SOW_Chillers_3546_23_10_18.pdf

Statement Of Work

(SOW)

For

Mounted In-Line Chiller

And

Auto Hydraulic Hose Reels

309th AIRCRAFT MAINTENANCE GROUP

OGDEN AIR LOGISTICS COMPLEX (OO-ALC)

HILL AIR FORCE BASE, UTAH 84056

Project Engineer: Kirt Ehlers Civ 309 AMXG/ENL

October 23, 2018

TABLE OF CONTENTS

SCOPE

RESERVED

CONTRACTOR REQUIRMENTS

3.1. REQUIREMENT #1 - Build New Mounted Inline Chiller (MIC)

3.2. REQUIREMENT #2 - Portable Inline Chillers (PICU) converted to a Mounted Inline Chillers (MIC)

3.3. REQUIREMENT #3 - Auto Wind-up Hydraulic Reel (AWHR)

3.4. Common Requirements for AWHR and MIC (New or Converted PICU)

3.5 Maintainability Design Provisions of MIC and AWHR

3.6 REPORTS

3.7 SCHEDULE

3.7.2 WORK SCHEDULE COORDINATION:

3.8 PRE ON-SITE IMPLEMENTATION MEETING:

3.9 ON-SITE IMPLEMENTATION:

4 GENERAL

4.1 GOVERNMENT FURNISHED PORPERTY (GFP)

4.2 Safety Requirements

4.3 Environmental

4.4 Manpower Reporting

4.5 Quality

4.5.2 Quality Control

4.5.3 Quality Assurance

4.6 TOOLS, MATERIAL AND EQUIPMENT CONTROL

4.7 DESIGN FOR FOREIGN OBJECT DEBRIS (FOD) CONTROL:

4.8 GOVERNMENT CONTRACT MANAGMENT

4.9 RAILING RETENTION:

4.10 NON-SLIP SURFACES:

4.11 OPERATION, SAFETY & WARNING SIGNS:

4.12 PAINT:

4.13 VERIFICATION & INSPECTION OF EXISTING CONDITIONS:

4.14 GOVERNMENT SUPPLIED CAD & TECHNICAL FILES:

4.15 OWNERSHIP OF PROJECT DESIGNS & DOCUMENTATION:

4.16 GOVERNING REGULATIONS & GENERAL DESIGN REQUIREMENTS:

4.17 WELDING

4.18 FLATNESS AND ALIGNMENT

4.19 FABRICATION

4.20 MATERIAL DELIVERY, STORAGE & HANDLING:

4.21 DISPOSAL OF MATERIALS & HAZARDOUS MATERIALS:

4.22 INTERRUPTIONS TO UTILITIES:

4.23 O&M MANUALS:

4.24 OPERATIONAL TRAINING:

4.25 MAINTENANCE TRAINING:

4.26 HOURS OF OPERATION

4.27 SECURITY REQUIREMENTS: Bldg 225 and 237

4.28 PHYSICAL SECURITY

4.29 PUBLICATIONS AND FORMS

4.30 Summary of Deliverables

4.31 APPENDICIES

Appendix A: Acronyms & Abbreviations List

Appendix B: Safety, Fire Protection and Health Specification

Appendix C: Building 225 OCCs East Side Locations

Appendix D: Building 233 OCCs Location

Appendix E: Console and PICU pics

Appendix F: A/C Hose Connectors

ATTACHMENT 1: Government Furnished Property (GFP)

ATTACHMENT 2: Avionics Air Hose Cart Specification

Appendix A

Appendix B

Appendix C

Appendix D

Appendix E

Appendix F

SCOPE

Hill Air Force Base (HAFB) has twenty-five (25) F-35 aircraft Operator Control Consoles (OCCs) located in

Buildings 225 (Appendix C) and Building 233 (Appendix D). The OCCs have controlled air-conditioning and hydraulic plumbing that pass through them.

Each OCC air-conditioning outlet can connect to a Portable Inline Chiller Unit (PICU) that is used to reduce OCC air conditioned temperature of 100°F to a lower operating temperature of 50°F at point of use. (Aircraft undergoing avionics testing).

Hydraulic hoses are used for aircraft hydraulic system tests and come from the OCC and stored on metal frame stands. All hoses are wound and un-wound by hand when needed.

A requirement is needed to reconfigure existing10 PICUs to permanently Mounted Inline Chillers (MICs) close to the OCC and to build 15 MICs from scratch near each of the OCCs. In the same area of the MIC and OCC the hydraulic hoses racks need to be converted into Auto Wind Hose Reels (AWHR)

There are a total of four (4) Design requirements (details are listed in Section 3.0)

1- Build 15 New Mounted Inline Chiller (MIC) near the OCC including an initial prototype.

2- Convert 10 PICUs to a Mounted Inline Chillers (MIC) including an initial prototype

3- Design and install 25 Auto Wind-up Hydraulic Reel (AWHR) including an initial prototype

4- Design 25 Mounting system to hold the MICs/AWHRs

RESERVED

CONTRACTOR REQUIRMENTS

Note: Mounted Inline Chiller (MIC) is equivalent to the following:

Converted components from each of 10 PICUs to a MIC.

Building from scratch 15 new MICs.

Permanently Mounted Inline Chillers (MICs) and Auto Wind-up Hydraulic Hose Reels (AWHRs) shall be located as close to the OCCs as possible.

