Revision 3 - SOW for Composite Processing Ovens.pdf

Statement of Work

Composite Processing Oven

CSN#:

Preparing Organization

76 CMXG\MXDEB Tinker AFB, OK 73145

Preparation Date: 4/23/2021

Revision Number: 3 Revision Date: 4/17/2022

SOW – Composite Processing Ovens

TABLE OF CONTENTS

1. SCOPE OF WORK

1.1. Scope Summary

1.2. Background

2. APPLICABLE DOCUMENTS AND DEFINITIONS

2.1. Minimum Requirements

2.2. Government Standards

2.3. Non‐Government Standards

3. GENERAL REQUIREMENTS

3.1. Design

3.2. Construction

4. TRANSPORTATION, RIGGING, FOUNDATIONS, AND INSTALLATION………………………………………10

4.1 Transportation……………………………………………………………………………………………………………...10

4.2 Rigging……….………………………………………………………………………………………………………………….10

4.3 Installation…………………………………………………………………………………………………………………….10

4.4 Utility Hook‐Up……………………………………………………………………………………………………………...10

4.5 System Charging…………………………………………………………………………………………………………….11

4.6 Installation Drawing……………………………………………………………………………………………………….11

Appendix A……………………………………………………………………………………………………………..……………….12

1. SCOPE OF WORK

1.1. Scope Summary

Procurement of two Class C type II composite curing ovens per NFPA 86 and AMS 2750. Ovens will be acquired as a turn‐key system. Both of the ovens will have interior dimension of width length height respectively of 15’x25’x12’. Assemblies will be transported to Building 9001 post TBD, Tinker AFB, Oklahoma.

Note: Detailed requirements will be specified in the ‘Requirements’ section as well as table “TABLE I: STC Model Minimum Requirements” in the appendix.

1.2. Background

The composite shops in the 553rd CMXG are responsible for the repair of all composite assets on the B‐1, B‐52, KC‐135, and E‐3. Most parts require a curing oven to meet the high temperature curing specifications called out in the technical data. The shops currently have three curing ovens. These ovens often end up being the bottleneck during the repair process. The composite shops expect to increase workloads as the scope of repair for assets expand as well as the introduction of potential new workloads such as the KC‐46 and B‐21. The current amount of ovens will not be able to support the needs of the shop in the future. The addition of two ovens will allow the shop to increase flow efficiency and support additional workloads

2. APPLICABLE DOCUMENTS AND DEFINITIONS

2.1. Minimum Requirements

The Contractor, at a minimum, is required to comply with the current editions of the following requirements for design, construction, installation, and safety as applicable. The term “most recent edition” shall be understood to mean the “most recently released edition as of date of issuance of contract”.

2.2. Government Standards

2.2.1. The following documents form a part of the purchase description to the extent stipulated herein.

2.2.1.1. 29 CFR 1910 – General Industry, OSHA Safety and Health Standards (29 CFR 1910), 2020 or most recent edition (available at http://www.osha.gov/)Environmental Protection Agency rules or regulations

2.2.1.2. OSHA rules or regulations

2.2.1.3. Misc. Federal Standards

2.2.2. U. S. Department of Labor

2.2.2.1. 29 CFR 1910 – General Industry, OSHA Safety and Health Standards (29 CFR 1910), 2010 or most recent edition (available at http://www.osha.gov/)

2.2.2.2. Application for copies should be addressed to the U.S. Department of Labor, 200 Constitution Ave, Washington, D.C. 20210

2.2.3. Environmental Protection Agency (EPA)

2.2.3.1. 40 CFR 82 – Protection of Stratospheric Ozone, 2010 or most recent edition

2.2.3.2. Application for copies should be addressed to the U.S. Department of Labor, 200 Constitution Ave, Washington, D.C. 20210

2.2.4. Federal Standards

2.2.4.1. (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)

