Hydraulic Test stand Tech Specification.docx

Technical Specifications Hydraulic Test Stand

JML 51270158

1. SPECIFICATIONS:

1.1. SCOPE: This specification describes the government’s requirements for the procurement of a new hydraulic test stand.

2. APPLICABLE DOCUMENTS:

2.1. General: The documents listed in this section are specified in sections 3 and 4 of this specification. This section does not include documents cited in other sections of this specification or recommended for additional information or as examples. While every effort has been made to ensure completeness of this list, document users are cautioned that they must meet all specified requirement documents cited in section 3 and 4 of this specification, whether or not they are listed.

2.2. Government Documents:

2.2.1. Other Government documents, drawings and publications form a part of this document to the extent specified herein. Unless otherwise specified, the issues are those cited in the solicitation.

2.3. Non-Government Publications: The following documents form a part of this document form a part of this document to the extent specified herein.

2.3.1. American Petroleum Institute (API): API-598: API STD 598 Valve Inspection and Testing

2.3.2. ANSI-American National Standards Institute: ANSI B16.5: Standards for pipes and pipe fittings.

2.4. Order of precedence: In the event of a conflict between text of this document and the references cited herein, the text of this document takes precedence. Nothing in this document however, supersedes applicable laws and regulations unless a specific exemption has been obtained.

3. REQUIREMENTS

3.1. DESIGN: The equipment shall be new and capable of performing its intended function in accordance with the operation and performance requirements specified herein. The equipment shall be complete, so that when connected to the utilities identified herein, it can be used for any function for which it is designed and constructed.

3.1.1. USE OF ASBESTOS: The use of asbestos and materials containing asbestos on or in the furnished equipment is prohibited.

3.1.2. SAFETY AND HEALTH REQUIREMENTS: Covers, guards, or other safety devices shall be provided for all parts of equipment that present safety hazards. Safety devices shall not interfere with operation of the equipment. The devices shall prevent unintentional contact with the guarded part and shall be removable to facilitate inspection, maintenance and repair of the parts. Machine parts, components, mechanisms, and assemblies furnished on the unit shall comply with all specific requirements of "OSHA Safety and Health Standards (29 CFR 1910), General Industry" that are applicable to the equipment itself. Additional safety and health requirements shall be as specified in other paragraphs of this specification. The design and manufacture shall be in accordance with all applicable ANSI safety standards.

3.1.3. CONTROLS: Operating controls shall be located convenient to the operator at normal workstation. All controls shall operate freely with minimum friction and without binding, sticking, leaking or jamming; however, the controls shall remain in selected position during operation of the equipment.

3.1.4. USE OF POLYCHLORINATED BIPHENYL (PCB): The use of polychlorinated biphenyl (PCB) on or in the equipment is prohibited.

3.1.5. USE OF MERCURY: The equipment shall not contain mercury or mercury compounds, nor shall it be exposed to free mercury during manufacture.

3.1.6. HAZARDOUS MATERIAL EXCLUSIONS: Supplies or materials being provided as part of the equipment shall be free of known hazardous materials. Hazardous materials shall not be brought on site without prior approval of the technical point of contact. Hazardous materials not needed for this project are prohibited. Definitions of hazardous materials are specified in the latest version, including revisions adopted during the term of the contract, of Federal Standard No. 313.

3.2 SIZES AND CAPACITIES: The test stand shall be designed and constructed to conform to the following sizes and capacities. The sizes and capacities are to be considered minimum unless otherwise specified. When a range is indicated, it shall be from the stated minimum or less to the stated maximum or more.

3.2.1 INSTALLATION FOOTPRINT: Test stand installation footprint dimensions shall be a maximum/not to exceed 22’ x 16’ x 11’ (L x W x H). Total test stand weight shall not exceed floor load capacity of installation site.

3.2.2 TEST BED CAPACITIES: The test bed shall be designed to accommodate subplates and hose line connections to test submarine type hydraulic accessories such as valves, actuating cylinders, pressure regulators, accumulators, hand pumps, etc. Test bed component handling capacities shall be at minimum to handle static weight of 800 lbs. and component lengths up to 66 in. Support tables for test bed shall be ported. Test bed dimensions shall be no less than 80” x 24” and equipped with adequate overhead lighting.

3.2.2.1 The test bed shall be stainless steel constructed in such a manner as to provide proper drainage and control splashing.

3.2.2.2 Test bed will be equipped with a switch to drain excess oil from the test bed to the reservoir by return piping incorporating a 50-mesh strainer.

3.2.2.3 The test bed shall be capable of supporting submarine valves which weigh up to 800 pounds with a length of 66 inches and width of 24 inches.

