SOW_for_Foundry_Furnace_and_Crucible_(B9001).pdf

STATEMENT OF WORK (SOW)

For

Foundry Melting Furnace

PREPARATION DATE: 21 August 2015

PREPARING ORGANIZATION:

1.0 SCOPE 4

1.1 PURPOSE 4

1.2 BACKGROUND 4

1.3 OVERVIEW 4

2.0 APPLICABLE DOCUMENTS 5

2.1 AIR FORCE POLICY DIRECTIVES AND INSTRUCTIONS 5

2.2 TINKER AIR FORCE BASE (TAFB) INSTRUCTIONS 5

2.3 NON-GOVERNMENT STANDARDS AND OTHER PUBLICATIONS 6

2.3.1 UNIFIED FACILITY CRITERIA (UFCS) 6

2.3.2 NATIONAL FIRE PROTECTION AGENCY (NFPA) 6

2.3.3 INTERNATIONAL CODE COUNCIL (ICC) CODE PUBLICATIONS 6

3.0 REQUIREMENTS 7

3.1 SPECIFICATIONS 7

3.1.1 DIMENSIONS 7

3.1.2 ELECTRICAL CHARACTERISTICS 7-8

3.1.3 FOUNDATION 8

3.1.4 MANUALS 8

3.1.5 MAINTENANCE AND REPAIR 8

3.1.6 MELTING FURNACE OUTER SHELL 8

3.1.7 ELECTRICAL 8

3.1.8 DOORS/LIDS 8

3.1.9 CONTROL PANEL 8

3.1.10 ACCESSIBILITY 8-9

3.1.11 UTILITIES INTERCONNECTION 9

3.1.12 ALARM SYSTEMS 9

3.2 CONTRACTOR REQUIREMENTS 9

3.2.1 DESIGN REVIEWS 9-10

3.2.2 DOCUMENTATION 10

3.2.3 TRAINING 11

3.3 CONTRACTOR PERSONNEL 11

3.3.1 PROGRAM MANAGER 11-12

3.4 COMPLIANCE WITH LAWS AND REGULATIONS 12

3.5 QUALITY SYSTEM REQUIREMENTS 12

3.5.1 QUALITY SYSTEM 12

3.5.2 QUALITY PROGRAM 13

3.5.3 DEFICIENCY REPORTS 13

3.5.4 WARRANTY 13

4.0 ENVIRONMENTAL/BIO-ENVIRONMENTAL REQUIREMENTS 14

4.1 SURVEY 14

4.2 ENVIRONMENTAL PROTECTION & SAFETY 14-15

4.3 MATERIAL SAFETY DATA SHEET / SAFETY DATA SHEET (MSDS/SDS) 15

4.4 HAZARDOUS MATERIAL (HAZMAT) 15-16

4.5 HAZARDOUS WASTE 16

4.6 DISCHARGES 16

4.7 OFF-SITE DISCHARGES 16-17

4.8 ENVIRONMENTAL TRAINING 17

Appendix A Acronyms 18

Appendix B Reliability Centered Maintenance 20-25

Appendix C Shop Drawing 26

Appendix D Foundry Furnace Pictures 27

1.0 SCOPE

The purpose of this Statement of Work (SOW) is to design, procure, and install one turnkey

Furnace with three (3) Melting Crucibles for the Sheet Metal Foundry in B9001.

1.1 PURPOSE

The purpose of this Statement of Work (SOW) is to establish the engineering, technical, and logistics support required to provide the subject Melting Furnace. The Melting Furnace is to provide casting capability for the Sheet Metal Manufacturing Shop area. The Melting Furnace shall be installed inside the Building 9001 Foundry shop located near post P19.

The Melting Furnace shall provide support for the B-1B, B-2, B-52, E-3, and KC-135 weapon systems at the OC-ALC. The Melting Furnace will be used to melt non-ferrous metals in use of form molds to manufacture various aircraft components.

The Contractor shall provide all personnel, equipment, supplies, facilities, transportation, tools, materials, supervision and other items (e.g. Personal Protective Equipment (PPE)) necessary to perform the requirements of this SOW and contract as defined in this Statement of Work (SOW).

The Contractor shall provide and use only new parts and material unless authorized by the

Contracting Officer (CO).

1.2 BACKGROUND

Tinker Aerospace Complex (TAC) requires a melting Furnace & Crucible for the foundry to provide support for the sheet metal manufacturing operation. The new Furnace & Crucible provides indirect support for the B-1B, B-2, B-52, E-3, and KC-135 weapon systems at the OC-

ALC. The use of the equipment is to safely melt kirksite (zinc alloy), aluminum, and lead ingots and cast into molds and dies that are used to produce sheet metal replacement parts. The primary usage is for kirksite casting. It is required for the operation of the new foundry shop located in the west end of B9001, near post P19. The furnace will be used on an intermittent basis to produce molds and dies. The system shall require the contractor to provide a turnkey system to include but not limited to design, fabricate, install, test, and conduct training for Tinker personnel.

