Statement of Work (SOW) 0001.pdf

STATEMENT OF WORK

FOR

H0WC06 300 TON PRESS CONTROL UPGRADE

PREPARED BY:

76 CMXG/ENX

AIRCRAFT MANUFACTURING & DEVELOPMENT

ENGINEERING BRANCH

TINKER AFB, OK

21 October 2019

Revised in December of 2019

STATEMENT OF WORK

H0WC06

1 SCOPE: The contractor shall be responsible for all aspects required to design, supply certified drawings, install, assemble, organize, and project manage the successful completion of the 300 Ton Stretch Draw Press Control Upgrade described with in this statement of work (SOW). All requirements, both specified and implied, within this SOW to achieve comprehensive turnkey systems shall be the sole responsibility of the contractor unless otherwise stated in this SOW.

2 APPLICABLE DOCUMENTS: The following standards shall be adhered to through the completion of this contract. This list is not all inclusive and does not limit the contractor from applying additional applicable industry standards:

STANDARDS – FEDERAL

FED-STD-H28A - Screw Thread Standards for Federal Services (1994 edition)

DEPARTMENT OF DEFENSE

MILITARY STANDARDS

MIL-STD-130N w/Change 1: Identification Marking of U.S. Military Property (2012 Ed.) Item Unique Identification Marking (IUID)

(Application for copies should be addressed to Air Force Product Data Systems Modernization Standards (TMSS) Office, 554 ELSG/SBP, 4375 Chidlaw Road, Bldg.

262, Room S008, Wright-Patterson AFB, OH 45433-5006, Phone (937) 257-0870 or 0853 or https://quicksearch.dla.mil/qsSearch.aspx)

U.S Department of Labor, Occupational Safety and Health Administration (OSHA)

29 CFR 1910 Vol. 5: General Industry, OSHA Safety and Health Standards (2017 Ed.)

(Application for copies should be addressed to the OSHA Publications Superintendent of Documents P.O. Box 37535 Washington, D.C. 20013-7535)

Other Government Documents, Drawings, and Publications. The following other Government documents, drawings, and publications form a part of this document to the extent specified herein. Unless otherwise specified, the issues of these documents are those listed in the solicitation or contract.

LOCAL FACILITY DOCUMENTS

https://quicksearch.dla.mil/qsSearch.aspx

ATTACHMENT A: INSTALLATION LAYOUT

(Applications for these documents should be addressed to the contracting officer)

Non-Government Publications, Specifications, Standards, and Handbooks. The following documents form a part of this document to the extent specified herein. Unless otherwise specified, the issues of these documents are those listed in the solicitation or contract.

American Gear Manufacturers Association (AGMA)

AGMA ISO 1328-1-B14: Cylindrical Gears - ISO System of Flank Tolerance Classification - Part 1: Definitions and Allowable Values of Deviations Relevant to Flanks of Gear Teeth (2014 Ed.)

(Address application for copies to: 500 Montgomery Street, Suite 350, Alexandria, VA 22314-1581 USA)

American National Standards Institute, Inc. (ANSI)

ANSI B5.1M: T-Slots, their Bolts, Nuts, and Tongues, Revision of ANSI B5.1-1985 (R1998 Ed. 2014R)

(Address application for copies to the American National Standards Institute, 11 West 42nd Street, New York, NY 10036)

American Society of Mechanical Engineers (ASME)

ASME B5.48: Ball Screws (1977 Ed. 2013R)

ASME Y14.100: Engineering Drawing Practices (2017 Ed.)

(Applications for copies should be addressed to ASME International Three Park Avenue New York, NY 10016-5990 or www.asme.org )

International Organization for Standardization (ISO)

ISO 4413: Hydraulic fluid power-General rules and safety requirements for systems and their components (2010 Ed.)

ISO 4414: Pneumatic power-General rules and safety requirements for systems and their components (2010 Ed.)

http://www.asme.org/

(Application for copies should be addressed to the International Organization for Standardization (ISO) 1 rue de Varembé, Casepostale56, CH211Geneva 20, Switzerland)

National Electrical Manufacturers Association (NEMA)

NEMA 250: Enclosures for Electrical Equipment (1000 V Maximum) (2018 Ed.)

NEMA ICS 1: Industrial Control and Systems General Requirements (2000 Ed.

2015R)

NEMA ICS 6: Industrial Control and Systems: Enclosures (1993 Ed. 2016R)

NEMA MG 1: Motors and Generators (2018 Ed.)

