PS_-_C-130_FOM_Carousel_for_B225_West_Docks_2016.02.18.pdf

PURCHASE SPECIFICATION (PS)

FOR

C-130 FOM STORAGE VERTICAL CAROUSELS

FOR B225 EAST DOCKS

(572 AMXS/MXDPAA)

Hill AFB, UT

2 March 2016

1. Scope:

1.1. This purchase specification covers the general design and performance requirements for up to four vertical storage carousels and the installation of the carousels in building 225, C-130 aircraft docks C1, C2, C7 & C8. The unit shall provide storage of parts removed from the C-130 aircraft during the overhaul process. Unless noted otherwise the contractor shall include all management, supervision, engineering, design, materials, labor, fabrication, transportation, shipping, off loading, equipment, installation, utility connections, modification to existing systems (if required) and items and activities necessary to provide completely functional units.

1.2. There are 12 existing vertical storage carousels installed on C-130 docks in bldgs.

225, 204 and 206 at Hill AFB, UT. 8 are taller and 4 are shorter. Docks C3, C4, C5

& C6 have the shorter units which are integrated in with the C-130 maintenance stands. This contract is to purchase 4 more units equivalent to those 4 shorter units.

In accordance with AFI 21-101 sections 2.4.4, 3.2.1, 8.2.1 and AFI 21-201 section

2.5.28.2 standardization of depot maintenance workspace, processes and equipment shall be implemented so far as possible. For consistency with the existing systems, ease of operator use, standardized training, standardized maintenance, standardized processes and to avoid safety issues caused by workers confusion on the proper operation of carousels made by different manufacturers, the carousels shall limit operational changes. The functional use, basic methodology and user operations shall be comparable to the existing systems. Tray sizes and intermediate shelves shall match trays on existing units to allow standardized storage configuration.

2. Delivery Orders:

2.1. For each carousel ordered (up to a total of 4) the contractor shall provide a White

Model 364010-144 with 10 pans and 13 intermediate shelves or approved equivalent meeting the design specifications in section 3. below.

2.2. Each unit shall be installed in B225 dock C1, C2, C7 or C8 as indicated

3. Design:

3.1. PRODUCTION MODELS: The units shall be new and one of the manufacturer's current production models, which on the date this solicitation has been designed, engineered, sold or is being offered for sale through advertisements or manufacturer's published catalogs or brochures. Products such as a prototype unit, pre-production model or an experimental unit do not qualify. The units shall include all components parts and features necessary to meet the dimensional and performance requirements specified herein.

3.2. DIMENSIONS: Existing Gen 2 C-130 MX stands were designed to integrate with the carousel. As such the carousel must meet certain dimensional constraints in order to properly integrate with the Gen 2 stands while still clearing the building structure.

Any variations from the nominal size must have PM’s approval at time of bid. Any additional costs resulting from size variations (such as stand, FVS or facility mods) shall be incorporated into the bid. Each unit shall meet the following dimensional parameters:

Footprint Width: Nominal = 176.5” Allowable = 156” to 208”

Footprint Depth: Nominal = 104” Allowable = 88” to 128”

Height: Nominal = 269” Allowable = Up to 272”

The height requirement is a function of the depth and must clear the arched roof truss.

Taller units may be acceptable if they are less than 128” deep. Variations from the specified nominal sizes shall be field verified for fit and approved by the PM prior to submitting a bid.

3.3. PROTRUSIONS: The contractor shall provide two units with the motor box protruding to the left and two with the motor box protruding to the right. The standard motor box and light protrusions with the White unit have already been verified for proper fit. Any protrusions other than the standard motor box and light box protrusions on the White units (motor boxes, light boxes, shelf, etc.) which extend outside the footprint specified must be field verified by the contractor to not conflict with existing MX stand columns, existing walkways or other existing conditions.

