Statement_of_Work_(SOW)_-_20120821.pdf

OKLAHOMA CITY AIR LOGISTICS CENTER

TINKER AIR FORCE BASE, OKLAHOMA

STATEMENT OF WORK

FOR

GAS COMPOSITE DRYING OVEN

SOW-20120821

21 August 2012

1.0 SCOPE: This performance Work Statement (SOW) specifies the minimum requirements for the purchase of one (1) each Heavy Duty Gas Walk-in Composite

Drying and Moisture Removal Oven with Top Mounted Heat Chamber, hereafter referred to as Oven. The Oven shall be a NFPA 86 Class “A” oven with a maximum operating temperature of 200° F and average operating temperature of 120° F. The Oven shall have interior work area dimensions of at least 312” D x 288” W x 144” H. The rest of this specification shall be taken as minimum requirements unless otherwise stated and a standard unit which meets or exceeds these minimums may be offered in place of a custom unit. The following items shall be included: assembly prints, wiring schematics, oven (pre-wired, tested and balanced as specified), start-up and training, maintenance manuals, operator manuals, calibration manuals and information and standard one (1) year warranty. Bidders shall furnish total amperage required for their equipment along with their bid.

1.1 Purpose: To permit system design, manufacture, inspection, performance and procurement.

All hardware, firmware, and software supplied with the system shall be supported with full documentation. Permission to reproduce all manuals, drawings, and other documentation for internal usage by the Government shall be granted by the Contractor.

The documentation shall be considered proprietary and protected against unauthorized disclosure by the Government through a mutual non-disclosure agreement between the

Contractor and the Government.

1.2 Material:

1.2.1 Parts Design. All material shall be new and of the latest manufacture.

Wherever possible, all material and devices shall be of commercial manufacture and readily available from the manufacturer or a distributor.

1.2.2 Standard Parts. All replaceable parts shall be manufactured to definite standards for tolerance, clearance and finish in order that any such part may be field installed without further machining. All parts shall be permanently and legibly marked with the original manufacturer’s part number, where practical.

1.2.3 Specialty Parts. Parts or assemblies that require “fitting” for proper assembly in the field must be identified and separately listed in the parts manual.

2.0 APPLICABLE SPECIFICATIONS, CODES AND STANDARDS: The

following are included as a portion of this specification, to be applied to the Oven defined in Paragraph 4, of this SOW where applicable. In the event of a conflict between these codes and standards, the most stringent shall apply. Detail requirements listed in this specification, except those concerning regulatory safety requirements shall override any contradictory portions of the following specifications, codes and standards.

2.1 Government Publications:

2.1.1 Government Supplied Drawings. The using organization will provide a plan view of the location where the Oven is to be installed. The drawing(s) shall include approximate locations of utilities, floor space and overhead clearance dimensions.

2.1.2 Occupational Safety and Health Administration (OSHA)

29 CFR 1910 Occupational Safety and Health Administration

Standards for General Industry

29 CFR 1926 Occuparional Safety and Health Administration

Standards for Construction

(Applications for copies should be directed to the Superintendent of Documents, Government Printing Office, Washington, D.C., 20402.)

2.2 Non-Government Publications:

2.2.1 National Fire Protection Association (NFPA)

NFPA 70 National Electrical Code – 2011 edition

NFPA 79 Electrical Standards for Industrial Machinery –

2012 edition

NFPA 86 Standard for Ovens and Furnaces – 2011edition

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

Association, 1 Batterymarch Park, Quincy, MA 02169-7471)

2.2.2 National Electrical Manufacturer’s Association (NEMA)

ICS 1-2000 (R2005) General Standards for Industrial Control & Systems

ICS 2-1996 (R2004) Industrial Control and Systems

ICS 6-1993 (R2001, R2006) Industrial Control & Systems Enclosures

MG 1-2006 Motors and Generators

(Application for copies should be addressed to the National Electrical

Manufacturers Association, 1300 N 17th Street, Suite 1752, Rosslyn, VA 22209)