2.3. Non‐Government Standards

2.3.1. The following documents form a part of the purchase description to the extent stipulated herein.

2.3.2. National Fire Protection Association (NFPA)

2.3.2.1. NFPA 1 – Fire Code, 2020 edition or most recent edition

2.3.2.2. NFPA 70E – Standard for Electrical Safety in the Workplace, 2011 edition or most recent edition

2.3.2.3. NFPA 79 – Electrical Standards for Industrial Machinery, 2007 or most recent edition

2.3.2.4. NFPA 86 – Standard for Ovens and Furnaces, 2019 or most recent edition

Note: Application for copies should be addressed to National Fire Protection Association, Battermarch Park, Quincy, MA 02269

2.3.3. Telecommunications Industry Association (TIA) Standard

2.3.3.1. EIA/TIA‐232‐F – Interface Between Data Terminal Equipment and Data Circuit‐Terminating Equipment Employing Serial Binary Data Interchange, 1997 (R 2002) or most recent edition

2.3.3.2. Application for copies should be addressed to IHS International Inc., http://www.ihs.com, or call 1‐800‐854‐7179 for U.S. and Canada

2.3.4. National Electrical Manufacturers Association

2.3.4.1. NEMA MG 1 – Motors and Generators, 2009 (R2010) or most recent edition

2.3.4.2. NEMA ICS 6 – Industrial Control and Systems: Enclosures, 1993 (R2006) or most recent edition

Note: Application for copies should be addressed to National Electrical Manufacturers Association, 1300 N 17th Street, Suite 1752, Rosslyn, VA 22209

2.3.5. American National Standard Institute

2.3.5.1. ASTM SI 10 – American National Standard for use of the International System of Units (SI): The Modern Metric System, 2010 or most recent edition

Note: Application for copies should be addressed to American National Standards Institute, Attn: Sales Department, 1430 Broadway, New York, NY 10018‐3363

2.3.6. American Welding Society Inc (AWS)

2.3.6.1. AWS D14.4 – Specification for Welded Joints in Machinery and Equipment, 1997 or most recent edition

Note: Applications for copies should be addressed to the American Welding Society Inc, 550 North LeJeune Road, Miami, FL 33126

2.3.7. International Organization for Standardization

2.3.7.1. ISO 4413 – Hydraulic Fluid Power – General Rules and Safety Requirements for Systems and Their Components, 2010 or most recent edition

Note: Application for copies should be addressed to International Organization for Standardization, 1, ch. de la Voie‐Creuse, Case postale 56, CH‐1211 Geneva 20, Switzerland, e‐mail central@iso.ch or IHS International Inc., http://www.ihs.com, or call 1‐800‐854‐7179 for U.S. and Canada

2.3.8. Order of Precedence: In the event of a conflict between the test of this specification and the references cited herein, the test of this specification takes precedence. Nothing in this document, however, supersedes applicable laws and regulations unless a specific exception has been obtained.

3. General Requirements

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

3.1.1. Installation Offeror shall provide turnkey installation of the ovens.

3.1.2. Measuring and Indicating Device Graduations Measuring and indicating devices on the machines shall be graduated in both US customary units and International System of Units (SI).

3.1.3. Machine Controls Electrical, mechanical, hydraulic, and pneumatic operating controls shall be located convenient to the operator’s workstation.

3.1.4. Safety and Health Requirements Machine parts, components, mechanisms, and assemblies furnished on the machine, whether specifically required herein, shall comply with requirements of OSHA 29 CFR 1910.

3.1.5. Safety Guarding Covers, guards, or other safety devices shall be provided per NFPA 86. The safety devices shall not interfere with the operation of the machine. The safety devices shall prevent contact with the guarded part, and shall be easily removed to facilitate inspection, maintenance, and repair of the parts.

3.1.6. 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 three (3) feet away from the equipment. Noise generated by the ambient workplace shall be excluded in determining compliance of the equipment with the 84 dB requirements.

3.1.7. Mercury Restriction The machines shall not contain mercury or mercury compounds nor be exposed to free mercury during manufacture.