3.4. STORAGE CAPACITY: Each unit shall meet or exceed the following minimum storage capacity parameters:

Total Capacity: 34,600 lb. gross live load

Pans: 10 ea. @ 1,000 lb./pan

Pan Width: 144” (pans shall include full coverage side walls)

Pad Depth: 36”

Pan Clear Height: 36” (pans shall include 36” high back wall to support parts)

Intermediate Shelves: 13 ea. @ 400 lbs. distributed load per shelf

Shelf Deflection: 1/8” max with no intermediate supports

Shelf Size: 144” x 36”

Shelf Spacing: 12” cc vertically in each pan

Shelf Installation: Adjustable (bolted in place)

3.5. PART SIZES: Pans and shelves shall be capable of storing a variety of aircraft parts removed during aircraft maintenance activities. The larger sizes range from de-icing ducts which are 120” long to APU door panels which are curved pieces approx. 51” wide x 56” long (stored at an angle on the shelf with the edge leaning against the back wall of the 3’ tall pan). Wheel doors are 122” x 36.5” x 11.5”. Other parts include engine cowlings which are 35” x 46” x 14” and 48” x 36” x 16.5”. Wing tips are 91” x 12.5” x 13” while vertical stab. tips are 59” x 12” x 27”. Other panels are

75” x 24” x 3” while kidney plates are stored in bags approximately 28” x 40” x 30”.

There are a multitude of other parts and sizes being stored. Over the past several years, thousands of man hours have gone into configuring these storage carousels in a manner which is efficient for mechanics. New carousels shall have identical pan sizes so as to standardize configurations between docks.

3.6. PAN & SHELF COATING: A polyarmor protective coating (or approved equivalent rubberized coating) shall be installed on all interior surfaces of pans, shelves and dividers to prevent aircraft parts from direct metal-to-metal contact. Coating shall be

12-20 mil min.

3.7. POWER REQUIREMENTS: A 240 volt, 3 phase, 60 Hertz, 40 Amp fused disconnect is provided for power connection. The fused disconnect is located on the column of the MX stands, next to the CAROUSEL installation location. Contractor shall include connection to this disconnect or to other existing facility electrical service as required.

3.8. DUPLEX OUTLETS: Unit shall include one 120VAC, 20 Amp, 60Hz duplex outlet at each access window.

3.9. MOTOR DRIVE SYSTEM: Unit shall have a min. 7.5 horsepower drive motor system.

3.10. CARRY SYSTEM: Unit shall have a trunnion & scissor pan carry system to ensure accuracy of positioning, reliability and service life longevity.

3.11. LOAD IMBALANCE CAPABILITY: Unit shall be capable of handling a 50% load imbalance and still be fully operational

3.12. FINISH: The unit shall have a standard factory baked on paint.

3.13. DUST COVER: The unit shall have a dust cover on top. If the dust cover is not capable of supporting maintenance personnel walking on it then it shall have “No

Step” stickers on it.

3.14. PART VISIBILITY: The unit shall be a vertical type unit which allows users to easily rotate/move through storage pans to visually find required aircraft parts.

3.15. USER CONTROLS: The unit shall have controls at each access. The unit shall have an emergency stop button on both sides of each access window.

3.16. AUTOMATIC SAFETY STOP: The unit shall incorporate sensors to automatically stop movement in any direction if an object or user is in a position to get pinched between the rotating/moving pans and any other part of the carousel.

3.17. RS232 PORT: The unit controller shall be a command driven interface with asynchronous responses communicating through an ASCII RS232C 9 pin connection

(or approved equivalent). Pan positioning shall be directed from Air Force automation control host system MPS/D230 using ASCII commands. The controller shall respond when commands are completed and not require continuous polling to determine completion status.

3.18. ACCESS DOORS: The unit shall have lockable access doors with the same key for all doors on the same unit. Keys shall be different for each unit but a master key shall also be provided.

3.19. LIGHTS: The unit shall have full width high efficiency fluorescent or LED lights over each access door.

3.20. SEISMIC RATING: The unit shall have a seismic rating of 4.

3.21. FIRE PROTECTION: In Accordance With AFI 32-10141, each unit shall provide fire sprinklers complying with guidance provided in FM Data Sheet 8-33 Carousel

Storage (latest version). As a minimum sprinklers shall consist of 2 Head internal sprinkling, top mounted, 1” connection. Vendor shall run fire sprinkler pipe to end of unit. Connection to facility fire sprinkler system shall be by others. Units shall not have any counters at the access windows.

3.22. DUAL WINDOW ACCESS: Unit shall have two access windows. Both access windows shall be on the same side of the unit. Openings shall be 38” high x 146” wide min. Bottom of lower window shall be 36” to 40” above floor. Bottom of upper window shall be at 143” to 148” above floor. Windows shall be installed such that the upper window is accessible from the deck of the MX stands.