1.3 OVERVIEW

The contractor shall provide one Melting Furnace. The Melting Furnace shall be of an open top design. The approximate external clear area measurements of the Melting Furnace Crucibles shall be 6 ft. wide by 4 ft. high by 6 ft. long. Equipment installations that are expected to exceed

4 feet in height shall be coordinated with the Government. A loading access platform shall be required in that case.

2.0 APPLICABLE DOCUMENTS

The Contractor shall ensure requirements in this SOW are accomplished In Accordance With

(IAW) the latest version of the following documentation if it does not impact cost and delivery schedules or if a conflict does not arise in implementation of the new procedures. If any of the preceding conditions occur, a written evaluation, along with specific backup data and estimated cost data for those changes which impact the Contractor’s performance shall be provided to the

Procurement Contracting Officer (PCO) within ten (10) workdays after receipt of an updated publication. The Contractor shall not incorporate these publication changes until approved by the

PCO. In the event there are conflicts between two or more referenced documents, the Contractor shall provide written evaluation, along with specific backup data to the PCO within ten (10) workdays after knowledge of the conflict. Resolution of the conflict will be provided by the PCO.

In addition, the Contractor shall immediately implement those publication changes that result in no change in contract price or delivery or have no conflicts. The Contractor shall be aware that only those military, federal, and contractor specifications cited in Section II, down to and including the equipment and product specifications and there first-tier references shall be mandatory for use and that lower tier references are for guidance only and will not be contractually binding unless raised to the direct cite level. The contractor shall submit a list of hazardous materials planned to be used within 10 working days after contract award.

Document No. Title

2.1 AIR FORCE POLICY DIRECTIVES AND INSTRUCTIONS

a. AFI 32-7086 Hazardous Waste Material Management

Programhttps://wwwmil.tinker.af.mil/tafbforms/docs/htm/32series.htm

b. AFI 91-301 Air Force Consolidated Occupational Safety Standard

2.2 TINKER AIR FORCE BASE (TAFB) INSTRUCTIONS

a. TAFBI 32-7004 Hazardous Waste Management Program https://wwwmil.tinker.af.mil/tafbforms/docs/htm/32series.htm

b. Tinker AFB Base Standard for Building/Utility Electrical Distribution Systems

c. Tinker AFB Facility Standard (includes Architectural Compatibility Plan)

d. Tinker AFB Specification Standards 00 70 0 General Requirements for Construction on

Tinker AFB

e. Tinker AFB Specification Standards 00 71 00 General Safety Requirements for Tinker

AFB

f. Tinker AFB Specification Standards 00 72 00 Environmental Requirements for

Construction of Tinker AFB https://wwwmil.tinker.af.mil/tafbforms/docs/htm/32series.htm

2.3 NON-GOVERNMENT STANDARDS AND OTHER PUBLICATIONS

a. ICS6-1993 Enclosures for Industrial Control Systems

b. 40 CFR 63

c. Subpart GG National Emissions Standard for Hazardous Air Pollutants

2.3.1 UNIFIED FACILITY CRITERIA (UFCS) TO INCLUDE

a. UFC 1-200-01, General Building Requirements

b. UFC 3-310-04, Seismic Design for Buildings

c. UFC 3-520-01, Interior Electrical Systems

d. UFC 26-05-13-00, Medium Voltage Cables

e. UFC 4-211-02 Aircraft Corrosion Control and Paint Facilities

f. UFC 3-600-01 Unified Facilities Criteria (UFC) Fire Protection

Engineering for Facilities

2.3.2 NATIONAL FIRE PROTECTION AGENCY (NFPA)

a. NFPA 13, National Fire Protection Association

b. NFPA 70, National Electric Code (NEC)

c. NFPA70E, National Electric Safety Code

d. NFPA 101, Life Safety Code

e. NFPA 241, Standard for Safeguarding Construction, Alterations, and

Demolition Operations

f. NFPA 72, National Fire Alarm

g. NFPA 484, Standard for Combustible Metals

h. NFPA 86, Standard for Ovens and Furnaces

2.3.3 INTERNATIONAL CODE COUNCIL (ICC) CODE PUBLICATIONS TO

INCLUDE

a. International Building Code

b. International Fire Code

3.0 REQUIREMENTS

3.1 SPECIFICATIONS

The contractor shall provide one (1) Melting Furnace with the following specifications:

a. Approximate size – Furnace top height maximum is 45” above floor level. Kirksite metal holding capacity is a maximum of 1,100 lbs. (498.9 kg).

b. Crucibles (3) – 24”H x 24” OD (610 x 610 mm). Material is cast iron or ceramic, whichever is most suitable for the material being melted.

c. Temperature – Capable of melting/pouring all materials being worked. Range from

600 degrees F (315.5 degrees C) to 1400 degrees F (760 degrees C)

d. Materials:

i. Kirksite (Zinc alloy) - 787F melting – 780-835F casting

ii. Lead - 621F melting – 720F pouring

iii. Aluminum - 1218F melting – 1350F pouring

e. Other

i. Tilt to pour – powered rotation either pneumatic/hydraulic ram or electric motor.