3.1. REQUIREMENT #1 - Build New Mounted Inline Chiller (MIC)

3.1.1. The contractor shall design, build, and assemble/install 15 MICs that reduce OCCs conditioned air 100°F down to 50°F operating temperature at point of use on the aircraft. (MIC) See Attachment 2 (Avionics Air

Hose Cart specification) to use as a minimum baseline for the acceptable quality of the MIC. All A/C connections with the MIC (In-Out) ports to interface with the current OCC output flange and current hose to the aircraft. See Appendix F for A/C Hose Connectors. When using refrigerant, the contractor shall comply with AFMAN 32-7089.

3.1.2. The new MICs shall be designed and assembled using new components that match the required performance..

3.1.3. The new MIC design shall incorporate the basic specifications of Section 3.2 but with all new components and have the same comparable outputs.

3.1.4. The MIC design shall incorporate Section 3.3, Requirement #3, with minimal floor space.

3.1.4.1 Drip troughs shall be provided to prevent water from draining on the operator, instrument panel, or into the enclosure. The bottom of enclosures shall be provided with necessary drains to prevent fluids from accumulating within the enclosure. Protect equipment lines and wiring within enclosures by routing the lines and wiring close to the structural members where they can be secured if necessary, and by providing protection or clearance where they can pass through panels and bulkheads.

3.1.5. The MIC’s steady state discharge air temperature shall be regulated to within +/-4° Fahrenheit within 10 minutes of a cold start in all operating conditions.

3.1.6. The MIC ducting air outlet to be located and mounted at the same height from the floor as the OCC air outlet.

3.1.7. The MIC ducting air outlet shall have a cover to protect against FOD when the aircraft hose is not attached.

3.1.8. The MIC cooling system shall be operated and controlled the same as the original PICU.

3.1.9. The MIC refrigeration system shall use R410A, R-404A, or approved equivalent refrigerant.

3.1.10. The MIC air conditioning unit shall be equipped with standard off the shelf type air filters and shall be readily removable.

3.1.11. A temperature and air-flow testing unit provided by HAFB shall be used to verify air discharge back pressure of 5.50 psig ± 0.25psig as indicated by the pressure gauge. Air discharge temperature shall be 40°F and airflow rate may be 46.5-60 pounds per minute for design purposes. If tempareture is 92°F or above contractor shall refrence Table 1 in section 3.6.6

3.1.12. Additional requirements see Section 3.4 and 3.5.

3.2. REQUIREMENT #2 - Portable Inline Chillers (PICU) converted to a Mounted Inline Chillers (MIC)

3.2.1. The contractor shall collect sample base line data at PICUs to validate that the new MICs will function the same or better and provide documentation in the Technical Report (CDRL A001).

3.2.2. The contactor shall design, build, and assemble/convert PICUs to MICs that reduce OCC conditioned air

100°F down to 50°F operating temperature at point of use on the aircraft. All A/C connections with the MIC

(In-Out) ports to interface with the current OCC output flange and current hose to the aircraft. See Appendix

H for connector PN information.

3.2.3. The contractor shall design each MIC to prevent freezing up during operation.

3.2.4. The contractor shall convert 10 of the PICUs located at HAFB into MICs using the existing major components from the PICUs (such as controls, probe connection, compressor, and heat exchanger), reassemble and mount permanently near each OCC, plumb with insulated ductwork, and connect to temperature controls.

3.2.5. Each MIC shall have the same operator interfaces or equivalent features as on a PICU, such as switches, gauges, alarm, and indicator lights.

3.2.6. The PICU to MIC conversion design shall incorporate Requirement #3 (Section 3.3) and shall consider minimalizing the floor space foot print.

3.2.7. Drip troughs shall be provided to prevent water from draining on the operator, instrument panel, or into the enclosure. The bottom of enclosures shall be provided with necessary drains to prevent fluids from accumulating within the enclosure. Protect equipment lines and wiring within enclosures by routing the lines and wiring close to the structural members where they can be secured if necessary, and by providing protection or clearance where they can pass through panels and bulkheads.

3.2.8. The MIC’s steady state discharge air temperature shall be regulated to within +/-4° Fahrenheit within 10 minutes of a cold start in all operating conditions.

3.2.9. The MIC ducting air outlet to be located and mounted at the same height from the floor as the OCC air outlet.

3.2.10. The MIC ducting air outlet shall have a cover to protect against FOD when the aircraft hose is not attached.

3.2.11. The MIC cooling system shall be operated and controlled the same as the original PICU.

3.2.12. The MIC refrigeration system shall use R410A, R-404A, or approved equivalent refrigerant. Reference

AFMAN 32-7089.

3.2.13. The MIC air conditioning unit shall be equipped with standard off the shelf type air filters and shall be readily removable.

3.2.14. A temperature and air-flow testing unit provided by HAFB shall be used to verify air discharge back pressure of 5.50 psig ± 0.25psig as indicated by the pressure gauge. Air discharge temperature shall be 40°F and airflow rate may be 46.5-60 pounds per minute for design purposes. If tempareture is 92°F or above contractor shall refrence Table 1 in section 3.6.6.

3.2.15. Additional requirements see Section 3.4 and 3.5.

3.3. REQUIREMENT #3 - Auto Wind-up Hydraulic Reel (AWHR)

3.3.1. Each OCC is supplied with 6,000 pounds per square inch of hydraulic pressure. Pressures applied to the aircraft operates up to 4,500 pounds per square inch pressure. Connected to each OCC are five 70-foot long hydraulic hoses, four with a 1.7-inch outside diameter (OD) and one with a 0.5-inch OD. These hydraulic hoses are manually unwrapped off a hose rack while being used and manually wrapped onto the rack for storage while not being used.