3.23. BASIC WARRANTY: Unless noted otherwise, contractor shall provide a written warranty which warrants all products provided under this contract, under normal use, shall be free from defects in materials and workmanship and that each unit/system shall perform its design function for a period of no less than one (1) year. Warranty period shall start from date of final acceptance of each installed unit/system. Any defects in materials or workmanship or failure of any product or component to perform its designed function during the warranty period shall be fixed by the contactor at no additional cost to the government. Warranty shall include the cost(s) of, parts, shipping and labor. Warranty repairs shall be fixed within 7 days of notice of failure.

4. INSTALLATION REQUIREMENTS:

4.1. DELIVERY, STORAGE & HANDLING: Contractor shall make all arrangements necessary, provide all equipment necessary, and cover all costs to deliver and off load all job related equipment, supplies, materials, fabrications, etc. to the job site at Hill

Air Force Base, Utah. Contractor shall coordinate delivery and off-loading with

AMXG as required

4.2. INSTALLATION SITES:

4.2.1. The four units shall be incorporated into the existing C-130 MX stands on docks

C1, C2, C7 and C8. Space for these units was designed into the stands. Two stands are mirror image of the other two stands.

4.2.2. Aircraft will be vacated from each dock during the carousel installation.

4.2.3. Units shall be installed within 1” of the deck of the stands on two sides.

4.2.4. Overhead speakers shall be relocated as required.

4.2.5. Contractor shall remove any temporary railing system installed and provide

OSHA approved fall protection methods for their employees during entire installation process. (Contractor may use existing overhead fall arrest system if desired, but must provide their own harnesses).

4.2.6. Existing roof truss system, second level mezzanines and existing utilities are in very close proximity to the installation site.

4.2.7. Offerors are urged and expected to field survey each site, examine limited available space and existing site conditions, and include all work required to adapt the site to accommodate the carousel as well as all equipment and labor needed to perform the installation and erection of the machines. In no event shall the failure to inspect the sites constitute grounds for a claim after the contract award.

4.2.8. On some docks the C-130 Gen 2 MX stands may already be installed. On other docks the contractor may have to install the carousels simultaneously with the stand installer. The contractor shall work in the same space and coordinate with the other contractor (through the government) without any additional costs or delays to the government.

4.3. TOOLS, MATERIALS, AND EQUIPMENT CONTROL:

4.3.1. TOOL CONTROL: In accordance with section 10.2.1.24.1 of AFI21-101

AFMCSUP OO-ALCSUP dated 4 February 2014, contractors performing functions in industrial areas within OO-ALC shall have a method for controlling and accounting for tools used. The contractor’s tool program shall be outlined in the contractor’s quality plan and must be coordinated with the respective contracting officer and contract functional manager or his/her designated representative. All contractors working within

OO-ALC will be required to inventory their tools at the beginning of the shift, at the end of each task, and at the end of each shift to check for any lost or missing tools.

4.3.2. LOST TOOLS: If tools and/or equipment are lost in the aircraft maintenance area, the contractor will report the loss to the contracting officer, production area supervisor and AMXG tool manager within 30 minutes of discovering the item is lost.

Every effort shall be made to recover the item before reporting it as lost.

4.3.3. FOREIGN OBJECT DAMAGE (FOD) Safety Requirements: FOD is any foreign object which causes damage to an aircraft. To ensure no construction materials become FOD the contractor is required to; ensure all deliveries and construction vehicles are properly covered and clean prior to entering the industrial area, ensure all work areas are cleaned daily, ensure all construction debris is contained within the contractor’s work area, thoroughly clean all installed products and all construction areas prior to turn over to government..

4.4. WORKING AROUND AIRCRAFT:

4.4.1. The aircraft maintenance area is defined as the entire secure (or controlled) area behind the pacer protect fence (also known as the red line area) and includes the flight line, tarmac and all facilities. No person shall enter the aircraft maintenance area without first obtaining permission, obtaining appropriate badges (or escorts), knowing the rules and agreeing to conform to the rules governing the area. WARNING: The area classified as the flight line has additional restrictions and requirements. The boundary of the flight line is indicated by a double yellow dashed line. Access to the aircraft maintenance area does NOT grant access to the flight line. All persons entering the flight line must receive additional appropriate training prior to entering.