Hydraulic fluid shall be high flash point fluid > 200F if used.

ii. Heating fuel = Natural Gas

iii. Non-asbestos refractory/insulation.

iv. Complies with all applicable Federal and State regulations.

v. The equipment and materials shall all be new.

vi. Open top, no lid over the melting crucible.

vii. Usage – Non-continuous use. Will be used to make molds on an as needed basis, approximately one time per week.

viii. Three sets of manuals and schematic drawings required, plus one copy in electronic format.

ix. Control panel with electronic temperature control and digital temperature readout.

x. Ventilation – The furnace will utilize an existing fume hood over the area to vent any fumes or gasses from the furnace. The furnace shall be interlocked with the fume hood exhaust blower.

3.1.1 DIMENSIONS

The Melting Furnace shall be 45” high, 72” wide and 72” long outside dimensions.

3.1.2 ELECTRICAL CHARACTERISTICS

The Melting Furnace shall utilize standard 480/3/60 building power, or 120V/208V power as required. The Melting Furnace shall be connected to utilities provided by the Government. The contractor shall provide any transformers needed to vary the voltage from the supplied building voltage. The contractor shall inform 76 CMXG engineering of the required amperage and voltage in the approval drawings. Power panels and wiring shall conform to National Electrical Code (NEC).

3.1.3 FOUNDATION

A foundation is typically not required for this type of system. The furnace will be installed directly to the shop floor.

3.1.4 MANUALS

The Melting Furnace shall be delivered with three full sets of training, operation and repair manuals, in both hard copy and electronic form on CD.

3.1.5 MAINTENANCE AND REPAIR

The Melting Furnace shall be installed to allow for easy access for maintenance and repair. Isolation valves shall be provided for incoming air or natural gas at 4’ AFF.

Any motors shall be provided with lubricators. Platforms with ladders and guard rails shall be provided for access to equipment located above normal working height. All blower fan motors shall comply with Appendix B requirements.

3.1.6 MELTING FURNACE OUTER SHELL

The Melting Furnace outer shell shall be steel. The Melting Furnace shall have a powder coated exterior shell with a durable, heat resistant finish. The exterior shall be a dark blue.

3.1.7 ELECTRICAL

All electrical systems shall have a surge protector to protect the equipment.

3.1.8 DOORS/LIDS

The Melting Furnace does not require a lid over the melting crucible, it shall be open top.

3.1.9 CONTROL PANEL

The contractor shall install a control panel on or near the exterior of the Melting

Furnace. Requirements of the control panel shall be governed by existing regulations.

3.1.10 ACCESSIBILITY

The contractor shall provide maintenance access to the control panel, and ingot loading. Note stairs shall include fall guard or hand rails. Platforms with guard rails and fall protection shall be installed around the Melting Furnace to allow for access as needed if the furnace loading height is above the specified height of 45 inches. The load rating on the work platform shall be adequate to support personnel and up to 2,000 pounds of ingots for the Melting Furnace. Load ratings shall be clearly marked where personnel can see the load rating. Electrical panels and disconnects shall be located where they are free from obstructions per NFPA 70, National Electric Code (NEC).

3.1.11 UTILITIES INTERCONNECTION

The contractor shall route and connect required utilities to a Government-specified location within 25 feet of the Melting Furnace. The Government will provide the utility interconnection points in such a way that the vendor can make the connections with appropriate coordination. Compressed air, electricity, shutoff value(s) and breaker box(es) shall be located near each other on the same side of the

Melting Furnace (location specified on drawing, this location shall not be changed without written authorization from the Government).

The contractor shall install an electric power disconnect switch for the Melting

Furnace and it shall be located about 4 feet above the floor on the outside of the

Melting Furnace. All electrically powered equipment for the Melting Furnace shall be routed through the electric disconnect switch. The contractor shall connect the disconnect switch to the Government-provided central power panel.

The contractor shall install an emergency shutoff valve for compressed air and natural gas and it shall be located about 4 feet above the floor on the side of the

Melting Furnace. Regulators and pressure gauges shall be installed by the contractor.

The contractor shall install an emergency for shut-off valve for the gas and it shall be located about 4 feet above the floor on the side of the Melting Furnace. A regulator and pressure gauge shall be placed on this line by the contractor.

3.1.12 ALARM SYSTEMS

The contractor shall submit shop drawings in .dwg format, wire diagrams, and material data for approval with the 100% design review prior to installation.

Installers shall be licensed in the State of Oklahoma and shall meet the qualification requirements of the UFC and NFPA.

3.2 CONTRACTOR REQUIREMENTS

3.2.1 DESIGN REVIEWS:

3.2.1.1

25% Review. The 25% design review shall take place within 2 week of contract signing. This review shall show equipment location (to include foot prints of all major pieces), safety alarms, etc. Also, a timeline that shows major milestone dates, such as design reviews, fabrication dates, delivery, installation, training, etc.

