FOUO C08.0.1 Attachment 2 PWS 07-02-2020.pdf

HANKOOK R-80 SHAFT LATHE REPAIRS PERFORMANCE WORK STATEMENT (PWS)

ATTACHMENT 2 LATHE PWS 07/02/2020

General Information

1. GENERAL: This is a non-personnel services contract to provide corrective maintenance on a Hankook R-80 shaft located at Puget Sound Naval Shipyard in Bremerton, WA.

1.1. Description of Services/Introduction: The contractor shall provide all personnel, equipment, supplies, facilities, transportation, tools, materials, supervision, and other items and non-personal services necessary to perform repairs as defined in this Performance Work Statement. The contractor shall perform to the standards in this contract.

1.2. Background: During execution of Contract N4523A19P1317, unforeseen conditions were identified by Hankook America. These conditions include the milling spindle taper not having the correct angle, the need for horizontal adjustment, in the X-axis, on the steady rest rollers, and additional hydrostatic work to correct the over pressure condition.

1.3. Objectives:

• Grinding of Milling Spindle Taper.

• Taper Inspection and Runout Test

• Steady Rest Roller Modification

• Steady Rest Roller Slide Drawings

• Steady Rest Roller Slide Manufacturing and Installation

• Steady Rest Roller Slide Test

• Hydrostatic Line and Ferrule Replacement

• Headstock oil and filter change

• Open and Inspection of the Hydrostatic System

• Open and Inspection Findings, Corrective Actions, and Cost Estimate Report

• Repair of the Hydrostatic System

• 8-Hour Run Test

1.4. Scope: The contractor shall be responsible for the requirements identified within this PWS. This includes but isn’t limited to grinding and testing the milling spindle taper, manufacturing, installing, and testing adjustable steady rest rollers, replacing all flexible hydrostatic lines, changing of the headstock oil and filter, and performing an open and inspection and findings report of the hydrostatic system.

1.5. General Information

1.5.1 Quality Assurance: The government shall evaluate the contractor’s performance under this contract in accordance with the Quality Assurance Surveillance Plan. This plan is primarily focused on what the Government must do to ensure that the contractor has performed in accordance with the performance standards. It defines how the performance standards will be applied, the frequency of surveillance, and the minimum acceptable defect rate(s).

1.5.2 Recognized Holidays:

New Year’s Day Labor Day

Martin Luther King Jr.’s Birthday Columbus Day

President’s Day Veteran’s Day

Memorial Day Thanksgiving Day

Independence Day Christmas Day

1.5.3 Hours of Operation: The contractor is responsible for conducting business, between the hours of 07:00 – 15:30, Monday thru Friday except Federal holidays or when the Government facility is closed due to local or national emergencies, administrative closings, or similar Government directed facility closings.

1.5.4 Place of Performance: The work to be performed under this contract will be performed at Puget Sound Naval Shipyard, Bremerton, WA, Building 431.

1.5.5 Security Requirements: The Contactor will abide by the security requirements defined in the contract and standard PSNS&IMF Security Policies. These policies if applicable shall be provided to the Contractor by the COR. Badging requirements shall be provided in separate attachment contained within this contract.

1.5.6 Post Award Conference/Periodic Progress Meetings: The Contractor shall attend all post award conference or other progress meetings as identified by the contracting activity or contract administration office. During these meetings appropriate action shall be taken to resolve outstanding issues. These meetings shall be at no additional cost to the government.

1.5.7 Contracting Officer Representative (COR):

Brian Weirth brian.weirth@navy.mil

(360) 710-7057

The COR monitors all technical aspects of the contract and assists in contract administration. The COR is authorized to perform the following functions: assure that the Contractor performs the technical requirements of the contract; perform inspections necessary in connection with contract performance;

maintain written and oral communications with the Contractor concerning technical aspects of the contract; issue written interpretations of technical requirements, including Government drawings, designs, specifications; monitor Contractor's performance and notify both the Contracting Officer and Contractor of any deficiencies; coordinate availability of government furnished property; and provide site entry of Contractor personnel. The COR is not authorized to change any of the terms and conditions of this contract. If the contractor believes the COR has effectively issued a change resulting in a change in effort and price/cost of the contract, the Contractor shall immediately notify the Contracting Officer.