3.3.2. The contractor shall design and build 25 AWHR systems, each with four 1.7-inch OD hoses near each OCC with easy access and with provision to hang a 0.5-inch OD hand coiled hydraulic hose.

3.3.3. The contractor shall design and position each AWHR such that it is near and is located on the same side of the personnel pathway as its respective OCC. The contractor shall integrate the AWHR and MIC designs to minimize floor space and to facilitate operator and maintenance personnel access.

3.3.4. The contractor shall provide the four 1.7-inch OD hoses that connect the OCC to the auto hose reels.

3.3.5. The contractor shall incorporate the current hose by-pass valve used to flush the 1.7 hoses prior to use.

3.3.6. The contractor shall include an adapter to flush the 1/2" hose on the same by-pass valve used on the larger

1.7 dia hoses.

3.3.7. All control and indicator displays shall be located un-obstructed at eye level.

3.3.8. The four large 1.7” OD hoses are to be auto-wound via auto traversing feed powered reels. If this power source is to be hydraulic, then it must contain its own power system. The OCC cannot be used to supply hydraulic power to the AWHR.

3.3.9. If the AWHR is mounted off the floor, the maximum operation height should enable a 5’6” height person to run the AWHR standing with a normal reach flatfooted on the ground.

3.3.10. Hoses shall be capable of being auto-wound and un-wound under no OCC operating pressure.

3.3.11. Reels shall accommodate 70-foot length hoses.

3.3.12. The AWHR design shall specify commercial off-the-shelf components as much as possible.

3.3.13. Hose reels shall be designed so that one person can manually un-wind by pulling the hoses out.

3.3.14. The auto-wind function shall have both manual and auto-shutoffs to reduce motor overloads and hose binding, and to stop retraction when the hose end bumper is detected.

3.3.15. Additional requirements see Section 3.4 and 3.5.

3.4. Common Requirements for AWHR and MIC (New or Converted PICU).

3.4.1. The contractor shall have obtained government approval at Preliminary Design Review (PDR) prior to building the prototype MICs and prototype AWHR system. The contractor shall have obtained government approval at the Critical Design Review (CDR) prior to building the remaining MICs and AWHRs.

3.4.2. The contractor shall build, install and test one prototype of each MIC (new and converted PICU) showing that it performs as well as the original PICU.

3.4.3. The contractor shall build, install and test one prototype of an AWHR showing that it performs as needed.

3.4.4. All prototype builds must be signed off by the Project Manager (PM) as acceptable before the remaining

MIC and AWHR builds and installations begin.

3.4.5. Elevated platforms are acceptable as long as the design has been certified by a Professional Engineer

(PE)and located near the OCC.

3.4.6. The contractor shall evaluate each OCC location to understand the slightly different design integration challenges of each MIC and AWHR set. Different obstacles surrounding each OCC may require modifications such as mounting methods, lengths of wiring / piping, connections, access points, platform design mods.

3.4.7 The contractor shall design/provide air hose storage racks to be incorporated into the MIC. The rack must be able to accommodate 80-feet of collapsible hose. (Reference Appendix F Picture 1)

3.4.8 All materials used in the MIC and AWHR shall be fungus-resistant or shall be suitably treated to resist fungus. Materials treated for fungus resistance shall retain their original electronic, physical, or other properties sufficiently to remain entirely suitable for the purpose, and shall not present toxic hazards to personnel or have corrosive effects on adjacent materials.

3.4.9 The period of effectivity of such fungus resistant treatment shall be at least equivalent to the service life of the part or component on which it is used.

3.4.10 Magnesium, magnesium alloys, zinc, and zinc alloys shall not be used in constructing MICs and AWHRs without specific procuring activity approval except where the material is solely used for sacrificially protecting adjacent materials against corrosion, that the magnesium, zinc, or alloy parts do not provide a structural function, and the corrosion products will not interfere with adjacent parts’ functions or be deposited on adjacent surfaces susceptible to corrosion. Plating, dipping, or other means of surface treatment with such materials (including galvanizing) for corrosion resistance shall require approval from

PM.

3.4.11 Cadmium and cadmium compounds shall not be used in the construction of the MIC and AWHR.

3.4.12 The use of dissimilar metals in contact shall be avoided as far as practical in the design of the MIC and

AWHR. Where such conditions cannot be avoided, dissimilar metals in contact shall be protected in accordance with MIL-STD-889.

3.4.13 The use of materials that may emit products that are corrosive to adjacent materials will be avoided as far as practical. Where avoiding the use of such materials is not practical, the possible corrosive effects shall be controlled or eliminated by the provision of effective drainage and ventilation, choice of construction material, protective treatment (finishing) of corrosion- susceptible materials, or effective combinations of these measures.

3.4.14 When liquids or chemical solutions are used in the construction of equipment to clean or otherwise condition parts or surfaces, the manufacturer shall assure that such liquids are completely neutralized and removed and that the part is clean and dry before application of finish or completion of assembly.

3.4.15 Ventilation openings, when permitted by enclosure requirements, shall be designed to prevent accidental contact with live electrical circuits and moving mechanical parts.

3.4.16 During normal operation, the MIC and AWHR shall not produce a sound pressure level exceeding 75 A-weighted decibels (dbA) at a 10-foot radius measured from the center of the MIC and AWHR. Any sound absorbing or suppression material used in the construction of the MIC and AWHR shall be of the non-moisture absorbing type, so that condensation is not absorbed and held adjacent to metal structure and panels. Fiberglass, felt, and open cell foam shall not be used for sound suppression.