2.2.3 UL Standards

3.0 GENERAL REQUIREMENTS:

3.1 Safety and Health Requirements: Covers, guards, and other safety devices shall be provided for all components of the Oven that present potential safety hazards. The safety devices shall not interfere with the operation of the Oven. The safety devices shall prevent unintentional contact with the guarded part, and shall be removable to facilitate inspection, maintenance and repair of the Oven. All machine parts, components, mechanisms, and assemblies furnished on the Oven must comply with all current manufacturers’ practices. All equipment in this system must conform to 29 CFR 1910

(OSHA). System electrical utility specifications shall comply with the applicable requirements of NFPA 79. The electrical system shall be tolerant of line fluctuation of

+/- 10 percent. The electrical system shall be complete. This shall include any electrical transformer(s) that may be required to modify the existing source voltage to the proper operating voltage of the equipment. A properly rated and fused single disconnect device shall be utilized on the Oven. Under-voltage protection shall be provided in accordance with NFPA 79. Lockout devices shall conform to the requirements of OSHA Standard

29 CFR 1910.147.

3.2 Restrictions.

3.2.1 Mercury Restrictions. The equipment shall not contain mercury, mercury instruments or mercury compounds nor be exposed to free mercury during manufacture.

3.2.2 ODS Restrictions. Class I ozone depleting substances in accordance with section 602(a) of the Clean Air Act Amendments 1990, 42 USC 7671a(a) as implemented by 40 CFR 82 Protection of Stratospheric Ozone, shall not be contained within used on or in the manufacture or design of this equipment.

3.2.3 Polychlorinated Biphenyl (PCB) Restriction. The use of Polychlorinated biphenyl on or in the machine, or components of the machine, is prohibited.

3.2.4 Asbestos Restriction. Asbestos and materials containing asbestos in any suspended form (such as in gasket materials) shall not be used on or in the machine without prior written approval from the Contracting Officer of the

Issuing Contracting Agency.

3.3 General Requirements:

3.3.1 Minimum Requirements. The requirements stated in this document are minimum requirements, and as such are not intended to limit the manufacturer from surpassing the stated requirements.

3.3.2 Standard Products. Materials and equipment shall be a standard product from a manufacturer regularly engaged in the manufacture and supply of Class

“A” Drying ovens.

4.0 EQUIPMENT REQUIREMENTS:

4.1 Equipment Requirements. The Oven shall be a heavy duty Gas heated walk-in oven with top mounted heat chamber for drying and moisture removal of composite materials. The Oven shall be a NFPA 86 Class “A” oven with a maximum temperature of 200° F and an average operating temperature of 120° F. The Oven shall have interior work area dimensions of at least 312” D x 288” W x 144” H. The Oven shall either have a built in digital chart recorder or be designed for addition of a digital recorder with “plug and play” design. The chart recorder shall be capable of monitoring and charting multiple inputs. The Oven shall meet NFPA 86, NFPA 70, OSHA and UL codes.

4.2 Interchangeability. To provide for replacement of worn parts, all parts shall be manufactured to definite dimensions and tolerances, which will permit installation of replacement parts without modification of any part or to the system.

4.3 Construction. The system shall be constructed of parts which are without defects, and are free of repair.

4.3.1 Castings and Forgings. All castings and forgings shall be free of scale and mismatching. No process such as welding, peening, plugging, or filling with solder or paste, shall be used for reclaiming any defective part.

4.3.2 Welding, Brazing or Soldering. Welding, brazing or soldering shall be employed only where specified in the original design. None of these processes shall be employed as a repair measure for any defective part.

4.3.3 Fastening Devices. All screws, pins, bolts, and other fasteners, shall be installed in a manner to prevent change of tightness. Those subject to removal or adjustment shall not be swaged, peened, staked, or otherwise permanently installed.