PART 2

DEFINITIONS & STANDARDS

2. DEFINITIONS AND ACRONYMS:

2.1. DEFINITIONS:

2.1.1 CONTRACTOR. A supplier or vendor awarded a contract to provide specific supplies or service to the government. The term used in this contract refers to the prime contractor.

2.1.2 CONTRACTING OFFICER. A person with authority to enter into, administer, and or terminate contracts, and make related determinations and findings on behalf of the government. The only individual who can legally bind the government.

mailto:brian.weirth@navy.mil

2.1.3 CONTRACTING OFFICER'S REPRESENTATIVE (COR). An employee of the U.S. Government appointed by the contracting officer to administer the contract. Such appointment shall be in writing and shall state the scope of authority and limitations. This individual has authority to provide technical direction to the Contractor as long as that direction is within the scope of the contract, does not constitute a change, and has no funding implications. This individual does NOT have authority to change the terms and conditions of the contract.

2.1.4 DEFECTIVE SERVICE. A service output that does not meet the standard of performance associated with the Performance Work Statement.

2.1.5 DELIVERABLE. Anything that can be physically delivered, but may include non-manufactured things such as meeting minutes or reports.

2.1.6 PHYSICAL SECURITY. Actions that prevent the loss or damage of Government property.

2.1.7 QUALITY ASSURANCE. The government procedures to verify that services being performed by the Contractor are performed according to acceptable standards.

2.1.8 QUALITY ASSURANCE SURVEILLANCE PLAN (QASP). An organized written document specifying the surveillance methodology to be used for surveillance of contractor performance.

2.1.9 QUALITY CONTROL. All necessary measures taken by the Contractor to assure that the quality of an end product or service shall meet contract requirements.

2.1.10 SUBCONTRACTOR. One that enters into a contract with a prime contractor. The Government does not have privity of contract with the subcontractor.

2.1.11 WORK WEEK. Monday through Friday, unless specified otherwise.

2.2. APPLICAPLE DOCUMENTS

2.2.1 ANSI/ASME B5.10-1994 Standard for Machine Tool Tapers

2.2.1.1 It is the responsibility of the Contractor to procure industry standard ANSI/ ASME B5.10- 1994 if required.

PART 3

GOVERNMENT FURNISHED PROPERTY, EQUIPMENT, AND SERVICES

3. GOVERNMENT FURNISHED ITEMS AND SERVICES:

3.1. Facilities: The Government will provide the necessary workspace for the contractor’s staff to provide the support outlined in the PWS.

3.2 Utilities: The Government will provide 120 volt electricity and 90 psi air. The Contractor shall instruct employees in utilities conservation practices. The contractor shall be responsible for operating under conditions that preclude the waste of utilities, which include turning off the water faucets or valves after using the required amount to accomplish cleaning.

3.3 Lifting and handling. The Government will provide all rigging services for this PWS. Government lifts will take priority over Contractor lifts. The Contractor shall understand that Government priority lifts will not be cause for Government caused delays.

3.5 Test shaft. The Government will provide a test shaft that will be used for steady rest alignment.

PART 4

SPECIFIC TASKS

4. Specific Tasks:

4.1.1 Grinding of Milling Spindle Taper. A bluing inspection of the milling spindle taper during Contract N4523A19P1317 revealed a spindle taper with only 50% contact at the smaller diameter portion of the milling spindle taper. The contractor shall in-place grind the milling spindle taper to ANSI B-5, CAT- 50 taper standards. The contractor shall inspect and test the spindle taper for contact and runout and correct as necessary.

4.1.1.1. Taper Inspection, Runout Test, and Test Report. The contractor shall inspect the contact and runout of the spindle taper. The inspection and test shall be performed using a calibrated 18-inch, CAT 50 taper test bar. Bluing contact of the spindle taper shall be 90% with full contact at the front and rear of the taper. The runout test requirement is 0.0005 inches at 1-inch from the spindle nose and 0.0015 inches at 6-inches from the spindle nose. A test report shall be provided with the test results (CDRL A001).