3.4.17 Instrument and control size, shape, function, operation, and location selections shall be appropriate to the specifications. Instruments and indicators (gauges and control measurement indicators) shall always be of the direct reading type (no calibration charts or curves requiring interpolation) and shall present to the viewer the required information in an easily understood manner. Mark devices with normal and abnormal ranges. All controls shall be marked, indexed, sized, and located such that control settings can be readily identified.

3.4.18 U.S. customary weights and measures shall be the primary measurement units for all physical dimensioning and measuring.

3.4.19 Instrument selection shall be governed by the accuracy and repeatability required in the measurement being made.

3.4.20 If analog mechanical pressure gauges are used for primary indications, they shall be of the flush-mounted dial type with a minimum dial diameter of 3.5 inches and a measurement error not exceeding ±2% of full-scale reading at any measured reading, and shall conform to ASME B40.100. A calibration tap shall be included between each pressure gauge supply line (reference gauges are excluded) and the isolation valve to facilitate the calibration of the pressure gage from the front of the control panel. If analog temperature gauges are used for primary indication, then they shall be of the flush-mounted dial type with a minimum dial diameter of 2.5 inches and a measurement error not exceeding ±2% of full-scale reading at any measured reading, and shall conform to ASME B40.200. For analog gauges, the normal operating value of the quantity to be indicated should be between 0.3 and 0.8 of full-scale deflection, wherever practicable.

3.4.21 Smooth and rapid control operability shall be provided with locking positions or detents if required by the controlled function. Controls and their related indicators shall be positioned on a noninterference basis when the control is being operated. These controls are usually on the front panel. The contractor shall minimize lay and backlash in controls. They shall operate freely and smoothly without binding, jerking, or other undesired actions. The controls shall be single action, controlling only one parameter, and shall not require further adjustment of other controls to obtain the correct setting. Control sizing, spacing, and shapes are to be determined by human factors criteria, considering the intended use and operating location of the equipment. Control orientation shall be such that to increase the controlled parameters, the control will move either upward (to the top of the panel), clockwise, forward, or to the right. Controls shall have mechanized stops and locking devices, except for those designed for continuous rotation. The control shall have provisions to prevent the device from rotating in the panel. Knobs provided shall have a positive means of retention on their shafts. Plastic knobs shall use metal inserts and will not warp or crack.

Switches, levers, and other controls shall be of rugged design for long-term hand use.

3.4.22 Controls required for adjustment or calibration and not used for operation shall be mounted behind covered openings on the faces of the equipment from which they are most accessible when installed. If not hand adjustable, the adjustments should accept a common screwdriver blade. If only infrequent adjustment is required, access openings are not required; however, the control shall be easily accessible when the item is opened for maintenance and will normally be adjustable with a common screwdriver. For mechanical devices, common hand tools should be used.

3.4.23 Instruments and control circuits shall have appropriate circuit protection, cable routing, and type of connector for their intended use.

3.4.24 The MIC and AWHR components requiring periodical supply of either a consumable product or uploaded/downloaded information, shall include provisions to accept the product and conduct it to the point(s) of use or storage within the equipment item. Such equipment items shall also contain provisions for draining (e.g., consumable products). Servicing provisions shall be suitably identified, permitting access within 5 minutes. Means shall be provided to prevent filling the expansion space of liquid tanks during servicing operations.

3.5 Maintainability Design Provisions of MIC and AWHR

3.5.1 The design shall facilitate ease of maintenance and permit maintenance to be accomplished quickly, safely, accurately, and effectively with a minimum number of personnel, minimum skill level, no special tools, and minimum cost.

3.5.2 MIC and AWHR, if periodically supplied with a consumable product, shall include provisions to accept the product and conduct it to the point(s) of use or storage within the equipment item. Such equipment items shall also contain provisions for draining (e.g., consumable products). Servicing provisions shall be accessible within 5 minutes, suitably identified, and shall be compatible with the servicing provisions equipment. Means shall be provided to prevent filling the expansion space of liquid tanks during servicing operations.

3.5.3 MIC and AWHR shall be designed for accessibility. Components (e.g. controls, instruments, circuit breakers, fuses, batteries, power supplies, printed circuit boards, servicing provisions, and items requiring frequent maintenance) intended for Unit level on equipment maintenance shall be accessible for removal and replacement without disassembling the mounting structure, removing undamaged parts, or removing panels that consume greater than 5 minutes of time to open. Components (e.g. fuses, circuit breakers, filters, etc.) shall be remotely located, if necessary, to provide the required accessibility. Covers or plates that must be opened or removed for daily or weekly access to components shall be equipped with panel latches. The MIC and AWHRs overall enclosure(s) shall be removable by overhead lift or manual lifting handles on each corner of the enclosure for improved maintenance action accessibility. Depending on the weight of the item, one or more individuals wearing a full complement of C/B or arctic (except mittens) protective equipment should be able to remove, replace, or repair malfunctioning components. Difficult-to-remove components shall not block access to components that are easier to remove. Line replaceable units (LRUs) shall be mounted so they can be removed and replaced without removal of other LRUs or components.

3.5.4 Structural members of the MIC and AWHR shall not prevent access to or removal of LRUs. Replaceable items shall not be mounted in a manner that will make them difficult to remove. Where accessibility depends upon removal of panels, cases, or covers, the design shall ensure that such items are not blocked by structural members or other items.