The contractor shall provide any required MSDS’s for any chemicals to be used.

The Government will have 1 week to review and respond to the contractor regarding the proposal.

3.2.1.2

65% Review. This review shall take place within 3 weeks of the 25% review and shall include details about type of equipment specifications, utility requirements, air flow, safety equipment locations, etc. This review shall allow the Government to review all applicable documentation to verify compliance with all regulations noted in para. 2.0. The Government will have 2 weeks to review and respond to the contractor regarding the proposal.

3.2.1.3

100% Review. This review shall take place within 3 weeks of the 65% review to include all details necessary for the Government to verify that all changes have been made to meet the stated intent of this SOW. The Government will have 2 weeks to review and respond to the contractor regarding the proposal.

3.2.2 DOCUMENTATION

• Minimum of three sets of the approved work plan and required shop drawings to the

CO prior to beginning construction.

• Work plan drawings shall be stamped 'field verified as-built' by the Contractor prior to their final submittal as part of the Project Documentation requirements. Both hardcopy sets and electronic .dwg files on CD of the field verified drawings shall be delivered to the CO prior to the Project's final inspection.

• Operation and Maintenance (O&M) Manuals & Training: The Contractor shall provide electronic operations and maintenance training manuals. O&M’s shall be in electronic format if possible. Three hardcopy manuals are required.

• Detailed installation drawing(s) thirty (30) days after award to the Contracting Official.

The facility representative will review and make acceptance determination. The drawings shall be legible and in the English Language.

• Three (3) sets of installation drawings showing a dimensioned top view of the equipment, along with applicable electric and air requirements 90 days ARO to enable government lead time of roughed in utilities. Equipment grounding requirements shall be indicated on drawing and the installation of such grounding requirement shall be the responsibility of the contractor. This shall include assembly prints, wiring schematics and/or gas schematics and oven (pre-wired, tested and balanced as specified).

3.2.3 TRAINING

The Contractor shall be required to furnish training. After satisfactory completion of acceptance testing of the system, the services of a qualified representative(s), who is proficient in the English language, shall be provided for specialized training to familiarize receiving activity personnel with the equipment and to help ensure reliable performance and maximum service life, during normal usage. All printed training aids shall be in the English language. Training shall be performed at

TAFB, OK. Training shall be for eight (8) hours per day during normal work hours. The training shall apply to personnel as follows:

Training shall be provided for up to ten (10) maintenance personnel at a journeyman mechanic level. This training shall include preparation of equipment for operation, control features, safety, and actual safe operation of the equipment.

Training shall be for a minimum of 2 days to shop and maintenance personnel.

3.3 CONTRACTOR PERSONNEL

The selection, hiring, assignment of duties, reassignment of duties, transfer, supervision, management, control, and termination of Contractor employees in performance of this SOW shall be the responsibility and prerogative of the Contractor. Contractor employees who are required to communicate with Government personnel shall have the ability to clearly read, write, and speak English.

The Contractor shall ensure the following key personnel performance requirements are accomplished:

3.3.1 PROGRAM MANAGER

The Contractor shall provide a Program Manager who shall be responsible for the performance of the work and shall have full authority to act for the Contractor on all matters relating to the performance of this contract. The Program Manager shall:

a. Be responsible for all work performed under this SOW.

b. Provide in writing to the PCO, within ten (10) working days after contract award, the Program Manager name with both duty hour and non-duty hour telephone numbers.

c. Select, hire, assign duties, reassign duties, transfer, supervise, manage, control, and terminate Contractor employees in performance of this SOW.

d. Maintain a program management structure to accomplish administrative planning and integration of program requirements to optimize workflow actions by organizing, directing, and controlling overall program requirements, to include the following:

1. Develop, maintain, and deliver an organizational chart, which reflects key personnel with a line of responsibility between the organizational elements.

2. Develop, maintain, and deliver a cross-utilization chart, which identifies each task against specific positions or elements within the organization, if cross-utilization is to be used.

3. Be available to be contacted by telephone during duty hours to discuss issues.

4. Be available to be contacted by telephone during non-duty hours to discuss and resolve critical issues.

5. Develop, maintain, and deliver a contact list of individuals who can address routine questions and provide data and status information during duty hours.

6. Deliver all plans, reports, correspondence, briefings, and documents required by this SOW, including forms, CDRLs, and required notifications in Microsoft (MS) Office format via e-mail unless otherwise directed by the

PCO.

7. Identify, review, analyze, and forecast all budgetary and financial impacts to program.

3.4 COMPLIANCE WITH LAWS AND REGULATIONS

The Contractor shall be knowledgeable of and comply with all applicable Federal, State, and

Local laws, regulations, and requirements regarding environmental protection. In the event environmental laws and regulations change during the term of this contract, the Contractor shall be required to comply with such laws when they come into effect. If there is an increase or decrease in cost as a result of the change, the Contractor shall inform the PCO of the change and the PCO will determine if an equitable adjustment is required. The Contractor shall develop, maintain, and deliver a Hazardous Materials Management Program (HMMP) Report. (DI-

MGMT-81398, CDRL A00X).