NEMA Z535.4: Product Safety Signs and Labels (2011 Ed. 2017R)

(Application for copies should be addressed to the National Electrical Manufacturers Association, 1300 N 17th Street, Rosslyn, VA 22209)

National Fire Protection Association (NFPA)

NFPA 70: National Electrical Code (2020 Ed.)

NFPA 79: Electrical Standard for Industrial Machinery (2018 Ed.)

(Applications for copies should be addressed to the National Fire Protection Association, ATTN: Support Services, 11 Tracy Drive, Avon, MA 02322)

Society of Automotive Engineers (SAE)

SAE EIA-267-C: Axis and Motion Nomenclature for Numerically Controlled Machines (2016 Ed.)

SAE EIA-274-D: Interchangeable variable block data contouring, format for positioning and contouring/positioning numerically controlled machines (2015 Ed.)

(Application for copies should be addressed to: Society of Automotive Engineers 400 Commonwealth Drive, Warrendale PA 15096)

TECHAMERICA

TIA-232-F: Interface between Data Terminal Equipment and Data Circuit- Terminating Equipment Employing Serial Binary Data Interchange (1997 Ed. 2012R)

(Application for copies should be addressed to: TECHAMERICA, 601 Pennsylvania Ave., NW, North Building Suite 600 Washington D.C. 20004-2650)

3 REQUIREMENTS:

3.1 Computer Numerical Controls (CNC): The contractor shall provide a fully automatic, solid-state, integrated circuit, multiple microprocessor based-type computer numerical control for the 300 Ton Stretch Draw Press. The control system shall conform to EIA 274-D, EIA 267-C, and EIA TIA/EIA-232-F standards. The unit shall be an Allen Bradley (or equivalent) providing automatic control for all machine functions, and have the below listed functions & features:

3.2 New Motor Control Cabinet: The contractor shall replace the existing motor control cabinet with a new cabinet.

3.3 Operator Station: The contractor shall replace the existing operator station with a new operator station.

3.3.1 HMI (Human Machine Interface): The operator station shall include a human machine interface.

3.3.1.1 The HMI shall include a minimum of one 19 inch screen monitor/operator’s panel with the ability to enter process parameters to control pressure, cycle times, and positioning of the press components.

3.3.1.2 The HMI panel controls (buttons, switches, joy sticks, etc.) shall be labelled in

English to allow rapid selection of parts programs and control of forming force and press position parameters in manual and automatic modes.

3.3.1.3 The HMI shall use Windows 10 based operating system.

3.3.1.4 The HMI shall include a function to show scheduled maintenance with a resettable countdown in units of run hours for each component with a maintenance schedule.

This function shall include a non-resettable log of all countdown resets.

3.3.2 Control System Functions: The operator station shall run Cyril Bath Opsys control system.

3.3.2.1 The control system shall be capable of recording all parameters for each forming cycle, storing all recorded parameters in a specified local and network location, displaying recorded parameters in graph form, generating an average for each parameter over all recorded cycles, and reporting any values outside user specified upper and lower boundaries for each parameter for each cycle.

3.3.2.2 The control system shall be capable of applying an input from the user as a percentage tolerance to the control system generated average of every recorded parameter for each part and setting the upper and lower boundaries for each parameter to be the specified percent tolerance above and below the control system generated average.

3.3.2.3 The control system shall automatically display an error report to both the HMI and the computer work station whenever any parameter is recorded outside the user specified boundaries.

3.3.2.4 The control system shall be capable of generating a cycle report consisting of specified recorded parameters for each machine cycle and storing each cycle report in a specified local and network location.

3.3.2.5 The cycle reports shall be automatically saved and stored in such a way that they are easily sorted and filtered by at minimum date, part, and errors.

3.3.2.6 The system shall include at minimum an integrated 2TB solid state drive and a removable 2TB backup hard disk drive.

3.3.2.7 The system shall run off the solid state drive and automatically backup all data onto the hard disk drive.

3.3.2.8 The system shall be capable of storing and analyzing critical forming cycle data and performing production analysis and statistical process control functions.

3.3.2.9 The control system shall be capable of generating a part forming program from the part model.

3.3.3 Emergency Shutdown Instructions: The operator station shall include a printed set of emergency shutdown instructions such that the instructions are easily readable from twenty (20) feet away and can be easily followed by an untrained operator. The instructions shall be physically mounted to or printed onto the operator station in such a way that the instructions can be easily read from every location that the operator must be throughout the emergency shutdown process.