3.1.8. Asbestos Restriction Asbestos and materials containing asbestos shall not be used on or in the machines.

3.1.9. Lead Lead and materials containing lead shall not be used on or in the machines with the exception to radiation cladding and lead solder in circuits.

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

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

3.1.12. Interior Dimensions The two ovens shall have the following dimensions 15’X25’X12’. The qualified working zone should be 1ft from the interior of the wall per AMS 2750.

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

3.1.14. Special Tooling and Equipment All special tooling and equipment required for proper operation of each machine (such as special tools needed for maintenance) shall be furnished. A list of these items shall be furnished at time of proposal.

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

3.1.16. Machine Nameplate A nameplate shall be securely attached to each machine.

The nameplate data shall meet the requirements of NFPA 79 and contain, at a minimum, the following information listed below. If the machine is a special model, the model designation shall include the model number of the basic standard machine and a suffix identified in the manufacturer's permanent records.

Manufacturer’s Name

Manufacturer’s Model Designation

Manufacturer’s Serial Number

Rated voltage, number of phases, and frequency

Full‐load current for each supply

Ampere rating of the largest motor or load

Short‐circuit current rating of the industrial control panel

Maximum ampere rating of the short‐circuit and ground fault protective device, where provided

Electrical diagram number(s) or number of the index to the electrical drawings

3.1.17. Identification Marking of Military Property: An Item Unique Identification Marking (IUID) shall be provided in accordance with MIL‐STD‐130N and all applicable documents within the standard with Machine Readable Information (MRI) and item identification marking and automatic data capture. The application of Human Readable Information (HRI) shall be used in combination with MRI and free text. At a minimum this tag shall contain the information listed in Paragraph 3.7.2 Nameplate.

3.1.16.1 Warranty Data Plate: At machine acceptance, Contractor shall securely attach a warranty data plate to the machine enclosure. In accordance with MIL‐STD‐

130N, the data plate shall include the statement “WARRANTED ITEM” and the warranty expiration date.

Nomenclature

Cage Code

Manufacturer

Model Number

Serial Number

Date of Manufacture

Contract Number

3.1.18. Add‐ons The following add‐ons or greater are required;

• 2 Windows located on the oven doors

• 1 PC for Vent and Vacuum

• 3 Vacuum source ports

• Interior lighting

• External Services and Shipping

• Operator training upon installation

• 5 year customer support after installation

3.2 Construction Machine shall be constructed with a heavy steel tubing and large insulated section. The insulated sections shall not use sheet‐metal side supports due to issues with warping and leakage during cure cycles. The machines shall be constructed of parts that are new, without defects, and free of repairs. The structure shall withstand all forces encountered during operation of the machine to its maximum rating and capacity without distortion.

3.2.1 Machine Enclosures The test area shall be fully enclosed during testing.

3.2.2 Electrical System Each 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 including electrical transformer(s) that may be required to modify the existing source voltage to the proper operating voltage of the equipment. A properly rated and fused single disconnect device shall be utilized on the machine with means of lockout in the off position only. Wiring inside electrical enclosures shall be individually labeled.

3.2.3 Electrical Enclosures Construction of electrical enclosure(s) shall conform to NEMA ICS 6 standards. The electrical enclosure(s) shall be a NEMA type 12 intended for indoor, non-hazardous location. All electrical components shall conform to applicable NEMA ICS 1 standards. Machine electrical cabinet shall meet requirements of NFPA 79. Electrical enclosure(s) shall provide means for ventilation.

3.2.4 Arc Flash Protection Each machine’s electrical enclosure and enclosures of disconnecting devices shall be marked for arc flash hazard warning in accordance with NFPA 79 Paragraph 16.2.3.

3.2.5 Facility Connections Electrical connections made to the facility electrical system shall conform to NFPA 70.

3.2.6 Emergency Stop A means to cut power shall be provided in a location convenient to the operator’s workstation. The emergency stop shall be activated by a single pushing action. The emergency stop shall not be deactivated unless at least two steps are taken to ensure no accidental deactivation.