3.5 QUALITY SYSTEM REQUIREMENTS

The Contractor shall ensure the quality system and quality program meets the following requirements:

3.5.1 QUALITY SYSTEM

The Contractor shall provide and maintain a quality system that adheres to the requirements of International Standard ISO 9001-2000, Quality Management Systems – Requirements.

The Contractor shall develop, maintain, and deliver a Quality System Plan. The Contractor shall ensure the quality system procedures, planning, and other documentation and data comprise the quality system and is made available to the Government for review. The

Contractor shall utilize existing quality documents that meet the requirements of the contract. The Contractor shall support the Government’s requested quality audit for inspections, verifications, and evaluations to ascertain conformance to requirements and the adequacy of implementing procedures. The Contractor shall allow on a non-interference basis Government audits to be performed on Contractor maintained files. Upon completion of the Government’s quality audit, the Contractor shall incorporate into the repair process corrective action(s) to eliminate the cause of the defects. The Contractor shall ensure all material purchased or subcontracted from other contractors meets all technical requirements of this contract. The Contractor shall develop, maintain, and deliver a

Quality Assessment Report. (DI-QCIC-81379, CDRL A00 and DI-QCIC-81187, CDRL

A00).

3.5.2 QUALITY PROGRAM

The Contractor shall ensure the quality program is designed to detect and correct conditions adverse to quality. The Contractor shall investigate all Deficiency Reports (DRs) submitted against defective items manufactured, repaired, or overhauled by the Contractor.

The Contractor shall ensure each deficiency report is processed IAW T.O. 00-35D-54, USAF Deficiency Reporting and Investigating System. When the Contractor receives a

DR or QDR, the Contractor shall ensure deficiency reports include: analysis of data to determine extent and cause of deficiencies; analysis of trends in processes or performance of work to prevent recurrence; and introduction of required improvement, corrections, and monitoring of the effectiveness of corrective action taken. (DI-ALSS-81535, CDRL A00X and DI-QCIC-80736, CDRL A00X).

3.5.3 DEFICIENCY REPORTS

If the Contractor receives defective items, the Contractor shall develop and deliver a

Deficiency Report (DR) or Quality Deficiency Report (QDR). The Contractor shall report

IAW TO 00-35D-54 Government Furnished Material (GFM) found damaged, malfunctioning, or otherwise unsuitable for use. In the event of damage or malfunction during or after installation, the Contractor shall determine and record probable cause.

3.5.4 WARRANTY

Warranty shall guarantee that the equipment furnished is free of defects in workmanship and materials for state period not less than one year after final acceptance on site.

Component parts such as controls, motors, 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.

4.0 ENVIRONMENTAL/BIO-ENVIRONMENTAL REQUIREMENTS

4.1 SURVEY

An EM/BIO survey indicates the following shall be required:

a. Heavy metal abatement shall be required on all horizontal surfaces to be disturbed during construction.

b. Avoid disturbance/damage to any insulated piping in the project area as it may contain asbestos.

c. Contractor shall contact project engineer prior to any action that may disturb/damage insulated piping.

4.2 ENVIRONMENTAL PROTECTION & SAFETY

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 with 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) Supplement 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.

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, a copy for UEC and one (1) copy for record.

The format of the report shall be left up to the Contractor, but the report shall contain the following information:

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

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.

4.3 HAZARDOUS MATERIAL (HAZMAT)

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 (4 th

) day of the following month or the first (1 st subsequent business day.

4.4 MATERIAL SAFETY DATA SHEET (MSDS/SDS)

Material Safety Data Sheet/Safety Data Sheet (MSDS/SDS): Upon COR receipt of the “No

HAZMAT Usage” certification, the requirements of this section no longer apply.

The Contractor shall not transport, ship or use any chemical, material or substance used in the performance of this SOW on 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 Material Safety Data Sheets

(MSDSs) or Safety Data Sheets (SDSs) and a completed OC-ALC Form 152, MSDS/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 MSDS/SDS shall accompany the shipment. Contractor shall comply with the effective dates for SDS requirements

IAW the Occupational Safety and Health Administrations (OSHA) Hazardous Communication

Standard, Title 29, Code of Federal Regulation (CFR) Part 1910.1200. The COR will forward all MSDS/SDS submittals to 72 ABW/CEIE for approval. A current manufacturer MSDS/SDS shall be submitted to the COR if the Contractor changes manufacturer or vendor for any chemicals that were prior approved. The Contractor shall maintain copies of manufacturer

MSDSs/SDSs for all chemicals and MSDSs/SDSs shall be readily accessible at all times by

Contractor personnel as well as government employees.

4.5 HAZARDOUS WASTE

Hazardous Waste: If no HAZWASTE will be generated during performance of this contract, the contractor shall certify “NO Hazardous Waste Generation” in writing on company letterhead.