4.3.4 Surfaces. All surfaces shall be clean and free of sand, dirt, fins, spurs, flash, scale, flux, and other harmful, or extraneous materials. All edges shall be either rounded or beveled unless sharpness is required to perform a necessary function. Except as otherwise specified herein, the condition and finish of all surfaces shall be in accordance with the manufacturer’s commercial practices.

4.3.5 Instruction and Indicating Plates. All wording in the instruction manuals and on indicating plates shall be in the English language. There shall be 3 copies of manuals including drawings, electrical and mechanical schematics, Bill of

Materials and recommended preventative maintenance procedures. Characters shall be engraved, etched, embossed, or stamped in boldface on a contrasting background. When these methods are not practical, the instructions shall be applied directly on the item by environmentally protected decalcomania transfer, metal wrap around tag, stencil, silk screen, or by any other method suitable for the use intended, which shall be as permanent as the normal life expectancy of the item on, or to, which it is applied, and capable of withstanding the environmental tests and cleaning procedures specified for the item.

4.3.6 Nameplate. A corrosion resistant metal nameplate shall be securely attached to the Oven. The nameplate shall contain the information listed below.

The captions listed may be shortened or abbreviated, provided the entry for each caption is clear as to its meaning. This shall be in addition to any other information which the manufacturer normally lists on the Oven.

Nomenclature

Manufacturer’s Model Designation

Date of Manufacture

Contract Number and/or Order Number

National Stock Number or Plant Equipment Code

4.3.7 Body Construction. The Oven shall be formed of rigidly designed and electrically arc welded structural frame and shall be suitably reinforced to form a solid structural unit. The interlocking insulated panels shall fit into a rugged channel base frame. Standard tongue and groove interlocking panels shall be of sufficient thickness for the rated maximum temperature and shall be secured to the aforementioned base frame. These panels shall be of all welded construction and shall consist of heavy gauge materials with minimal through metal contact construction so as to minimize heat transfer to the outer skin of the unit. The insulation to be used shall be a mineral fiber felt or other material which retains its original thermal resistant qualities throughout its life and does not contain any asbestos. Overall wall thickness shall be no more than 6” with at least 18 gauge end channels. It shall be insulated with either 5” of Rockwool insulation of 4# density or better, or the equivalent thermal resistance of another type or weight of insulation. The body may be in sections that attach together on site to reduce the size and weight of the unit to manageable segments for transport. Oven exterior shall have no greater than 10 degree F delta temperature rise between the oven wall and 3 feet from the oven wall.

4.3.8 Floor Construction. The oven floor shall be the existing factory concrete floor.

4.3.9 Door Construction. The Oven shall have double bi-parting doors, or single guillotine raising door with the same thermal resistance equivalent as the walls on one end only. The doors for this unit shall be fabricated of triple wall construction and shall be reinforced with a minimum of 12 gauge channels and

1/4" plates as required to attach hinges and pressure release latches. The door gasket shall be installed around the doors for a good seal and to avoid heat loss.

The insulation to be used shall be a mineral fiber felt or other material which retains its original thermal resistant qualities throughout its life and does not contain any asbestos. The doors shall be mounted on multiple heavy duty hinges to prevent sagging. Door opening is 15”W x 10’H minimum.

4.4 Dimensions. The interior work area dimensions shall be at least 312” D x 288” W x 144” H. The interior work area dimensions of the actual unit offered may be larger as long as the exterior dimensions do not exceed 328” D x 304” W and the overhaul height

(including heat chamber and fan motors) does not exceed 240”. Door opening shall be a minimum of 15’W x 10’H.

4.5 Air Circulation. Heated air shall re-circulate within the work area by means of a high temperature fan which shall be mounted within the heat chamber. Recirculation fan and shaft shall be of steel construction.

4.6 Powered Exhaust. The oven shall be fitted with a powered exhaust fan and an adjustable damper. Both shall be located on the oven roof. In addition, a fresh air inlet with an adjustable damper shall also be provided for final oven balancing. The exhaust fan shall be constructed of mild steel. The exhaust fan shall be stubbed out for connection to an exhaust stack so that the unit may be exhausted to the roof of the building. The top of the roof is approximately 25 feet A.F.F and may require two (2) each 90° bends to connect to an existing roof penetration. The manufacture shall calculate the required exhaust CFM and report back to 76 CMXG engineering for air permitting purposes.