3.2.2.4 Test bed shall automatically drain through filter to reservoir

3.3 PERFORMANCE: The test stand shall perform/have capabilities as listed below:

3.3.1 Operational Temperature Range, degrees: 32oF to 110oF.

3.3.2 Relative Humidity: up to 100% Non-Condensing

3.3.3 Oil Test Temperature Range, degrees: 90oF – 130oF

3.3.4 Test duration of 30 Minutes, Minimum: +/- 10% setting

3.3.5 Automatic capability of maintaining test fluid temperature as specified.

3.3.6 AC/DC variable power for solenoids, DC positive and negative polarity

3.3.7 Fully enclosed structure with provisions for personnel protection during testing.

3.3.8 Contain spillage/exterior leakage

3.3.9 Manual control with data recording and printing test parameters and results

3.3.10 Means of maintaining system pressure while shifting from one port to another

3.3.11 Means of maintaining oil system cleanliness requirements

3.3.12 Capability of Directional Valve Tests (2-way, 3-way, 4-way and 5-way porting)

3.3.13 Ability to regulate pressure independent

3.3.14 Automatic temperature control by adjustable thermostat

3.3.15 Hose capacity- Max Hose Diameter 2.5”

3.3.16 STRENGTH TESTING: Test stand shall be capable of performing hydrostatic strength testing to 10,000 psig. Strength testing/hydrostatic circuit shall be provided with a means to “creep” to the final test pressure. It shall have appropriate relief valves to prevent damage. Static pressure port shall be (#6) 3/8” JIC port.

3.3.17 SUPPLY SIDE: Operating testing circuit #1 shall be 5,000 psig with a minimum flow rate of 50 gpm. 5,000 psig shall be continuous. Circuit #1 shall have 2 ea. output ports, rated at 65 gpm with 1” JIC ports and be equipped with flow control valve, bypass valve, pressure control valve and relief valve. Circuit #2 shall be 5,000 psig with a minimum flow rate of 30 gpm. Circuit #2 shall have 2 ea. output ports, rated at 130 gpm with 1 ½” JIC ports, contain flow control valve, bypass valve, pressure control valve, relief valve, and have ability to accept flow from Circuit #1 utilizing crossover valve for maximum flow through Circuit #2 ports. Both circuits require ability to regulate pressure independently, adjustable relief valves, pressure indicators, flow meters, dual connection ports. Circuit #2 requires an integrated directional valve (bi-direction circuit for testing cylinders). Installed 4-way solenoid controlled valve shall be capable of automatic cycling, interface w/ two limit switches to control valves for extension/retraction of test cylinders, and have ability to set/count automatic cycles. All gauges shall be equipped with ability to connect secondary gauges.

3.3.18 RETURN SIDE: Shall be equipped with two independent return circuits, flow meters, flow control valve, back pressure regulator, means of measuring leakage. Control Side of Return shall be equipped with two control circuits, which may be cross-connected by means of a single valve. Each circuit will require flow meter, pressure indicator, flow control valve, and means of measuring leakage. Return lines shall have temperature sensors installed. Flow meters shall be turbine meters in lieu of gear meters. Hydraulic return side shall contain 5 total return ports to include 1 ea. high flow return (2 ½” JIC port, rated minimum 130 gpm), 2 ea. medium flow returns (1 ½” JIC port, rated at 60 gpm) and 2 ea. low flow returns (1/2” JIC port, rated 7gpm). All return ports shall have return pressure control and return pressure gauges. All gauges shall be equipped with ability to connect secondary gauges.

3.4 HYDRAULIC SYSTEMS: Hydraulic systems shall conform to requirements of the NFPA/JIC T2.24.1.

3.4.1 HYDRAULIC POWER SUPPLY: The hydraulic power supply shall consist of the reservoir, hydraulic pumps, pump controls, motors, emergency relief valve(s), heat exchangers, filter(s) and electrical components mounted on a heavy duty welded structural and plate steel base. Hydraulic power supply shall be contained within test stand housing. All hydraulic and electrical connections shall terminate on the same side of power supply for ease of installation and shall be clearly labeled, showing function and schematic nomenclature. System shall operate with fluid/s MIL-PRF-17331J, Symbol 2190 TEP and MIL-PRF-17672D, Symbol 2110 TH and Symbol 2075 T-H.

3.4.2 HYDRAULIC PUMP SYSTEM: The hydraulic system shall provide at a minimum the following combinations of fluid flows and pressure capabilities. Combining pumps to achieve higher flow rates is acceptable.