This certification shall be provided to the COR within ten (10) days after award. Upon COR receipt of the “No Hazardous Waste Generation” certification, the requirements of this section no longer apply. Appropriate penalties for the contractor, or administrative and disciplinary action for the later shall be assessed if found in violation of above certification.

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

4.6 DISCHARGES

Discharges: Any discharges into Tinker’s Industrial Waste Treatment Plant (IWTP) or sanitary sewer will be approved and done IAW Tinker Industrial Waste Water Discharge Permit as instructed by 72 ABW/CEIE, Natural Infrastructure Management (Environmental Compliance).

The COR will submit the required notice of intent documentation to the UEC for 72 ABW/CEIE approval. The Contractor shall maintain records of written approval issued by 72 ABW/CEIE for discharges into IWTP and sanitary sewer.

4.7 OFF-SITE DISCHARGES

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.

4.8 ENVIRONMENTAL TRAINING

Environmental Training: Upon COR receipt of the “No Hazardous Waste Generation” certification, the requirements of this section no longer apply.

Contractor personnel performing duties in the service of this SOW shall have training that acquaints the person with the details of Resource Conservation Recovery Act (RCRA) regulations in 40 CFR 260 through 279; applicable State Laws and regulations; DoD, Air Force and local requirements. This training can be obtained through creditable training institutions or companies. All training shall be approved by 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_enus000000 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”.

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

APPENDIX A - Acronyms

AF Air Force.

AFF Above Finished Floor

AFI Air Force Instruction.

AFMAN Air Force Manual.

AFMCI Air Force Material Command Instruction.

AFPD Air Force Policy Document.

AFTO Air Force Technical Order.

ANSI American National Standard Institute.

ASQC American Society for Quality Control.

ASTM American Society for Testing and Materials.

CDRL Contract Data Requirements List.

DLAR Defense Logistics Agency Regulation.

DoD Department of Defense.

DR Deficiency Report.

GIDEP Government Industry Data Exchange Program.

HMMP Hazardous Materials Management Program.

IAW In Accordance With.

IEC International Electrotechnical Commission.

IPPS Initial Provisioning Performance Specification.

ISO International Standards Organization.

LMI Logistics Management Information.

MIL-STD Military Standard.

MS Microsoft.

OC-ALC Oklahoma City Air Logistics Center.

OSS&E Operational Safety, Suitability, & Effectiveness.

PCO Procurement Contracting Officer.

PIO Provisioned Item Order.

PTD Provisioning Technical Documentation.

QA Quality Assurance.

SDFP Supplemental Data For Provisioning.

SF Standard Form.

SOW Statement of Work.

TAFBI Tinker Air Force Base Instruction.

TO Technical Order.

USAF United States Air Force.

APPENDIX B – Reliability Centered Maintenance (RCM)

RCM Acceptance Testing with Baseline Data

Baseline data is condition monitoring information that is representative of equipment in a new and/or properly operating condition. The baseline data is the foundation of the predictive trending analysis required to forecast equipment condition. It is important that this data is established as early as possible in the life of the equipment. The baseline readings and periodic monitoring data should be taken and recorded under the same conditions (or as close as can be achieved), and will be used for acceptance testing. The Equipment Engineering Flight organization, 76 MXSS/MXDEA, will provide acceptance testing of equipment components using advanced technology listed in chapter 4.2. When the equipment has been accepted, the final data obtained will be used to establish the original installed baseline data for this system.

Criteria by Technology

Vibration Monitoring

The development of specific vibration criteria for every machine for all possible operating speeds, in all applications, and in every mounting arrangement, is very difficult. Vibration amplitude varies with operating speed, load, and mounting arrangement, so developing criteria based solely on amplitude can be misleading. The frequency content of the spectrum is often as important as the amplitude. For example, the presence of a frequency associated with an inner race defect on a new bearing is unacceptable, regardless of the amplitude.

Therefore; the vibration specifications utilized for acceptance testing will be based on generic

International Standards Organization (ISO) 3945, ISO 10816, American National Standards Institute

(ANSI), MIL-STD-167-1, MILSTD740-2 (Appendix C) and Lockheed Martin vibration specification

LMMSS SPECIFICATION NO. V 1.0-1997 (Attached appendix “B”). Equipment failing the vibration tests will be rejected by the Government.

Vibration Monitoring Locations

1. Data Gathering Points—For all rotating equipment provided under the contract, the contractor shall provide vibration monitoring points using the following guidelines:

a. The contractor has the option of machining the equipment case in order to achieve a flat and smooth spot of 1" diameter with a surface finish of 32 micro-inches RMS, or installing magnetic accelerometer pads either by welding or stud mount. The accelerometer pads must meet the size and finish requirements of the machined spot face.

b. The contractor shall ensure monitoring locations are positioned on structural members.

Installation of accelerometer pads on bolted cover plates or other non-rigid members are not acceptable.

c. Data gathering points are to be located in a horizontal, vertical and axial orientation with respect to component bearing/shaft centerline.