3.4 New Pressure Transducers, Resolvers and Proportional Valve: The contractor shall replace all existing pressure transducers, resolvers, proportional valves, connection piping and fittings, filters, flow rate controls, and pressure regulators with new components and calibrate all new components. The hydraulics system shall conform to ISO 4413 standards.

3.5 New Power and Control Wiring: The contractor shall replace all existing power and control wiring on the press and replace with new sets of wiring.

3.6 Computer Work Station and Monitors with FormCAM software:

3.6.1 Computer Work Station: The contractor shall provide a computer work station to operate FormCAM modeling software. The computer work station shall include the following at a minimum:

3.6.1.1 One dedicated PC and two 27” diagonal or larger monitors.

3.6.1.2 Dual Intel Xeon Silver 4108 Scalable Xeon Processors 8-core, or equivalent.

3.6.1.3 DirectX – compliant video card capable of supporting supplied monitors.

3.6.1.4 64 GB Random Access memory (RAM)

3.6.1.5 A solid state drive with a minimum of 2TB memory and two (2) backup 2TB drives.

3.6.1.6 The computer work station shall meet or exceed the requirements to operate FormCAM software.

3.6.1.7 The computer shall use a Windows 10 Professional (x64) with SP2 based operating system.

3.6.1.8 Shall be pre-loaded with an exact kinematic virtual model of the TAFB Cyril Bath

Model SD 300 stretch draw press

3.6.1.9 The work station shall be directly connected to the press control system in order to share and transfer programs and data without use of removable or flash memory devices.

3.6.2 FormCAM Software:

3.6.2.1 One license of FormCAM software shall be preloaded on the computer work station.

3.6.2.2 The FormCAM software shall be capable of automatic part program development to aid form tooling design.

3.6.2.3 The software shall be able to take a CAD 3D model of the end item and determine whether the part can be formed on the press, and estimate the press force characteristics and tool design geometries.

3.6.2.4 The stretch simulation software shall be capable of simulating forming operations other than stretch drawing and simulate physical factors such as springback.

3.7 Curved Sheet Holding Jaws Retrofit:

3.7.1 The contractor shall modify the existing pair of sheet holding jaws to be capable of working with the new CNC operating system.

3.7.2 The holding jaws shall be fully integrated with the machine operating control system to fully automate the jaw clamping and curvature in the part programs.

3.7.3 The jaws shall be capable of having the swing motion locked in infinitely variable positions throughout the full range of motion.

3.8 Documentation/Manuals/Data Package: The contractor shall provide three sets of hardcopy operation and maintenance manuals and include a CD containing an electronic copy in each manual.

4 ADDITIONAL REQUIREMENTS:

4.1 Hydraulic Coolant System: Chilled water shall be provided by the Tinker AFB. Any changes to the chilled system required by the new control system must be identified by the contractor. The current chilled water system provides water at 50 psi and 60°F through a 3” diameter pipe to the press, and a 3” diameter return line.

4.2 Hydraulic System: The hydraulic system shall conform to ISO 4413, and shall be complete including all valves, piping, cylinders, and pressure controls. The existing hydraulic power unit on the press shall be retained without modification.

4.3 Pneumatic System: The pneumatic system shall conform to ISO 4414, and shall be complete, including all valves, piping, cylinders, and pressure controls.

Compressed air available at the facility is 90 pounds per square inch (psi).

4.4 Electrical System: The machine shall conform to NFPA 79. The existing source power available at the facility is 480 volt, 3-phase, 60 Hertz (Hz). The machine’s electrical system shall be tolerant of fluctuation of ± 10 percent. The electrical system shall be complete. This shall include any electrical isolation transformer(s) that may be required to modify the existing source voltage to the proper operating voltage of the equipment. A properly rated and fused single disconnect device shall be utilized on the machine with means of lockout in the off position only.

4.5 Arc Flash: All electrical enclosures shall be marked for arc flash hazard per NFPA 79

Paragraph 16.2.3 “Safety Signs for Electrical Enclosures” for arc flash safety. Provide a thermal imaging window in the main electrical enclosure mounted directly in front of the three main fuses supplying the 480V 3 phase power.

