling the SDC fails this test.

29. Repeat the above test using five 463L pallets with the NEL.

Use the same success criteria as above, except all five pallets shall…