2. Blowers & Fans—Motors on blowers and fans shall have accelerometer pads installed in the radial

(2ea) and axial (1 ea) directions as previously described. Fan bearings shall be monitored radially in the vertical direction.

Bearing Information

1. Drawings—The contractor shall provide to the procuring organization section drawings that show the component arrangement for all rotating equipment supplied under the contract. The section drawings shall accurately depict the bearing support structural arrangement, be drawn to scale, and show the dimensions to the centerline of all rotating shafts.

2. Bearing Data—The contractor shall provide to the procuring organization the bearing manufacturer and part number for all bearings used in all rotating equipment supplied under this contract. The information shall be included on the sectional drawings for each bearing location.

3. Operating Data—The contractor shall provide the procuring organization with the operating speed for constant speed units and the normal operating speed range for variable speed equipment.

4. Lubrication Data-- The contractor/manufacture shall provide to the procuring organization the following information on all liquid lubricants contained within equipment/system or in bulk (5 gallons or more) supplied under this contractor/manufacture. In-turn the procuring organization will provide 76 th

MXSS/MXDEA with the following information:

a. Liquid Lubricants

Viscosity grade in ISO units

Viscosity Index

AGMA and/or SAE classification as applicable

Mil Spec and/or NATO Code as applicable

Cincinnati Milacron Specification Number as applicable

Viscosity in Centistokes (cst) @ 40° C and 100° C

Type Additive package. Example: ZDDP, Rust inhibitors, Foam inhibitors.

Neutralization, the TBN (alkalinity) and/or TAN (acidity).

Flash point

Pour point

b. Grease Lubricants

National Lubrication and Grease Institute (NLGI) Number

Type and percent of thickener

Dropping point

Maximum Service Temperature

Base oil viscosity range in SUS or centipoise

The following formula shall be used to calculate SUS and absolute viscosity:

Z = pt(0.22s-180/s) where: Z = absolute viscosity in centipoise at test temperature s = Saybolt Universal Seconds pt = specific gravity at test temperature t = temperature (deg F)

Changes in density can be calculated by the formula:

pt = pr-0.00035(t-60) where: pr = specific gravity at the reference temperature (normally 60 deg F) t = temperature (deg F)

Fans, Blowers

The contractor shall provide to the procuring organization the following information on all fans/blowers supplied under the contract:

Type of fan or blower

Number of rotating fan blades/vanes

Number of stationary fan blades/vanes

Rotating speed(s)

The contractor shall provide to the procuring organization the following additional information if the fans/air handlers are belt driven:

Number of belts

Belt lengths

Belt Part Number

Diameter of the drive sheave at the drive pitch line

Diameter of the driven sheave at the drive pitch line

For all fans supplied under the contract, the contractor shall ensure sufficient access to the fan is present in order to allow for cleaning and in-place balancing of the fan.

Rotating Machinery Alignment

1. All directly shaft-driven flexibly coupled rotating machine alignment shall be performed using only laser shaft alignment systems.

2. Machine bases shall be clean, level, planar, and rigid.

3. ‘Soft foot’ (machine frame distortion) shall be eliminated prior to final alignment.

4. Target specifications for expected machine movement during operation shall be considered and taken into account (if available) when performing final alignment of the machines. If target specifications are not available, all due diligence shall be exerted to obtain this information via the methods detailed below. These methods shall prevail in the following order of priority of acceptance:

a. Data derived from a study of positional change.

b. Machine vendors’ or manufacturers’ recommendations.

c. Calculation performed via the TLC method (detailed in Table B.)

d. A “hot alignment check”.

e. Final shaft alignment shall be performed to the relevant alignment tolerances specified in the

“Alignment Tolerances” charts in Table A.

f. All dimensions shall be measured and be accurate to the nearest 1/8 th inch (0.125″). A complete alignment report shall be generated from the device and printed out on a connected printer or stored on a PC for archival and documentation purposes.

Table A

Shaft Alignment Tolerances

Spacer coupling tolerances are to be applied anytime the distance between flex planes in a coupling or a across a spacer shaft or spool piece is equal to or greater than 4 inches.

Table B

Thermal Growth Calculation Method

Short coupling tolerances are to be applied anytime the distance between flex planes in a coupling is less than 4 inches.

Formula:

T x L x C = the thermal growth at any measured point along the shaft centerlines, in mils.

Where:

T = change in temperature in °F (Δt).

L = distance of material involved, in inches.

C = coefficient of linear expansion.

Common coefficients (C) in mils per inch of material per °F change in temperature:

Aluminum 0.0126

Bronze 0.0100

Cast iron, Gray 0.0059

Stainless steel 0.0074

Mild steel, ductile iron 0.0063

Input the calculated thermal growth values at the machine support locations into the laser alignment system utilizing the Thermal Growth function.