4.6 Motors: Motors shall be rated for continuous duty. Alternating-current (AC) motors shall be designed to operate on 60-Hz and each motor enclosure shall meet the requirements for a drip-proof enclosure. All motors shall meet the requirements of NEMA MG-1. Each motor shall have an identification plate to identify manufacturer, model identification, serial number, voltage, amperage, horsepower, phase, frequency and frame number. Motor horsepower shall be the manufacturer’s standard or standard horsepower as indicated on the manufacturer's design and construction drawing(s). Motor vibrations specifications shall be tested based on ISO 3945, ISO 10816, MIL-STD-167-1 and MIL-STD-740-2 as part of the RCM equipment acceptance tests referenced in section 5.6.8.1

4.7 Hour Meter: The machine shall be equipped with a non-resetting type, analog hour meter to display accumulated operating time of the drive motor(s), mounted on the main electrical panel visible from the outside, sealed to prevent the entrance of dust and moisture, and shall be mounted to withstand shock and vibration generated by the machine. The meter shall have a range of 0 to 99,999.9 hours in increments of 1 tenth of 1 hour. A control that tracks and displays total machine on time (a non-resetting type), controller on, program runtime, and run time of the motor(s) shall be considered to meet this requirement.

5 OPEN MARKET ITEMS: The following items shall be considered open market items, and shall be supplied by the contractor:

5.1 Skid, secure, “tarp”, and load the components for the 300 Ton Stretch Draw Press onto carrier (see para. 7.5).

5.2 RIGGING, MOVING, and ELECTRICAL Cost for all of the following:

5.2.1 Transportation of components, as required, to Tinker AFB.

5.2.2 Uncrating of equipment and cleaning of components.

5.2.3 Proper staging of equipment and installation of components to assist factory representatives.

5.2.4 Installation of required mechanical systems, including required air lines and fluid lines. Installation of required electrical systems, including required voltage system, interconnect wiring, transformer, and system checkout by the machine manufacturer and/or the installation/rigging company.

5.3 Oils and lubricants for initial fill of machine as required.

5.4 Testing material, tooling, part programming, and personnel to perform runoff (see para. 7.6).

5.5 Training (see para. 7.7).

6 CONTRACTOR RESPONSIBILITIES: The contractor shall be responsible for the following requirements:

6.1 Overview of Machine Controls Installation: The contractor shall provide all personnel, equipment, tools, supervision, transportation, materials, structural installation requirements, field testing, site oversight, waste handling/transportation/disposal, and any other incidentals necessary to install and setup the 300 Ton Stretch Draw Press Controls including associated machine startup/testing and training. The contractor shall have a sixty (60) working day period to complete the machine installation after the components are delivered on-site at Tinker AFB.

6.2 Personnel Evaluation Criteria: The contractor shall demonstrate, by project resumes and references, the following minimum personnel criteria:

6.2.1 All qualified representative(s), shall be an American citizen of good standing and repute and proficient in the English language. There shall be a background check on each representative prior to entry on Tinker Air Force Base. Resumes with letters of intent are not acceptable.

6.2.2 Evidence of at least one degreed engineer with five (5) years of experience in controls design and installation on Cyril Bath press equipment. Brief description of how they will be assigned to this project, shall prove they will be intimately involved and their expertise will be applied directly to this project.

6.2.3 Evidence of at least one (1) technician with five (5) years of experience with

Industrial Controls and PLC systems. Evidence shall at a minimum provide proof that this technician has had at least 3 past projects as Cyril Bath Equipment Controls and PLC subject matter expert. Brief description how they will be assigned to this project, shall prove they will be intimately involved and their expertise will be applied directly to this project.

6.2.4 Evidence of installation mechanics with at least three (3) years of experience in the design, fabrication, and installation of industrial hydraulic press equipment controls. Brief description how they will be assigned to this project, shall prove they will be intimately involved and their expertise will be applied directly to this project.

6.3 Inspection: The Contractor shall be responsible for performing, documenting, and certifying all inspections in this specification. The Government may perform any of the inspections set forth in the specification where such inspections are deemed necessary to assure materials and services conform to prescribed requirements.

The Government reserves the right to perform any or all of the tests deemed necessary to assure full compliance with this specification.

6.4 Warranty: The contractor shall warranty all equipment and document to the government workmanship free of defects for a period of 365 calendar days. The contractor shall be notified of defects by the Government in writing. The contractor shall respond to all reported problems within 24 hours of notification.

Defects shall be remedied at no cost to the Government within 10 calendar days of notification. Contractor shall be responsible for correcting any found defect or inconsistency with this SOW to the Government’s satisfaction. If the defect or inconsistency begins within but persists beyond the 365 calendar day period, the contractor shall still be responsible for corrective action until the issue is rectified.

All equipment will be subject to usage 24 hours a day, 7 days a week. Warranty period shall begin after all training, implementation audit(s), testing, deliverables, and final approval(s) are completed. The contractor shall be responsible for damages caused by the defect. All materials and labor for corrective action, modifications, and defects shall be supplied by the contractor including a tracking number and carrier emailed to the government POC. The period of performance for this contract shall include the one (1) year warranty.