3.5.5 Large components, which are difficult to remove, shall be mounted so they will not prevent convenient access to other items.

3.5.6 Items weighing over 80 pounds shall be mounted in such other manner that convenient access for the required handling equipment is provided.

3.5.7 Tools and Test Equipment: Check points, adjustment points, test points, test/servicing ports, cables, connectors, and labels shall be accessible and visible during maintenance. Sufficient space shall be provided for the use of test equipment and other required tools with gloved hand(s).

3.5.8 Rear Access: Sliding, rotating, or hinged equipment, to which rear access is required, shall be free to open or rotate their full distance and remain in the open position without being supported by hand. Rear access shall be provided to plug connectors except where precluded by any other operational requirements.

3.5.9 Components most critical to system operation and which require rapid maintenance shall be most accessible.

3.5.10 The MIC and AWHR design shall include consideration of component removals for major disassembly and major repair of the equipment whenever practical. Only removal of the defective item should be necessary. Pilot guides, slides, and other similar features shall be provided where they will appreciably facilitate removal and replacement. The design shall minimize improper installation by unsymmetrical configuration, different size connectors, guide pins, etc. Electrical enclosures required to be removed for maintenance or repair shall be designed with blind-mate connectors to facilitate removal and installation.

Stainless steel guide pins shall be used in blind-mate connectors. The enclosure mounting shall be designed to retain mating of the connectors while meeting all requirements in this specification.

3.5.11 The MIC and AWHR design shall include provisions for attaching lifting devices, hard points for lifting devices, slots or protrusions for attaching extraction tools, etc., which are necessary during removal and replacement of components and subassemblies.

3.6 REPORTS

3.6.1 Action Item Tracking Log (CDRL A002)

The contractor shall create and maintain an Action Item Tracking Log. The log shall be a living document which is continually updated as needed. Action Items discussed at project meetings shall be incorporated into the Action Item Tracking Log. Updated Action Item Tracking Log shall be emailed to the PM and the Contracting Officer Representative (COR) in electronic format at the conclusion of each meeting. Contractor shall provide hard copies of the Action Item Tracking Log upon request by the PM. Each item shall include:

Task order number

Item number

Item description

Date item was raised

Owner assigned to complete item (to be an individual, not an organization)

Target complete date

Actual complete date

Resolution and comments section

3.6.2 AS-BUILT DATA PACKAGE (CDRL A003)

The contractor shall provide a draft copy of the As-Built Data Package within thirty (30) days of completing:

Requirement #1 of this contract

Requirement #2 of this contract

Requirement #3 of this contact

The data package shall be In Accordance With (IAW) the following:

3.6.2.1 The package is to be comprehensive and include all information required to properly document the final designs developed and systems implemented in the performance of this contract. The package shall include, but is not limited to, all drawings, part lists, specifications, PE calculations, and written instructions necessary for an independent contractor to construct, install and/or repair all designs included in this contract. The package shall include documentation of all final system settings and configurations. The package shall be divided into the following three sub-packages; drawings, specifications and PE calculations.

3.6.2.2 All drawings shall be compiled into a single drawing sub-package with an appropriate index sheet which identifies the location of each drawing. Drawings in the package shall be formatted to the same paper size and shall be to a known scale and dimensionally accurate.

3.6.2.3 The drawing sub-package shall include the final version of all drawings created in the fulfillment of this contract. Drawings included shall be, but are not limited to, shop drawings, part drawings, detail drawings, assembly drawings, layout drawings, installation control drawings, construction drawings, and elevation and section drawings.

3.6.2.4 Drawings shall have a 309 AMXG/EN approved Title Block with the AF logo being the most dominant. Drawings shall be formatted to be legible when printed on a max paper size of

ANSI “D” (22” x 34”). Any drawings submitted which are formatted for paper larger than

ANSI “B” (11” x17”), shall include a copy printed half size (i.e. “D” size drawings shall include a copy printed half size on “B” size paper, “C” size drawings shall include a copy printed half size on “A” size paper.)

3.6.2.5 The drawing sub-package shall be provided in two (2) electronic formats and in a printed and bound hard copy. The contractor shall provide up to five (5) printed hard copies at PM’s request at no additional cost to the government. The electronic formats shall be in both Adobe

PDF and CAD formats. The CAD format shall be either AutoCAD 2015 (or newer) or

SolidWorks 2015 (or newer). The PE’s seal shall be included in both the printed and PDF formats, but not in the CAD format.

3.6.2.6 All specifications shall be compiled into a single specifications sub-package and include appropriate indexes. The specification sub-package shall be submitted in two electronic formats and in a printed and bound hard copy. The contractor shall provide up to five (5) printed hard copies at PM’s request at no additional cost to the government. The electronic formats shall be in both Adobe PDF and an editable Microsoft Word format.

3.6.2.7 All PE calculations shall be compiled into a single PE calculations sub-package. Each PE’s calculations shall include the PE’s seal and shall be submitted in Adobe PDF format only.

3.6.2.8 All electronic files shall be compatible with a Microsoft Windows OS.

3.6.2.9 The contractor shall provide draft copies of each data package for government review and acceptance prior to providing final copies. Draft copies shall be provided in both a digital format and in a printed and bound hard copy.