4.7 Make-up Air. All make-up air for the unit shall come from the roof of the building. The manufacturer shall include a third motor and fan of sufficient size to draw air down into the machine as needed to replace exhausted air. The length of stack needed shall be at least 30 feet with at least two (2) each 90° bends to connect to an existing roof penetration.

4.8 Heating Equipment. The oven shall be equipped with gas burners that are physically isolated from the interior of the oven to eliminate the possibility of igniting vapors evaporated from the parts.

4.9 Thermocouple Ports. The Oven shall have two (2) each sealable gang ports for thermocouples on both sides of the oven with four (4) each ports on each gang. The centerlines of the gangs shall be located approximately six and one half (6½) feet from either end of the oven and approximately four (4) feet from the bottom.

4.10 Sheet Metal and Panels. The interior sheet metal (duct work, panels, etc.) and the exterior panels shall be of 20 gauge aluminized steel as a minimum.

4.12 Wall Thickness and Insulation. Overall wall thickness shall be between 3” to 6” with 18 gauge end channels. It shall be insulated with the thermal equivalent of 5” of

Rockwool insulation of 4# density, or better, and shall not contain any asbestos.

4.13 Electrical Requirements. The Oven shall be powered by a 460 Volt, 3 Phase, 60

Hertz electrical service.

4.13.1 Main Disconnect Switch. The Oven shall have a main disconnect switch or circuit breaker which, when tripped, will completely shut off electrical power to every part of the unit.

4.13.2 Magnetic Starter/Motor Controller. The Oven motors shall be furnished with matching thermal overload for magnetic starters, and/or DC drive controllers.

4.14 Thermocouples. The Oven shall utilize Type J thermocouples.

4.15 Standard equipment. The Oven shall be furnished with all standard equipment normally furnished by the manufacturer. The contractor shall also provide any special or non-standard tools for maintenance.

4.16 Workmanship. Workmanship of the Oven and accessories shall be commensurate with the requirements specified herein, and shall be of a quality prevailing among manufacturers normally producing equipment of the type specified herein.

4.17 Quality. This Oven shall be fully tested after assembly in B9001, TAFB. That is, this Oven shall undergo a quality check which examines interior and exterior fit and finish, paint quality, conduit bends as well as a wide range and host of other items and components. This extensive quality system shall assure that the Oven is of the highest quality available.

4.18 Assembly/Installation. This oven shall be assembled on site in B9001, Tinker

AFB Oklahoma City by qualified installers. Price installation as a separate option.

5.0 REQUIRED CONTROL SYSTEMS:

5.1 Programming. The controller shall be a solid state digital controller capable of programming final temperatures in F or C.

5.2 Control Equipment. The controller to be used shall have a digital display and shall be adjustable in single degree increments. Allowable temperature variance of the oven is ±10° F on the temperatures set in the program for normal operations.

5.3 Control Panel. The control panel shall be NEMA 1 or better with UL listed insert and NEC 70 wiring with main disconnect switch. The motor starters shall be IEC rated and individually fused. All push buttons and pilot lights shall be full sized. The hi-limit controller in the work area shall be of solid state design with a manual reset.

5.4 Control Enclosure. A pre-wired control enclosure of suitable size and shape, and conforming to NEC and/or NEMA requirements, shall be provided. Within this enclosure, on a removable white enameled back plate, shall be mounted the necessary magnetic motor starter(s) for the operation of the fans, the control circuit transformer, fuse blocks, terminal blocks, along with the other necessary devices needed to operate the unit in a successful manner. All motors and step down control transformers shall all be individually fused.

5.5 Pushbuttons. Oil tight pushbuttons shall be provided in the end or in the door of the control enclosure and shall be clearly marked with indicating legend plates.