7 SPECIFIC TASKS:

7.1 The contractor shall follow the manufacturer’s drawings and specifications for the installation of the machine. The contractor shall coordinate with the contracting officer’s technical representative. The contractor shall be required to perform all installation actions during first shift of 0600 to 1630 hours. Non duty hours are from 1630 to 0600 hours, Government holidays, and on weekends. The Government Inspector shall oversee contractor installation activities IAW the contractor’s approved work plan schedule for non-duty hours, holidays, and weekends.

7.2 An Emergency and Project Point of Contact Telephone List shall be jointly developed. An emergency and project point of contact telephone list shall be provided by the contractor to the government inspector.

7.3 The contractor shall supply all items indicated on the manufacturer’s drawing as

“to be supplied by customer” including but not limited to anchor bolts/boxes, flat steel plate, expansion materials, angle iron, checkered plate, grounding rod, and concrete sealer. Specifications are as indicated on the manufacturer’s design drawings for the 300 Ton Stretch Draw Press.

7.4 The contractor shall be responsible for daily and final project clean-up of all areas including but not limited to the interior work site, utilized roadway, utilized facility aisles, utilized ramps, and outside lay down area. All generated debris, waste materials, and trash shall be swept up and removed daily. Before departing each day, the contractor shall pick up and dispose of all packing material, material remnants, and debris from the area.

7.5 Machine Transportation, Rigging, and Installation:

7.5.1 Transportation: The contactor shall arrange for commercial bill-of-lading (CBL) for transportation of the 300 Ton Stretch Draw Press Control upgrade components to Tinker AFB. The contractor shall skid, secure, “tarp”, and load the 300 Ton Stretch Draw Press Control upgrade components onto the carrier.

7.5.2 Rigging: The contractor shall furnish all labor and material handling equipment required for off-loading the 300 Ton Stretch Draw Press Control upgrade components at the final destination in B9001. The contractor shall be responsible for the disposal of all crating, skids, and packing materials.

7.5.3 Installation/Assembly: The contractor shall furnish all personnel, equipment, tools, and materials necessary to off-load, clean, and set on-site machine components and the associated assembly of said components with the supervision of factory representatives.

INSTALLATION RESPONSIBILITIES

Government Contractor ☐ ☒ a. Furnish labor and material handling equipment for off-loading and placing item on foundation ☐ ☒ b. Connect machine to the provided building utilities ☐ ☒ c. Provide all necessary tools, gages, and instrumentation necessary to perform the required tests ☐ ☒ d. Provide and charge all systems with fluids in accordance with manufacturer's instructions ☐ ☒ e. Material, material handling, rigging equipment, and qualified personnel for operational and performance testing ☒ ☐ g. Provide utilities connections within 25 feet of the machine

(pre-existing unless otherwise specified)

7.5.4 Utilities Connections: The contractor shall furnish all personnel, equipment and materials necessary to connect the 300 Ton Stretch Draw Press to TAFB provided 480V electrical and compressed air services that are available within twenty-five (25) feet of final connection points. The contractor furnished isolation transformers shall be of the “shielded type” and all electrical work shall be IAW National Electrical Codes (NEC). The contractor shall provide three sets of installation drawings showing a dimensioned top view of the 300 Ton Stretch Draw Press and applicable electric and air requirements 30 days ARO to enable government lead time of roughed-in utilities (if required). Equipment grounding requirements should be indicated on drawings and the installation of such grounding requirement shall be the responsibility of the contractor.

7.6 Final Inspection/Acceptance Test (Destination): Final inspection and acceptance test shall be performed on the machine and control system to ensure conformance with this SOW. The acceptance test shall be performed only after the machine controls are installed. The machine shall pass the examination, all tests, and the final inspection at Tinker AFB to be accepted.

7.6.1 Examination: The machine shall be examined for design, dimensions, construction, materials, components, electrical equipment, and workmanship to determine compliance with all requirements of this SOW.

7.6.2 Machine Performance/Acceptance Testing: The contractor shall provide all labor, tooling, test materials, and programs required for the tests that are to be completed at Tinker AFB. The contractor shall conduct the manufacturer’s standard commercial testing of the 300 Ton Stretch Draw Press and the following tests at Tinker AFB:

7.6.2.1 Operational Test: The machine shall be operated under no-load condition for not less than four (4) hours, starting at the point where the press achieves normal operating conditions after powering up. Proper operation of all controls, motors, and adjusting mechanisms shall be observed. All items shall be tested through the entire range of pressures at 500 psi intervals up to the maximum operational pressure limit. Any air, hydraulic, or other fluid leaks shall be repaired as they are discovered. Control functions and machine response shall be tested in each mode of operation (Manual and Automatic). The safety limit stops shall be checked by attempting to exceed the limits of travel in all axes. Jaws, upper and lower platens, and auxiliaries shall be tested through their full range of motion.