3.6.2.10 The Government response time to approve or disapprove contractor drawings is two (2) weeks.

3.6.3 ICR MEETING MINUTES

Meeting minutes shall be taken digitally during the Implementation, Coordination and Review (ICR) meetings, agreed on by all present in the meeting, and emailed to the PM and COR at the conclusion of each meeting. (CDRL A004)

3.6.4 CONTRACTOR ROSTER

The Contractor shall include an updated Contractor Roster which identifies, for all employees working on base supporting this contract for more than five (5) continuous days, the company name, employees’ names, Government POC names, employees’ supervisor’s (or lead’s) names, Defense

Biometric Identification System (DBIDS) (if issued) and line badges (if issued) no later than fifteen

(15) days prior to on site work. Changes made to the list or status of employees shall be provided one week prior to the scheduled work to ensure the Government is aware of all contract employees on site.

(CDRL A005)

3.6.5 TECHNICAL REPORT STUDY/SERVICES

The contractor shall collect sample base line data at PICUs to validate that the new MICs will function the same or better. Data collected shall include, but not limited to, input and output air flow, humidity, pressure, temperature. Collected data and analysis must be approved by the Government before the

PICU to MIC conversions begin. (CDRL A001)

3.6.6 ACCEPTANCE TEST PLAN

Functional Test. The contractor shall submit a test acceptance plan to the PM and COR, two (2) weeks prior to testing. The test plan shall demonstrate that each system will operate at a no load condition continuously for no less than twelve (12) hours based on calibrating incoming operator control console air temperature from 100° F down to 50° F. Proper operation of all controls, motors, adjusting mechanisms, and other accessories shall be verified during the test period. Acceptable temperature ranges are listed in Table 1 Below (CDRL A006)

Table 1

Temp from OOC Temp at Point of Use

100° F 50° F +0°/-4°

98° F 48° F +2°/-4°

96° F 46° F +/-4°

94° F 44° F +/-4°

92° F 42° F +/-4°

90° F 40° F +/-4°

88° F 40° F +/-4°

86° F 40° F +/-4°

84° F 40° F +/-4°

82° F 40° F +/-4°

82° F 40° F +/-4°

82° F 40° F +/-4°

3.6.7 ACCEPTANCE TEST REPORT

The contractor shall generate and deliver the acceptance test results to the PM and COR three (3) days after successful functional testing. (CDRL A007)

3.7 SCHEDULE

3.7.1 IMPLEMENTATION PHASE.

1) One (1) prototype PICU converted to a MIC per para. 3.4.6 and one (1) prototype AWHR per PWS para. 3.4.7 to be delivered three (3) months ARO.

2) One (1) prototype new MIC per SOW para. 3.1 And one (1) prototype AWHR per SOW para. 3.3 To be delivered three (3) months ARO.

3) Base Year 12 month period of performance: Four (4) Sets of MIC and AWHR units installed in Building 225 East Side (Appendix C)

4) Base Year 12 month period of performance: Four (4) Sets of MIC and AWHR units installed in Building 233 North Side (Appendix D)

5) The following schedule implementations shall be scheduled at a mutually convenient time for both parties:

a. Option 1 12 month period of performance: Six (6) MIC and AWHR units installed.

b. Option 2 12 month period of performance: Six (6) MIC and AWHR units installed.

c. Option 3 12 month period of performance: Three (3) MIC and AWHR units installed.

d. Option 4 12 month period of performance: Two (2) MIC and AWHR units installed.

3.7.1.1 MIC and AWHR implementation time period: All services and installations for each OCC shall be completed within a one (1) week maximum time frame from start to finish while aircrafts on either side are being overhauled.

3.7.1.2 All work required near each OCC, such as on associated infrastructure, modifications to existing systems, and installation of new systems, shall be completed prior to turn over to aircraft production and within the allotted time period for each installation.

3.7.1.3 Implementation Phase Start Dates. Dates for working in each MIC and AWHR will be provided by 309 AMXG/EN as the schedule matures. At the Governments discretion and at no additional cost to the government, the start dates may be as close as three (3) weeks apart.

The government may adjust schedule as required up to fourteen (14) days prior to the start date of each phase. The contractor shall attend ICR meetings and adjust schedule as coordinated in meetings.

3.7.2 WORK SCHEDULE COORDINATION:

3.7.2.1 Work hours when on site at HAFB to be IAW with Section 4.31.

3.7.2.2 The contractor shall coordinate on-site work and schedules with the PM as well as schedule on-site work around aircraft production activities. The PM will provide initial control console availability schedules to the contractor, but may alter established schedules as needed and at no cost to the government unless it is within thirty (30) calendar days of an established control console availability date. The contractor shall adapt their schedule to match control console availability schedules as they are revised.

3.7.2.3 The area between each aircraft will be cleared for access during each install. No dock will be shut down for any part of the installation. (Note: Aircraft Assembly Stands will not be cleared out.)

3.7.2.4 During installation, the area around each OCC shall be roped off to separate the construction site from the production area.

3.7.2.5 There will be minimal area for storage near each OCC so materials and components need to be brought in as needed and staged off site until installed.

3.7.2.6 Major fabrication such as welding, cutting, painting, etc., is to be completed off site prior to installation.

3.7.2.7 Multiple MIC and AWHR units shall be ready for installation at any given time to help with scheduling options. See section 3.4.6

3.7.2.8 Coordination with Production: The contractor shall coordinate on-site work and schedules with the PM as well as schedule on-site work around aircraft production activities. The PM will provide initial dock availability schedules to the contractor, but may alter established schedules as needed and at no cost to the Government unless it is within fourteen (14) calendar days of an established dock availability date. The contractor shall adapt their schedule to match dock availability schedules as they are revised.