The government shall perform a vibration analysis survey during the start-up phase of the installation. All defects noted by the government shall be corrected by the contractor at no additional expense to the procuring organization. The government will re-survey repaired areas to assure proper corrective action has been taken.

Thermography

Electrical—The government will perform a thermographic survey on all electrical distribution equipment, motor control centers, and transformers during the start-up phase of the installation.

Motors and Bearings— Large machines shall be scanned closely. Abnormal hot spots on the body may indicate flaws in the stator windings. The surface temperature of a motor is normally lower than the winding temperature. Bearing temperatures are normally higher than the housing temperature.

Any defects noted by an observable difference in temperature of surveyed components or unexplained temperature rise above ambient shall be corrected by the contractor at no additional expense to the procuring organization. The government will re-survey repaired areas to assure proper corrective action has been taken.

There are two basic criteria for evaluating temperature conditions; differential temperature ( T) and absolute temperature. Each is described below.

a. Differential Temperature ( T) - Temperature difference criteria are simple, easy to apply in the field, and provide an adequate qualitative screening system to identify thermal exceptions and problems. The T criteria compares component temperature to the ambient temperature and may be used for electrical equipment. T may also be used for mechanical components.

b. Absolute Temperature—Absolute temperature criteria are generally specific to an equipment model, type of equipment, class of insulation, service use, or any of many other salient characteristics. As a result, absolute temperatures are more suited to quantitative infrared thermography and critical temperature applications. The mechanical temperature specifications come primarily from manufacturer’s manuals. Electrical temperature specifications are set by three principal electrical standards organizations:

National Electrical Manufacturers Association, (NEMA) (Appendix C).

International Electrical and Electronic Engineers, (IEEE) (Appendix C).

American National Standards Institute, (ANSI) (Appendix C).

Airborne Ultrasonics

The government shall perform an airborne ultrasonic survey during the start-up phase of the installation.

The government shall survey electrical equipment for indications of arcing or electrical discharge, including corona. Piping systems shall be surveyed for indications of leakage. Baseline all electric motors for db levels using contact probe. All defects or exceptions noted by the use of airborne ultrasonics shall be corrected by the contractor at no additional expense to the procuring organization. The government will re-survey repaired areas to assure proper corrective action has been taken.

Motor Analysis

The government may perform a motor analysis survey during the start-up phase of the installation in order to verify the information to be provided by the contractor (or contractor’s representative) as listed in

4.2.4.1 through 4.2.4.5 below. All defects or exceptions noted by the government shall be corrected by the contractor at no additional expense to the procuring organization. The government will re-survey repaired areas to assure proper corrective action has been taken.

Motor Circuit Analysis (Complex Phase Impedance)

Upon motor installation, the contractor shall take and provide to the procuring organization the following acceptance/baseline readings and measurements, first for the motor alone, and then, for motor and circuit together:

Conductor path resistance

Inductive imbalance

Capacitance to ground

Motor Current Spectrum Analysis

With the motor installed and operational, the contractor shall conduct an acceptance/baseline spectral analysis on the loaded motor at 75% or greater load, when specified by the procuring organization.

Insulation Resistance

Upon installation, the contractor shall take and provide to the procuring organization the following acceptance/baseline readings and measurements; initially, for the circuit or for the motor alone, and then, for the motor and circuit together:

Dielectric Absorption Ratio (for all motors)

Leakage current at test voltage

Surge Testing

The contractor shall perform surge testing and high potential (high-pot) resistance testing of the motor(s) prior to their installation and procuring organization’s acceptance. The contractor shall provide to the procuring organization documentation of test results, including test voltage, waveforms, and high potential leakage current.

Start-up Tests

With the motor installed and operational, the contractor shall collect and provide to the procuring organization the following baseline data:

Coast-down time

Peak starting current

1. Maintainability and Ease of Monitoring

The contractor shall provide for equipment maintainability and ease of monitoring through design. For example, rotating equipment such as fans will shall be equipped with an inspection/ clean out port.

Accessibility to these ports shall facilitate inspection and cleaning of the fan blades.

2. Leveling of Equipment Upon Installation

The contractor shall level all installed rotating electrical and mechanical machinery. The government will check the level of the machinery to verify accuracy. Any discrepancies detected by the government will be corrected by the contractor. The government will re-survey repaired areas to assure proper corrective action has been taken.

3. Equipment Health Assessment Checklist

The contractor shall utilize the checklist shown in Appendix “A”, along with the requirements detailed in sections 4.2 through 4.4, in order to verify equipment health of newly installed equipment as part of the acceptance criteria and then provide the information to the Government for verification. The Government will verify the information on Appendix “A” by performing the same checklist to verify equipment health and establish baseline data of newly installed equipment. Contractor to fix/ repair any discrepancies found.

APPENDIX C – FOUNDRY SHOP DRAWING

NEW MELTING FURNACE

APPENDIX D – FOUNDRY FURNACE PICTURES

LINDBERG TILTING CRUCIBLE POT FURNACE

MIFCO POURING FURNACE

BAKER POURING FURNACE