Contractor shall provide results, including final report, to the Government

POC.

7.6.2.2 Performance Test: There will be a test on producing a representative aluminum sheet metal test standard part shown in Appendix B. Testing shall consist of forming two (2) identical parts utilizing Form Blocks in accordance with the manufacturer’s standard testing identified in the approved test procedures. The contractor shall provide all materials and form tooling at the destination. The test shall produce a part using the full depth of the machines forming capabilities. These parts will contain several compound angles and concave and convex regions per drawings in Attachment B. The test shall be inspected for cracks and defects using the visual inspection method. The part shall be checked for dimensions using a fit check assembly. During these tests the equipment shall have no shutdowns for repairs or adjustments. Any repairs or adjustments shall be done prior to or after the part run. All tests specified in Test Procedures shall be performed.

7.6.2.3 Test Procedures: The manufacturer shall be responsible for the development of all test processes, procedures, and tooling necessary for manufacturing the stretch draw formed parts illustrated in the attached drawings (see Attachment B). Two (2) copies of the manufacturer’s test processes, including machine pressure settings and procedures, shall be submitted within thirty (30) calendar days after contract award for review/approval by the Government. The Government shall notify the contractor within ten (10) working days of the acceptance/rejection of the test procedures. The test procedures shall become part of the contract. The manufacturer shall provide dimensioned drawings of all tooling, Form Blocks or otherwise, used in manufacturing each test part. Each drawing shall contain information to allow for the accurate reproduction of the item.

Test process, procedures, and drawings shall be in the English language.

Approved processes, procedures, tooling, and tool drawings shall become part of the contract for inspection testing and shall be retained by the Government.

7.7 Training Requirements: After satisfactory completion of acceptance testing of the system, the contractor shall provide the services of a qualified representative(s) who is an American citizen of good standing and repute and proficient in the English language for specialized training to familiarize Government personnel with the equipment, control system, and software and to help ensure reliable performance and maximum service life, during normal usage. All training shall be performed on site at the Government facility, Tinker AFB in B9001. The contractor shall provide 3 consecutive training courses. Each training shall be for eight (8) attendees. Training shall include a minimum of five (5) consecutive eight (8) hour working days of operator training, three (3) consecutive eight (8) hour days of maintenance training, and five (5) consecutive eight (8) hour days of FormCAM training. The courses shall be between 5:45 am and 2:30 pm excluding weekends and federal holidays, utilize as-built drawings and manuals provided under this contract, and include both classroom and hands-on portions. The contractor shall supply all printed training aids for the courses in the English language, and the training aids shall become the property of the Government.

7.7.1 Operator Training: The operator training shall include the following at a minimum:

7.7.1.1 Regular machine and control system operation

7.7.1.2 The differences between old and new equipment and operation

7.7.1.3 Demonstration of the performance test procedure as described in section 7.6.2.2

7.7.1.4 Tooling and work piece loading and unloading

7.7.1.5 Controller and machine setup

7.7.1.6 Press operation

7.7.1.7 Theory of forming operations and relevant troubleshooting procedures. This section shall include training in common work piece defects, probable causes of various possible defects, machine adjustments and other corrective actions to tune the forming process for better results, and other training and topics to aid in the attendees’ understanding of both the machine and forming processes.

7.7.1.8 Use of the machine in automatic and manual modes

7.7.1.9 Develop a part program from a set of manual inputs

7.7.1.10 Sorting, filtering, viewing, interpretation, and transfer of cycle reports and historical cycle report data

7.7.1.11 Establishment of statistical process control parameters

7.7.1.12 Basic control system troubleshooting procedures

7.7.1.13 Common alarm codes and corrective action procedures

7.7.1.14 Basic part and die modeling and forming simulation

7.7.1.15 Part and forming data transfer

7.7.2 Maintenance Training: The maintenance training shall include the following at a minimum:

7.7.2.1 Familiarization with the maintenance schedule(s) and processes for all components

7.7.2.2 Equipment troubleshooting procedure

7.7.2.3 Use of cycle reports to identify potential machine issues

7.7.2.4 Familiarization with printed and digital maintenance manuals

7.7.2.5 Alarm codes and corrective action procedures

7.7.2.6 Basic operation of the machine and control system

7.7.3 FormCAM Modeling Software Training: The FormCAM training shall include the following at a minimum:

7.7.3.1 Part and die modeling and tool design

7.7.3.2 Machine program generation

7.7.3.3 Transferring data to the machine for forming

7.7.3.4 Running and interpreting forming simulations

7.7.3.5 Generation of form dies from part models including consideration for springback and other common material properties and forming process limitations.