4.1.2 Steady Rest Roller Modification. During execution of Contract N4523A19P1317, steady rest alignment to the headstock spindle centerline could not be accomplished due to the roller plate mounting bolts interfering with the roller plate mounting holes. It was determined that the steady rest roller plates require horizontal adjustment in the X-axis plane. The contractor shall design, provide preliminary and final drawings, manufacture, ship, install, and test four (4) steady rest roller plates with horizontal slides in the X-axis. The slides shall have a push-pull mechanical adjustment and means of keeping the rollers aligned axially along the Z-axis. The steady rest roller modification shall maintain the size and capacity of supporting shafts with diameters between 20 and 32-inches ensuring the steady rest pressure will not exceed 45,000 PSI on the shaft.

4.1.2.1. Steady Rest Roller Slide Drawings. The contractor shall provide preliminary drawings (CDRL A002) of the steady rest roller slide design to the Government for review and concurrence. The contractor shall confirm receipt of the drawings for review by the Government. Electronic means of submittal is acceptable. Provide electronic copies to the Contracting Officer’s Representative (COR) and Contract Specialist. The Government will have 10 working days to review, request revisions and/or concur on the drawings. The contractor shall have 10 working days to make preliminary drawing modifications as required. The drawings shall include the diameter and weight capacity of the steady rests with the new slides, +/- 0.19 inches of travel distance of the slides from the spindle centerline, all design features that will be used to maintain alignments, and a lift plan for slide installation into the steady rests. The steady rest slides shall come with all hardware installed that is identified in the lift plan.

4.1.2.2. Steady Rest Roller Slide Manufacturing and Installation. Upon Government approval of the preliminary drawings, the contractor shall manufacture, ship, and install the steady rest roller slides. The Government will inspect the steady rest roller design to ensure all preliminary drawing requirements have been met. Once the slides have been inspected, the contractor shall install the steady rest slides with use of Government cranes.

4.1.2.3. Steady Rest Roller Slide Test and Test Report. The contractor shall perform testing of the steady rest roller slides. This test shall include verification of +/- 0.19 inches of travel distance from the spindle center line, verification of steady rest rollers axial alignment in the Z- axis (roller parallel with the Z-axis) is within +/- 0.0025 inches for the full travel of the steady rest roller slide, verification that the steady rests have the capacity to support shafts with outside diameters between 20 and 32-inches ensuring the steady rest pressure will not exceed 45,000 PSI on the shaft, and that the roller slides are holding position when the steady rest is loaded to capacity during turning operations. A test report shall be provided with the test results (CDRL A003).

4.1.3 Hydrostatic Line, Ferrule, and Gauge Replacement. All flexible hydrostatic lines, ferrules and gages in the hydrostatic system shall be replaced. The guage pressure rating shall be between 50 and 60 Bar.

The working pressure capacity of the flexible lines shall be greater than 40 Bar. The replacement lines shall be labeled for the entire length, from the manufacture in the English language, with the size, wall thickness, working pressure, manufacturer, and manufactures part number. The contractor shall identify the manufacturer and part number of the replacement flexible line for Government approval.

4.1.3.1. Flexible Hydrostatic Line Pressure Test and Report. The contractor shall perform sample pressure tests on two sections of flexible line from each coil of replacement tubing that will be used. Testing the entire coil of line is not acceptable. The test shall utilize a calibrated gage and pressurize the tubing to 150% (60 Bar) of the hydrostatic systems maximum pressure of 40 Bar.

The test procedure, test results including the length of time and the temperature the tube was tested at, and manufactures spec sheet shall be submitted to the Government for review and acceptance.

(CDRL 0006).

4.1.4 Headstock Oil and Filter Change. The headstock oil and filter shall be changed using OEM recommended oil and filter. The Contractor shall perform an open and inspection of the headstock oil reservoir for any signs of excessive metal particles. Any findings of excessive metal particles shall be reported to the Government in the Open and Inspection findings report detailed in paragraph 4.1.5.1.

4.1.5 Open and Inspection of the Hydrostatic System. During execution of Contract N4523A19P1317, unforeseen repairs of the hydrostatic system were discovered. An over-pressure condition occurred during the 8-hour run test causing gage pinning and the possibility of hydrostatic line burst. Hankook determined that an open and inspection needs to be performed to resolve the over-pressure condition.

The contractor shall perform an open and inspection of the hydrostatic system using certified Hankook Machine Tool factory engineers and provide an open and inspection report. (CDRL A004). Based upon the results of the open and inspection report, the Government anticipates beginning negotiations for a contract modification to complete the identified required repairs.