5.6 Pilot Lights.

5.6.1 Fan Light. An Amber pilot light shall indicate when the fan is operating safely.

5.6.2 Purge Cycle Complete. A Green pilot light shall indicate, by going out, when the purge cycle has been completed.

5.6.3 Heater Energized. A Red pilot light shall indicate when the heater has been energized.

5.7 Internal Wiring. All of the internal oven wiring shall be brought back to a clearly marked terminal strip to facilitate the activity of maintenance.

5.8 Heater Controls. Electronic sequencer shall be installed and functional so to provide more even wear of heater by alternating on/off different banks throughout heat up, soak and cool down cycles.

5.9 Door Switch. The door shall have a switch that cuts heat to the interior but not air flow if the door is opened during the programmed cycle. The heat shall automatically come back on when the door is closed and latched.

6.0 PAINTING:

6.1 Painting. Surfaces of purchased components normally factory finished, shall be furnished with manufacturer’s standard prime and finish paint finish system. Finish color shall be the manufacturer’s standard color. If multiple colors are available at no additional charge, customer preference is for Air Force blue or another blue color.

6.2 Touch-up Painting. Touch-up paint shall be included so that painted surfaces damaged during installation may be brought to an “as new” condition by touch up or repainting.

7.0 SAFETY REQUIREMENTS:

7.1 Safety Requirements. The following equipment is required as a minimum and shall be provided by the contractor and factory tested prior to shipment: one (1) each exhaust fan, two (2) each airflow switches (one (1) for the recirculation fan and one (1) for the exhaust fan), one (1) each manual reset excess temperature controls for the oven work area, one (1) each purge timer. The oven shall have an accessible e-stop button for emergency shut-down of the oven.

7.2 Other Safety Features. Any other safety features not specifically stated herein that are necessary to provide a complete, safe, and operable system shall be provided by the contractor.

7.3 Noise Requirement. The noise generated by the oven shall remain below 85 Dba at three feet from the operating oven.

8.0 START-UP AND TRAINING.

8.1 Start-up. The contractor shall furnish one (1) each factory trained representative to facilitate first start-up and operation of the Oven. This representative shall be versed in the installation and operation of the oven and shall inspect the installation of the equipment to ensure all service connections are done in accordance with the manufacturer’s instructions. The representative shall be capable of troubleshooting the installation and oven systems if the equipment does not function in accordance with the requirements stated in this document.

8.2 Operations and Maintenance. The contractor shall provide a training program, not later than one (1) workday after installation inspection. Training is to be conducted on site at B9001 Tinker Air Force Base, for not less than eight (8) operators at a minimum of two (2) hours of hands-on operational training, and for not less than two (2) maintenance personnel at a minimum of two (2) hours of thorough maintenance training. The training programs shall be conducted by contractor personnel qualified in all phases of the operation and maintenance of the Oven.

9.0 WARRANTY.

9.1 Warranty. Warranty shall guarantee that the equipment furnished is free of defects in workmanship and materials for state period not less than one year from date of shipment. Component parts such as controls, motors, heating elements, etc., which are incorporated into the design of the equipment shall carry their respective guarantees. The company assumes responsibility of incorporating these various items in the fabrication of the equipment and warrants that this has been done in a suitable and workable manner.

The company further warrants that their product bulletins accurately describe their equipment. If it is necessary to change the design or substitute various control or operating equipment, equal or superior equipment shall be used. Failure of any components purchased by the company and installed on their products shall be replaced free of charge for defective parts. Minimum length of warranty shall be one year after installation on site.

10.0 SHIPPING.

10.1 Shipping. The oven components and section shall be assembled on 4 x 4 lumber

(or larger as required) and shipped on flatbed truck(s). ). The oven box shall be tarped or crated at all times during transport to minimize road damage and abrasion to it. All other components shall be packages or crated so that they are protected against damage during handling. This shall include shock isolation to protect electronics, built-in control systems or other parts of the oven which are sensitive to instantaneous impacts or vibrations.