7.8 Documentation/Manuals: Documentation in the form manuals shall be provided for the 300 Ton Stretch Draw Press. The documentation shall be divided into a minimum of two manuals. One manual shall be configured for operation of the 300 Ton Stretch Draw Press, the other manual shall be configured for maintenance and repair support of the 300 Ton Stretch Draw Press. The contractor shall deliver a total of three hard copies of each manual and electronic files of the manuals. The manuals and electronic files shipped with the 300 Ton Stretch Draw Press controls.

These manuals shall be written in the English language and shall include the following provisions at a minimum:

7.8.1 Operation Manuals: Operation manuals shall include at a minimum:

7.8.1.1 A general overview section containing a description of the 300 Ton Stretch

Draw Press including labeled diagrams and pictorials of the 300 Ton Stretch Draw Press with all subsystems and their functions.

7.8.1.2 Daily routine checkout, start-up procedures, and shutdown procedures.

7.8.1.3 Programming instructions necessary for full operation of the 300 Ton

Stretch Draw Press including but not limited to entering values and parameters and selecting routines and events. The contractor shall also furnish a printout of the programming to assist personnel in understanding 300 Ton Stretch Draw Press operation, maintenance, and troubleshooting.

7.8.1.4 Safety precautions

7.8.1.5 Process and system alarm description and operator corrective action procedures

7.8.1.6 Step by step descriptive narrative of 300 Ton Stretch Draw Press process sequences

7.8.1.7 Operator inspection and maintenance procedures

7.8.1.8 Basic equipment operations

7.8.1.9 Emergency shutdown

7.8.1.10 Terms of the equipment warranty

7.8.1.11 Copy of the Lock-out – Tag-out Procedure

7.8.1.12 Basic troubleshooting

7.8.1.13 Calibration procedures for all items requiring calibration

7.8.2 Maintenance Manuals: Maintenance manuals shall include at a minimum:

7.8.2.1 Descriptive literature and brochures for all components, subsystems, and assemblies including but not limited to electrical schematics of each system, equipment assembly diagrams, exploded views where necessary, and reference to a complete bill of materials

7.8.2.2 Component manuals, authorized service center information, and other material received by the contractor with the components and sub-assemblies of the 300 Ton Stretch Draw Press.

7.8.2.3 Maintenance, troubleshooting, and repair instructions for the 300 Ton

Stretch Draw Press subsystems, components, and controls.

7.8.2.4 Preventative maintenance plan detailing all maintenance actions not performed by equipment operators complete with detailed illustrations.

The plans shall be sectioned by daily, weekly, biweekly, monthly, quarterly, biannual, and annual actions as applicable to the specific 300 Ton Stretch Draw Press subsystems.

7.8.2.5 Spare parts and consumables list identifying the part name, the contractor’s part number, the manufacturer's name and address, the manufacturer's part number if different from the contractor's part number, the part cost, and the number required per system or quantity recommended for spare parts inventory.

7.8.2.6 Backup copy of all software, software programs, and parameters in an electronic format such as CD or DVD. Flash memory drives shall not be considered a fulfilment of this requirement as they are not allowed.

7.8.2.7 Provide local and/or stateside Point of Contact (POC) with US telephone numbers for ordering spare parts and service.

7.8.3 The contractor shall provide 3 copies of visual displays of start-up/shut down procedures on an 8” x 11” laminated sheet in a readable font size (12 pt.

minimum).

8 ENVIRONMENTAL and SAFETY REQUIREMENTS:

8.1 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 Tinker Air Force Base (TAFB) Supplement to Air Force Instruction (AFI) 32-7086, “Hazardous Materials Management”, Tinker AFB procedures per Tinker Air Force Base Instruction (TAFBI) 32-7004, “Hazardous Waste Management”, and Complex procedures per Oklahoma City Air Logistics Complex (OC-ALC) Sup to AFI 32-7086, “Hazardous Material Management” and OC-ALCI 32-101 “Air Quality Record Keeping Procedure”. Publications are available digitally on e-Publishing website at www.e-publishing.af.mil for downloading or ordering.