4.1.5.1. Open and Inspection Findings and Corrective Actions. The contractor shall provide an open and inspection report with findings and required corrective actions to ensure hydrostatic pressures do not exceed 40 Bar and proper function of the Hankook Lathe. (CDRL A004).

4.1.6 8-Hour Run Test and Test Report. The contractor shall perform an 8-hour run test after all open and inspect, potential resulting contract modifications requirements have been met and all hydrostatic lines have been replaced. The test shall include full traverse of Z and X axes without interruption or controller alarms. The hydrostatic pressures shall be recorded prior to the start of the test and every hour during the test. The hydrostatic pressures shall not exceed 40 Bar. Any interruption, controller alarms, or hydrostatic pressures exceeding 40 Bar will be considered a failed test. If a failed test occurs, the Contractor shall provide a report (CDRL A005) containing information on why the test failed and corrective actions needed prior to restarting a new 8-hour run test. A test report shall be provided with the results and hourly readings taken during the test. A subsequent test shall be repeated after contractor has made required corrections. This process shall repeat until the lathe is capable of full function and passes the 8-hour run test.

PART 5

ATTACHMENT/TECHNICAL EXHIBIT LISTING

5. Attachment/Technical Exhibit List:

5.1. Attachment 1/Technical Exhibit 1 – Performance Requirements Summary (This document is required for every PWS. See attached example for format.)

5.2. Attachment 2/Technical Exhibit 2 – Deliverables Schedule (This document is required for every PWS. See attached example for format.)

PART 6

CONTRACTOR MAN HOUR REPORTING (NMCARS 252.237.102-90)

Contractor Manpower Reporting on labor hours used in the performance of CLINs 0001, 0002, 0003, 0004 in accordance with the PWS. For price estimating purposes, reporting takes approximately 1-2 hours of time for one employee to complete and is generally calculated using an accepted hourly wage for an administrative assistant or similar position.

The contractor shall report contractor labor hours (including subcontractor labor hours) required for performance of services provided under this contract via a secure data collection site. Contracted services excluded from reporting are based on Product Service Codes (PSCs). The excluded PSCs are:

(1) W, Lease/Rental of Equipment;

(2) X, Lease/Rental of Facilities;

(3) Y, Construction of Structures and Facilities;

(4) D, Automatic Data Processing and Telecommunications, IT and Telecom- Telecommunications Transmission (D304) and Internet (D322) ONLY;

(5) S, Utilities ONLY;

(6) V, Freight and Shipping ONLY.

The contractor is required to completely fill in all required data fields using the following web address https://doncmra.nmci.navy.mil.

Reporting inputs will be for the labor executed during the period of performance during each Government fiscal year (FY), which runs October 1 through September 30. While inputs may be reported any time during the FY, all data shall be reported no later than October 31 of each calendar year. Contractors may direct questions to the help desk, linked at https://doncmra.nmci.navy.mil https://doncmra.nmci.navy.mil/ https://doncmra.nmci.navy.mil/

6. TECHNICAL EXHIBIT 1

Performance Requirements Summary

The contractor service requirements are summarized into performance objectives that relate directly to mission essential items. The performance threshold briefly describes the minimum acceptable levels of service required for each requirement. These thresholds are critical to mission success.

Performance Objective

(The Service required—usually a shall statement)

6.1.1.1. Standard Performance Threshold

(This is the maximum error rate. It could possibly be “Zero deviation from standard”)

Method of Surveillance

PRS # 1.

The contractor shall in-place grind the milling spindle taper to ANSI B-5, CAT-50 taper standards. A blueing inspection of the milling spindle taper grind shall be performed. 80% contact area is required. Blueing shall be present at the front and rear of the taper.

The runout test requirement is 0.0005 inches at 1-inch from the spindle nose and 0.0015 inches at 6-inches from the spindle nose.

ANSI/ASME B5.10-1994

A bluing inspection of the milling spindle taper grind shall be performed. 80% contact area is required.

Bluing shall be present at the front and rear of the taper.

COR will witness bluing and runout test.

PRS # 2

The contractor shall design a steady rest roller plate with horizontal slide in the X-axis. The slide shall have a push-pull mechanical adjustment and means of keeping the rollers aligned axially along the Z-axis.