4.4.2. When working in the aircraft maintenance area, the Contractor will be required to work in close proximity to aircraft and shall use extra caution to insure that activities do not endanger aircraft or personnel nor delay aircraft maintenance activities. Special rules and regulations exist when working around aircraft. The contractor will be required to adhere to these rules and regulations. Highlights include, but are not limited to:

- No work will be allowed over the aircraft

- Tool control requirements

- No privately owned vehicles in pacer protect area

- Contractor vehicle restrictions

- Restrictions of Driving/parking to close to aircraft

- Flight Line restrictions

- No food/beverages except in designated areas

- No smoking except in designated areas

- Restrictions on phones, cameras, and electronic devices

- Obtaining access badges and/or security escorts

- Time restrictions for unescorted work

4.4.3. NORMAL WORK HOURS: When working in the aircraft maintenance area the contractor, unless noted otherwise, is to work during normal 309 AMXG work hours whenever possible. Normal work hours for 309 AMXG are defined as 0600 to 1530

Monday through Thursday and 0600 to 1430 on every other Friday (with opposite

Fridays as off Fridays).

4.4.4. EXTENDED WORK HOURS: The contractor, at no additional cost to the government, must work extended hours (weekday evenings, nights, weekends and/or holidays) as required in order to complete the tasks within the schedule constraints defined in this contract. Contractors must be escorted by government personnel when working extended hours. Contractor must obtain approval from the PM one week prior to working extended work hours to allow the PM time to arrange for a government escort.

4.5. SECURITY & ACCESS REQUIREMENTS:

4.5.1. The job site for this contract is in a controlled area at Hill AFB. All personnel entering the controlled area must meet the same security requirements as government employees. The general contractor is responsible for managing access to the job site in accordance with Hill AFB controlled area security requirements for all employees, sub-contractor’s employees, delivery drivers, and all personnel entering the controlled area in the performance of this contract.

4.5.1.1. The contractor may apply for a DBIDS base entrance card for each person which requires un-escorted access to Hill AFB for 30 continuous days or more.

4.5.1.2. The contractor may apply for a controlled area Line Badge for each person which requires un-escorted access to the controlled area for 90 continuous days or more.

4.5.1.3. The contractor may apply for a Vindicator card for each person which requires access to the controlled area through electronically controlled gates for

90 continuous days or more.

4.5.1.4. The contractor is responsible to escort all persons which do not have controlled area Line Badges. Person’s without controlled area Line Badges shall

Page be checked in by their escort and obtain temporary badges at the security office in bldg. 100.

4.5.1.5. DBIDS and Line Badges can be issued at the same time, provided that all requirements are previously met.

4.5.1.6. The contractor is responsible to account for all Government issued credentials and badges. All credentials and badges shall be returned to the COR within five business days after termination of the employee or completion of the contract.

4.5.1.7. The contractor shall report any lost credentials or badges within one business day to the COR and to the 309 AMXG Security Office. The contractor shall create an Incident/Mishap report for any lost credential or badge.

4.5.1.8. The contractor shall create a Credential Verification List which identifies the person’s name, DBID card number and date assigned, Line Badge number and date assigned, and Vindicator card number and date assigned for each person issued one of these cards or badges assigned to this contract. The contractor shall provide the list to the COR no later than 10 days prior to initial on-site work and provide an updated list whenever new cards or badges are issued. The COR will use this list whenever a person is terminated or no longer needs the badge or card and at the end of the contract to verify that all credentials have been turned in.

4.5.2. To be issued a Defense Biometric Identification System (DBIDS) card each person must pass a local files check and obtain the card through the following process:

4.5.2.1. The contractor shall fill out, or provide, all of the necessary information on the AFMC Form 496, Application for AFMC Identification Card.

4.5.2.2. The contractor shall verify all of the information on the AFMC Form 496 and present the completed AFMC Form 496 with all necessary documentation to the

COR, or, the person listed on each AFMC Form 496 shall appear in person and provide two original identity source documents for identity proofing. The identity source documents must come from the list of acceptable documents included in

Form I-9, OMB No. 1115-0136, Employment Eligibility Verification. At least one document shall be a valid State or Federal Government-issued picture identification.