3.7.2.9 Formal ICR Meetings and Reports: The contractor shall attend ICR meetings, to be held weekly in a 309 AMXG provided conference room, until the work is substantially completed.

During each meeting, the contractor shall update the Action Item Tracking Log IAW (CDRL

A002).

3.8 PRE ON-SITE IMPLEMENTATION MEETING:

3.8.1 The contractor shall initiate and conduct a pre on-site implementation meeting which shall convene a minimum of one (1) day prior to commencing work in any given project site. The contractor shall ensure sub-contractor(s) (if applicable) are briefed and made aware of site conditions and restrictions.

Meeting shall:

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

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

Review safety, tool control and FOD (Foreign Object Damage) control requirements, potential site hazards, access badges, controlled area access, work hours, schedule for completion, commissioning and training.

Review unique work conditions relative to the site such as, designated smoking areas, designated food consumption areas, food storage and transport restrictions, phone, camera, radio and electronic device restrictions, vehicle restrictions, etc.

3.9 ON-SITE IMPLEMENTATION:

3.9.1 The contractor shall:

3.9.1.1 Complete as much work as reasonably possible off-site to minimize disruption to aircraft production activities. Work to be completed off-site includes everything except for demolition, modifications to on-site systems and equipment, and final installation.

3.9.1.2 Provide layout lines indicating major equipment locations and receive PM’s approval prior to installation.

3.9.1.3 Isolate dissimilar materials to prevent electrolytic corrosion.

3.9.1.4 Provide applicable testing and certification under supervision of the manufacturer.

4 GENERAL

4.1 GOVERNMENT FURNISHED PORPERTY (GFP)

4.1.1 Other than the equipment listed in Attachment 1, no other Government furnished property will be provided. The contractor shall provide all equipment and operators required to complete the work, including all lifts, and crane service.

4.1.2 Other than the equipment listed in Attachment 1, Government furnished storage area: Other than the minimal area around the OCC site, see Appendix D, no other government area will be provided for staging or storing materials, parts or equipment.

4.2 Safety Requirements

4.2.1 The contractor shall implement a safety program that ensures protection of Government personnel and property. (CDRL A008 & Appendix B)

4.2.2 In the event of an accident/mishap, the contractor shall take reasonable and prudent action to establish control of the accident/mishap scene, prevent further damage to persons or property, and preserve evidence. A written or email copy of the accident / incident notification shall be sent within three (3) calendar days to the COR, who will forward it to OO-ALC safety. (CDRL A010)

4.3 Environmental

4.3.1 The contractor shall ensure their employees are made aware that the performance of these services will occur in industrial areas. The F-35 aircraft workload adjoining the job sites has the potential to expose workers to hazardous materials which may include, but is not limited to, lead, methylene chloride, hexavalent chrome and cadmium. While the contractor will not perform duties in a marked and signed regulated area (where exposures are expected to exceed the permissible exposure limits set by Operation Safety and Health Administration (OSHA), there may be contact hazards with these materials during cleanup of dust, metal shavings, etc. The contractor shall ensure proper protective measures and training is taken to ensure contracted employees are protected from these hazards.

4.3.2 Compliance with Laws and Regulations. The contractor shall be knowledgeable of and comply with all applicable Interstate, Federal, State, and Local laws, regulations, and requirements regarding environmental protection. In the event environmental laws/regulations change during the term of this contract, the contractor is required to comply as such laws come into effect. If there is an increase or decrease in cost as a result of the change, the contractor shall inform the Contracting Officer (CO)

IAW notice requirements and negotiate a modification to the contract.

4.3.3 Notification of Environmental Spills. If the contractor spills or releases any substance contained in

40 CFR 302, including hazardous materials, into the environment, the contractor or its agent shall immediately call 911. If the call is made from an on-base phone, it will go directly to Hill AFB dispatch. If using a cell phone, the call will go off- base and you will need to ask the 911 dispatcher to be transferred to Hill AFB. The liability for the spill or release of such substances rests solely with the contractor and its agent.

4.4 Manpower Reporting

4.4.1 The Contractor shall report ALL Contractor labor hours (including sub-Contractor labor hours) required for performance of services provided under this contract via a secure data collection site. The

Contractor is required to completely fill in all required data fields at http://www.ecmra.mil.

4.4.2 Reporting inputs will be for the labor executed during the period of performance for each

Government fiscal year (FY), which runs 1 October through 30 September. While inputs may be reported any time during the FY, all data shall be reported no later than 31 October of each calendar year. Contractors may direct questions to the Contractor Manpower Reporting Application (CMRA) help desk.

4.4.3 Uses and Safeguarding of Information: Information from the secure web site is considered to be proprietary in nature when the contract number and Contractor identity are associated with the direct labor hours and direct labor dollars. At no time will any data be released to the public with the

Contractor name and contract number associated with the data. User Manuals: Data for Air Force service requirements must be input at the Air Force CMRA link. However, user manuals for

Government personnel and Contractors are available at the Army CMRA link at http://www.ecmra.mil.