OEM design standards. The steady rest roller modification shall maintain the size and capacity of supporting shafts with diameters between 20 and 32-inches ensuring the steady rest pressure will not exceed 45,000 PSI on the shaft.

be capable of holding position when the steady rest is loaded to capacity during turning operations.

The steady rest rollers will be tested once installed to validate all design features provided in the design drawings.

PRS # 3

The contractor shall provide preliminary drawings of the steady rest roller slide design to the Government for review and concurrence.

OEM standard format. Zero deviation. COR and C980 mechanical engineers will review the preliminary drawings.

PRS #4

The contractor shall install the Government approved steady rest roller slides.

OEM standards. Zero deviation COR will witness the steady rest roller installation.

PRS # 5

The contractor shall perform an open and inspection with Hankook Machine Tool factory engineers and provide a report of findings, corrective actions, and cost estimates to the Government for review and concurrence of needed repairs.

OEM standards. Zero deviation. COR and C980 engineers will review the open and inspection report.

PRS # 6

The contractor shall make the Government approved repairs to the hydrostatic system.

OEM standards per the open and inspection report.

Zero deviation. COR and C980 engineers will witness the repairs per the open and inspection report.

PRS #7

The contractor shall perform pressure tests on the proposed hydrostatic lines being provided and submit the testing methods and report to the Government.

The test shall utilize a calibrated gage and pressurize the tubing to 150% of the hydrostatic systems maximum pressure of 40 Bar. The test procedure, test results including the length of time and the temperature the tube was tested.

Zero deviation. COR and C980 engineers will review the test methods and results.

PRS # 6

The contractor shall replace all flexible hydrostatic line,ferrules, and hydrostatic gauges. Hydrostatic line working pressure ratings shall have a minimum working pressure of 40 Bar.

Hydrostatic gauge pressure rating shall be between 50 and 60 Bar..

New flexible hydrostatic lines and ferrule shall have a minimum working pressure rating of 40 Bar. Hydrostatic gauge pressure rating shall be between 50 and 60 Bar.

Zero deviation. COR and C980 engineers will witness the hydrostatic line replacement.

PRS # 7

The contractor shall replace the headstock oil using OEM recommended oil and filter. The Contractor shall perform an open and inspection of the headstock oil reservoir for any signs of excessive metal particles. Any findings of excessive metal particles shall be reported to the Government in the Open and Inspection findings report detailed in paragraph 4.1.5.1.

OEM Standards Zero deviation COR will witness the oil change and inventory used filter.

TECHNICAL EXHIBIT 2

DELIVERABLES SCHEDULE

Deliverable Frequency # of Copies Medium/Format Submit To The contractor shall in-place grind the milling spindle taper to ANSI B-5, CAT- 50 taper standards.

A bluing inspection of the milling spindle taper grind shall be performed.

80% contact area is required. Bluing shall be present at the front and rear of the taper.

1-time

N/A

N/A

Puget Sound Naval Shipyard, Bremerton, WA

Brian Weirth

360 627 4769

The contractor shall design a steady rest roller plate with horizontal slide in the X-axis. The slide shall have a push-pull mechanical adjustment.

1-time 4-each N/A Puget Sound Naval Shipyard, Bremerton, WA

Brian Weirth

360 627 4769

The contractor shall provide preliminary drawings of the steady rest roller slide design to the Government for review and concurrence.

1-time 3-copies N/A Puget Sound Naval Shipyard, Bremerton, WA

Brian Weirth

360 627 4769

The contractor shall submit pressure test methods and results.

1-time 1-copy N/A Puget Sound Naval Shipyard, Bremerton, WA

Brian Weirth

360 627 4769

The contractor shall replace all flexible hydrostatic line and ferrules. Hydrostatic line working

1-time N/A N/A Puget Sound Naval Shipyard, Bremerton, WA

Brian Weirth

Deliverable Frequency # of Copies Medium/Format Submit To pressure ratings shall exceed the hydrostatic system pressures.

360 627 4769

The contractor shall provide and change the headstock oil and filter with recommended OEM oil and filter.

1-time N/A N/A Puget Sound Naval Shipyard, Bremerton, WA

Brian Weirth

360 627 4769

The contractor shall make the Government approved repairs to the hydrostatic system.

1-time N/A N/A Puget Sound Naval Shipyard, Bremerton, WA

Brian Weirth

360 627 4769