8.1.1 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 the CO, two (2) copies to the COR, one (1) 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.

8.2 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 Tinker AFB. Contractors shall be compliant with HAZMAT management procedures per Oklahoma City Air Logistics Complex (OC-ALC) 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.

Safety Data Sheet (SDS) and Labeling: 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 PWS on Tinker AFB before written approval is provided by 72 ABW/CEIE, Natural Infrastructure Management (Environmental Compliance). The Contractor shall submit to the COR, ten (10) calendar days after contract award date all Safety Data Sheets (SDSs) and a completed OC-ALC Form 152, SDS Information Sheet. The Contractor shall receive approval from the COR prior to shipping any chemical, material or substance to Tinker AFB. A copy of the manufacturer 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 Contractor shall ensure containers of hazardous chemicals are labeled with the following information, prior to shipping to Tinker AFB IAW OSHA Hazardous Communication Standard, Title 29, CFR Part

1910.1200 (2012): product identifier; signal word; hazard statement(s);

precautionary statement(s); pictogram(s); and name, address and telephone number of the chemical manufacturer, importer, or other responsible party. The COR will forward all SDS submittals to 72 ABW/CEIE for approval. A current manufacturer 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 SDSs for all chemicals and SDSs shall be readily accessible at all times by Contractor personnel as well as government employees.

8.3 Hazardous Waste (HAZWASTE): 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 applies. 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.

8.3.1 Discharges: Any discharges into Tinker’s industrial waste treatment plant (IWTP) or sanitary sewer shall be approved and done IAW Tinker Industrial Waste Water Discharge Permit as instructed by 72 ABW/CEIE, Natural Infrastructure Management (Environmental Compliance). Notice of intent documentation shall be provided to the COR within ten (10) days after award.

The COR will submit the required notice of intent documentation to the UEC for 72 ABW/CEIE approval. The Contractor shall not discharge into IWTP and sanitary sewer prior to approval issued by 72 ABW/CEIE. The Contractor shall maintain records of written approval issued by 72 ABW/CEIE for discharges into IWTP and sanitary sewer.

8.3.2 Off-Site Discharges: For discharges outside of Tinker 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.

8.3.3 Environmental Training: Upon COR receipt of the “No Hazardous Waste

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

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 72 ABW/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_en us000000, 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 Tinker AFB procedures per TAFBI 32-7004, “Hazardous Waste Management”.

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

8.5 Environmental Certification: Warranty work that requires the shipment of parts off base shall adhere to the following. The Government will ensure the part or equipment is clean, drained and purged before it is transferred to the Contractor for repair. The Government will provide written certification of such to the Contractor prior to shipment or pick up of the part or equipment. Certification will be on letterhead with a statement which specifies the part or equipment is certified to be clean, drained and purged. In addition, as a minimum, said letter will contain description of the part or equipment, make, model, serial number, and OC number (if applicable). This certification will be provided to the COR three (3) business days prior to the pick-up or shipment of the part or equipment. The COR will, in turn, provide it to the Contractor within two (2) business days prior to the pick-up or shipment of the part or equipment.

The Contractor shall ensure and provide written certification that the repaired the part or equipment is cleaned to remove all hazardous contaminants, dirt, shavings, oil, or grease, and drained and purged to remove all fluids, oils and liquids before returning to Tinker AFB. Certification shall be on company letterhead with a statement which specifies the part or equipment is certified to be clean, drained and purged. In addition, as a minimum, said letter shall contain description of part or equipment, make, model, serial number, and OC number (if applicable). This certification shall be provided to the COR two (2) business days prior to the return of the part or equipment.

8.6 Audible Noise Level: Audible noise emitted by the equipment shall not exceed 84

Decibels (dB), measured on the “A” weighted scale of a standard Type II sound level meter, at the operator's work position or any point at a distance of three (3) feet from the equipment. Noise generated by the work piece shall be excluded in determining compliance of the equipment with the 84 dB requirements.

8.7 Mercury Restriction: The equipment shall not contain mercury or mercury compounds nor be exposed to free mercury during manufacture.

8.8 Asbestos Restriction: Asbestos and materials containing asbestos shall not be used on or in the equipment.

8.9 Lead: Lead and materials containing lead shall not be used on or in the equipment.

8.10 Polychlorinated Biphenyl (PCB): The use of polychlorinated biphenyl (PCB) on or in the equipment is prohibited.

APPENDIX A

Location in B9001 Post B25

APPENDIX B

Test Standard

Fit Check Assembly