4.5 Quality

4.5.1 Unless noted otherwise, all materials shall be new and free of corrosion or other defects. All components and implementations shall be manufactured and installed in accordance with industry best standards of quality and workmanship. All surfaces shall have factory or shop applied paints or coatings wherever possible. Field touch-up of painted and/or coated areas shall be kept to a minimum. Field touch-up all components and installations as required to provide a factory finished / shop finished professional look. Field work shall be finished to match factory/shop standards. No

“chop” or “hack” jobs shall be accepted. The contractor shall ensure all installations are plumb, level, and flush with adjacent surfaces. All burs, weld splatters, sharp corners, and sharp edges shall be removed and ground smooth prior to painting. Final components, installations, and installation areas shall be completely cleaned and free of installation debris, road grime, etc. The contractor shall clean surfaces thoroughly prior to installation, prepare surfaces using the methods recommended by the manufacturer, and install in accordance with manufacturer’s instructions. The contractor shall check systems for signs of corrosion, wear, deformation and other defects, inspect all parts to insure no damaged parts are used, install equipment with no irregularities or projections capable of inflicting personal injury and ensure finished surfaces and edges of all parts are regular and smooth. The contractor’s quality and standard of work shall match or exceed existing.

4.5.2 Quality Control

The contractor shall establish a Quality Control Plan to ensure the requirements of this contract are provided as specified. The contractor's quality management program shall comply with the minimum quality management systems elements specified in the American National Standards Institute (ANSI), American

Standards Organization (ASO), and International Standard Organization (ISO) family of standards. The contracting officer will notify the contractor of acceptance or required modifications to the plan before the contract start date. Modifications shall be made within fifteen (15) days of start. (CDRL A009 Quality

Control Plan) http://www.ecmra.mil/

4.5.3 Quality Assurance

4.5.3.1 The Contracting Officer Representative is the authorized government representative(s) who will perform assessments of the contractor’s performance. Subsequent to contract award, the identity of the COR(s), with a letter defining duties and authority, will be promptly furnished to the contractor

4.5.3.2 The COR(s) or alternate(s) will inform the task manager in person when discrepancies occur and will request corrective action. The COR(s) or alternate(s) will make a notation of the discrepancy on the assessment checklist with the date and time the discrepancy was noted and will request the task manager (or authorized representative) to initial the entry on the checklist.

4.5.3.3 Any matter concerning a change to the scope, prices, terms or conditions of this contract shall be referred to the CO.

4.5.3.4 The services to be performed by the contractor during the period of this contract are, at all times and places, subject to review by the CO or authorized representative(s).

4.5.3.5 The Government will periodically evaluate the contractor’s performance by appointing a representative(s) to monitor performance to ensure services are received. The Government representative will evaluate the contractor’s performance through inspections and receipt of complaints from base personnel.

4.5.3.6 The government may inspect each task as completed or increase the number of quality control inspections if deemed appropriate because of repeated failures discovered during quality control inspections or because of repeated customer complaints

4.6 TOOLS, MATERIAL AND EQUIPMENT 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. Any lost tools not found must be reported immediately to the contracting officer, production area supervisor, and 309

AMXG tool manager.

4.7 DESIGN FOR FOREIGN OBJECT DEBRIS (FOD) CONTROL:

Except for removable railing sections or other large removable components, any smaller item incorporated into a design and/or implementation which can be removed without a tool (i.e. lock pins, quick release band clamps, etc.) shall be permanently attached to the unit with the use of a lanyard (or other AMXG/EN approved device) to prevent the item from becoming FOD (Foreign Object Debris) and causing damage to an aircraft.

4.8 GOVERNMENT CONTRACT MANAGMENT

4.8.1 The CO is a government official designated to enter into and administer contracts. The CO has the sole authority to issue modifications to the contract, resolve disputes, and to terminate the contract. No conversation, direction or recommendation, given or implied by government personnel, that will affect the scope, schedule, or price of this contract, shall be acted upon by the contractor unless first approved by the CO. Under no circumstances shall “approval” by the CO be interpreted as a release of the contractor from responsibility to fulfill requirements of the contract.

4.8.2 The Air Force PM is a government employee designated by the CO. The PM shall act as the technical advisor for the government. Only the PM (or designated alternate) has authority to review and accept contract deliverables. The PM will have the right to reject or require correction of any deficiencies found in products or deliverables. The PM may provide technical interpretation and/or direction to ensure the project is in compliance with the contract technical requirements, but the PM does not have authority to alter the requirements of this contract. If the contractor believes directions received from the PM are outside the scope or confines of the contract, the contractor shall notify the PM and CO prior to proceeding.

4.9 RAILING RETENTION:

All removable guardrails/railings, incorporated into the design and/or implementation of this contract, shall have a retention device which prevents unintentional removal of handrail section. Retention device shall be a ball lock pin such as McMaster-Carr #93750A803 or PM approved alternate. All removable pins shall have a lanyard or other PM approved device to secure the removable pin.

4.10 NON-SLIP SURFACES:

All stair treads and walking surfaces, incorporated into the design and/or implementation of this contract, shall have a slip resistant surface made from diamond tread plate with non-slip paint, serrated expanded metal, traction tread, or other PM approved surface.

4.11 OPERATION, SAFETY & WARNING SIGNS:

Equipment and component installations shall include all operation, warning and safety signs as required to instruct users in the safe operation of the equipment. Signage shall include, but are not limited to, warnings and instructions required for maximum capacity, lock pins, safety cautions, towing restrictions, usage instructions, etc.

All signage shall be approved by PM prior to fabrication and installation.

4.12 PAINT:

4.12.1 Unless otherwise noted, all surfaces without factory applied paints or industrial grade corrosion resistant coatings shall be painted per the following or PM approved equivalent.

4.12.2 All surfaces shall be free of corrosion, rust, oil, grease, and dirt and shall be cleaned and thoroughly dried before paint and primer applications. All surfaces shall be prepped, and painted per paint manufacturer’s recommendations.

4.12.3 Except for…