4.5.2.3. Upon receipt of AFMC From 496 a local files check is initiated.

4.5.2.4. Once the local files check is successful, the person will be directed to 75 SFS for issuance of the DBIDS card.

4.5.3. To be issued a controlled area Line Badge (CAB 1192), each person must pass a background check and obtain the badge through the following process:

4.5.3.1. The contractor shall coordinate a request for individuals in 309 AMXG’s controlled area with the 309 AMXG Security Office located in building 100.

4.5.3.2. The contractor shall submit to 309 AMXG security personnel the name, social security number and date and place of birth of each person along with the contract number and duration.

4.5.3.3. The 309 AMXG Security Office will then initiate a background check for each person (this could take from 2 weeks to 2 months).

4.5.3.4. Upon notification of a successful background check the contractor shall complete an “Unescorted Entry Authorization Certificate” (AF Form 2586) for that person.

4.5.3.5. The person shall take the completed AF Form 2586 to the Visitor Center to obtain a controlled area Line Badge.

4.5.3.6. Once the Line Badge is obtained the person shall return the AF Form 2586 to the 309 AMXG Security Office for accountability.

4.5.4. To be issued a Vindicator card each person must have a valid controlled area badge and obtain the card through the following process.

4.5.4.1. The contractor shall complete a 309 AMXG Building/Gate Access

Authorization form (AMXG Form 1A) and submit the form to the 309 AMXG

Security Office.

4.5.5. Prior to entering the controlled area, the contractor shall ensure appropriate training and safety briefings are conducted for each person as follows:

4.5.5.1. Each person applying for a controlled area Line Badge is required to take course #2315, Security Education Phase 1 & 2 (approx. 15 minutes).

4.5.5.2. Job site supervisors are required to take course #1300, FOD Awareness and

Prevention (approx. 25 minutes), and course #0038, Hydrazine Familiarization

(approx. 10 minutes).

4.5.5.3. Before allowing personnel access into the job site area, Job site supervisors are required to brief each person entering the controlled area about all job site hazards including appropriate PPE, Hydrazine hazards, FOD control, tool control and no food or drink except in designated break areas.

4.5.5.4. Training can be obtained by coordinating with the AMXG Training Manager at 801-586-1543.

5. SCHEDULE:

5.1. WORK SCHEDULE COORDINATION:

5.1.1. PRE-INSTALLATION MEETING:

Before any of the “on site” work within the scope of the contract is started, the

Contractor shall initiate and conduct a pre-installation meeting. Meeting shall:

5.1.1.1. Require attendance of persons directly supervising the on-site installation work.

5.1.1.2. Review schedule of installation, installation procedures and conditions, and coordination with related work.

5.1.1.3. Review safety requirements; FOD (Foreign Object Damage) control requirements; controlled area access and badge requirements; means of access to premises and building; delivery of materials and use of approaches; use of corridors, stairways, elevators, and similar means of communications; the location of fences, partitions and eating spaces for Contractor’s employees; sequence of procedure; work hours; schedule for completion, commissioning and training; and the like.

5.1.2. COORDINATION WITH PRODUCTION: Contractor must coordinate all on-site work and installation schedules with AMXG and schedule all on-site work around aircraft production activities. The contractor shall adapt their schedule to match site availability as granted by the PM. AMXG may alter schedules as needed and at no cost to the government up to 30 days prior to an establish start date.

5.1.3. INSTALLATION TIME REQUIREMENTS: Contractor shall complete the installment of each carousel within two weeks of each carousel site being released to them. The contractor will only have one week without an aircraft on dock. All heavy work (cranes/lifts/etc.) must be completed within the one week without an aircraft on dock. The remaining work may be completed in the second week with the aircraft on dock.

5.2. SCHEDULE CONSTRAINTS:

5.2.1. PHASED INSTALLATION: Contractor must have first unit available for installation within 12 weeks of contract award. Subsequent units shall be available at a rate of 1 unit every 4 weeks following the delivery of the first unit.

5.2.2. INSTALLATION DATES: The tentative installation date for each dock will be given at time of each order. IAW 5.1.2 the contractor shall adjust schedule as required.