3.2.7 Status Signal Light The equipment shall be equipped with a red signal light(s) indicating when a test is in progress. The light(s) shall be visible from all directions within twenty (20) feet of the enclosure. The light(s) shall be mounted no less than eight (8) feet from floor level. The light(s) visibility shall be measured from clear lines of sight during inspection. Facility and normal shop operation procedures that obstruct small portions of visibility are not cause for rejection.

3.2.8 Data Access The PC shall be able to connect to a BACNET system. All connections and supplies for connections shall be provided by offeror.

3.2.9 Controller/PLC Operating Systems and Interfaces The controller/PLC shall be based on Windows 10 Operating Systems. The machine shall be configured with maximum drive space, RAM, USER memory, and the latest Windows 10 updates at the time of order. The control shall meet the following minimum characteristics:

3.2.10 Account Privileges At a minimum, privileges shall be configured for user and administrative accounts. User accounts shall be able to perform all machine functions without use of Windows administrative privileges.

3.2.11 Anti‐Virus Software The controllers shall be compatible with McAfee ENS 10.7.X or later.

3.2.12 Universal Serial Bus (USB) Communications All internal and external USB communications used on the equipment shall be clearly documented and described within the contractor provided technical data. All external USB ports that are accessible to the user shall be configured to use administrative access controls and capable of being physically disconnected or rendered inoperable by non-permanent means. Contractor shall provide, as an appendix to the technical data, detailed easy to read instructions for disabling USB ports.

3.2.13 Crash Prevention The multipoint test machine shall be equipped with means to prevent components from colliding with itself as a damage prevention measure.

3.2.14 Testing Time Display and Test Count The controllers shall display a minimum of total machine powered on time, total machine test time, and total part count. All machine time displays and part counts shall be available as a discrete output for data collection purposes IAW Paragraph 3.2.12

3.2.15 Patches and Software Updates The Contractor shall provide as an appendix to the technical data, an offline patch management and update process that includes easy to read written instructions that clearly define the step-by-step processes detailing installation and verification of patch updates. At a minimum, the instructions shall cover, the base Operating System (OS). The scope of the instruction shall be expanded to include software installed on third party add-on hardware applications listed elsewhere in this SOW.

3.2.16 Uninterruptible Power Supply (UPS) Each machine shall be equipped with an uninterruptible power supply to safeguard installed industrial computer system(s) from damage in the event of main power interruptions. The alternative power supply shall be provisioned to automatically sense partial or total loss of main power and initiate a complete systematic shutdown the industrial computer(s).

4. TRANSPORTATION, RIGGING, FOUNDATIONS, AND INSTALLATION.

4.1 Transportation The Contractor shall provide the full transportation and delivery for each machine and all accessories to installation site at B9001, Tinker AFB.

4.2 Rigging The Contractor shall furnish all labor and material handling equipment required for off-loading the equipment at the final destination in B9001 Tinker AFB. The Contractor shall be responsible for the disposal of all crating, skids, and packing materials.

4.3 Installation The Contractor shall provide all personnel, equipment, tools, and materials necessary to clean and set on-site machine components and the associated assembly of said components with the supervision of factory representatives. Final location of machine shall be approved by process engineer.

Tinker engineers and maintenance personnel shall be permitted to observe installation activities.

4.4 Utility Hook-Up The Contractor shall furnish all personnel, equipment, and materials necessary to connect the equipment to Tinker AFB provided “rough-in” 480V electrical and compressed air services that are available within thirty-five

(35) feet of final connection points. Contractor shall be responsible for providing necessary transformers for compatibility to facility power supply.

4.5 System Charging The Contractor shall provide all fluids including but not specifically limited to hydraulic oils, way and lube oils IAW manufacturer’s instruction. Safety Data Sheet(s) (SDSs) of all chemicals used to satisfy the requirements shall be provided to the Government representative 90 days in advance of contractor bringing or shipping material on base for necessary authorization.

4.6 Installation Drawings The contractor shall provide to the receiving Government facility, engineering installation drawings (hard copy and electronic .dxf format) showing the necessary compressed air and electrical utilities, in addition to specific foundation requirement drawings of the machine. The final installation drawings shall be provided NLT one hundred twenty (120) days after Order Delivery Award (ODA). The drawings shall contain at a minimum, but shall not be limited to, the following information:

a. Overall and principal dimensions in sufficient detail to establish limits of space in all directions required for installation, operation, and servicing.

Amount of clearance required to permit opening of doors and removal of plug-in units. Clearance for travel or rotation of any moving parts.

b. Interface mounting and mating information, such as dimensions of location for attaching hardware and meet the manufacturer vibration design requirement.

c. Interface pipe and cable attachments required for installation and co-functioning of the item to be installed with related items.

d. Information necessary for preparation of foundation plans; including mounting place details, hardware requirement lists, drilling plans and shock mounting buffers.

e. Size and location of duct (exhaust duct can fit in an area no larger than 24”

X 24”)

f. Weight of each component and total unit.

g. Location, type and dimension of cable entrances, terminal boards, and electrical connectors.

h. Interconnecting and cable detail.

i. Peak electrical load (AMPS) required to support all proposed equipment in its fully configured and operational state, including all accessories.

Appendix A: STC Model Minimum Requirements

Interior Dimensions

Interior Length 25ft

Interior Width 15ft

Interior Height 12ft

Tooling Load

Thermal Load 5,000lbs carbide steel

Temperature

Max operating temperature 500°F

Heating Rate Adjustable 0.1-10°F/min

Cooling Rate Adjustable 0.1-10°F/min

Temperature Uniformity +/- 5°F

Floor

Floor capacity 10,000lbs

Floor type

Uninsulated floor, 12GA steel plate minimum.

Bolted to concrete floor.

No grooves in flooring.

Door

Opening type Swinging doors

Accessories

First oven: Pass through doors. One windows on each door

Second Oven: Single door. Two windows on door

Air Circulation

Flow Estimate 100,000 CFM or greater

Recirculation Fans 50,000 CFM or greater

Air Flow Adjustment Adjustable louvers

Air flow type Combination

Heating System

Heating Type Electric

Heat system rate 480V/3ph/60Hz

Location Heating unit shall be on top of the oven.

Part Thermocouples

Quantity minimum 40

Type J

Control type Leading and lagging controls

Air Thermocouples

Zone control TCs

Amount required for TUS calibration

Per AMS 2750 based on interior area cubic ft

Oven hi-limit-TC One per zone

Vacuum Pumps

Vacuum pumps 1

Vacuum pump flow 45 CFM

Vacuum lines minimum 20

Vacuum specs Feed through tubing

Vacuum specs Stainless steel tubing ½” or greater

Vacuum specs Connection to header

Vacuum Probe Lines

Line quantity minimum 20

Vacuum probe line specs Feed through tubing

Vacuum probe line specs Stainless steel tubing ½” or greater

Vacuum probe line specs Manual cut-off valve

Power System

Motor Controls Includes breaker and motor starter

Control Transformer Included

High voltage 480V/3PH/60Hz

Control Voltage

120V for computers

24VDC for all other components

Control System

Hi-limit controllers 2

Programmable Logic Controller

Modules Quantity minimum 18

Module Type

Discrete Inputs

Discrete Outputs

Analog Outputs

Analog Inputs

Thermocouple Inputs

Control PC

Memory RAM 1 GB or higher

Operating system Windows 10 Professional

Uninterruptable Power 250VA for 15 minutes

Miscellaneous

Selector switches Lights

Wire-way Terminal etc.

Capable of connecting to BACNET protocol

Remote desktop access capabilities

Use of barcodes to create/ use recipes