5,000 psig @ 50 gpm 5,000 psig @ 30 gpm with bi-directional flow 3,000 psig @ 130 gpm 500 psig @ 0-50 gpm 100 psig @ 40 gpm

3.5 PUMPS: The hydraulic pumps shall be electric motor driven, axial piston, variable volume, pressure compensator controlled. The compensator control circuit shall consist of a manually adjustable remote-control valve mounted on the operator’s control panel. Pump system does not have to be separate from test bench. Pumps shall achieve a maximum continuous pressure of 5,000 psig and a maximum intermittent pressure of 5,800 psig.

3.6 HEAT EXCHANGER: Heat exchanger shall be sized and rated to remove heat generated in the hydraulic power unit itself to maintain system temperature within design parameters specified herein. The heat exchanger shall automatically maintain within +/- 5º F hydraulic fluid temperature at any preset point between 60º F and 130º for 30 minutes during worst-case conditions from an energy dissipating viewpoint. Heat exchanger will be installed on the return line to the reservoir. Oil to water and oil to air heat exchangers are both acceptable. Oil to water system must be a closed loop system.

3.7 HEATERS: Electric heaters shall be provided for raising the reservoir test fluid to a temperature of 90° F to 150° F within four hours. The heater(s) shall have automatic temperature control with over temperature protection. The temperature controller shall control within +/- 10° F.

3.8 CHILLER: Standalone chiller provided shall provide capability to control target hydraulic temperature to include bypass valve for heater and cooler. Controls for chiller shall be provided.

3.9 RESERVOIR: The oil reservoir shall be manufactured to the applicable requirements of ANSI/ (NFPA) T3.16.2 R1 and shall be fabricated of no less than 12-gauge stainless steel. Working capacity of oil reservoir shall be not less than twice the maximum rated GPM flow of the test stand. The reservoir shall be totally enclosed, vented, and include inlet and outlet connections liquid level gauge, clean-out opening, drain, baffles, 200 mesh suction strainers, equipped with low level warning, temperature monitored and contain bypass valve control to open when oil temp less than setpoint. Reservoir shall be equipped with electrical heating system designed for hydraulic fluids, over temperature cutoff, over current cutoff, setpoint/power control at operator station and no more than 4-hour heating time between temperature range of 70oF – 130oF. The reservoir shall be capable of being pressurized to 5 psig to ensure positive suction to hydraulic pump.

3.10 INSTRUMENTATION: Test shall have instrumentation as listed below.

3.10.1 TEMPERATURE: RTD Temperature sensors shall be installed in each return line and hydraulic tank/reservoir.

3.10.2 PRESSURE: Digital gauges shall be within 0.25% accuracy, Analog gauges (shall be stainless steel constructed/liquid filled, 4”-6” diameter, and within 0.5% accuracy). Circuit #1 pressure gauge shall range from 0-6000 psig, Circuit #2 pressure gauge shall range from 0-6000 psig, Static pressure gauge shall range from 0-10000 psig, test stand shall contain 3 ea. independent pressure gauges ranging from 0-6000 psig for auxiliary pressure measurement and return port gauges ranging from 0-3000 psig.

3.10.3 FLOW METERS: Flow meters shall be configured for easy removal and installation for periodic calibration, contain second set of calibrated flow meters during calibration cycle, be configured for accurate flow measurements and accuracy shall be within 1% accuracy. Circuit #1 pressure 3-60 gpm, Circuit #2 pressure 8-150 gpm, high flow return port 15-150 gpm, 2 ea. medium flow returns 5-50 gpm, and 1 ea. low flow return rated 0.75-7.5 gpm. Flow meters shall be turbine meters in lieu of gear style meters. Flow Technology flow meters (Turbine) shall have flow range from 0.75 gpm-150 gpm. Flow Technology flow meters (Turbine) have been preapproved for use by cog tech Code 137.2.

3.10.4 GAUGE GRADUATIONS/REQUIREMENTS: All gauges installed shall be in accordance with Table 1. Two gages, a primary and a backup, shall be used during all strength and tightness testing. The primary gage shall be selected as specified in Table 1. The back-up gage range shall be greater than the test pressure, but not more than twice that of the maximum test pressure. Back-up gages for test pressures below 60 psig may be the same as the primary gage range. The primary and back-up test gages shall have an accuracy of at least +/- 1% of gage span and track within 2% of maximum test pressure of each other.

* Values agree with the requirement that gage range shall not exceed

200% of test pressure except for gage ranges of 0-60 psig and lower.

** Values allow for reading pressures up to relief valve settings.

*** A 0-400 psig range gage may be substituted for a test pressure range of 200-360 psig. A 0-160 psig range gage may be substituted for a test pressure range of 80-144 psig.

Table 1.

3.10.5 INDICATOR LIGHTS: Indicator lights/visual indication shall be installed on test stand to include low fluid level, high fluid temperature, clogged filters and emergency stop system reset requirement.

3.11 FILTRATION: Hydraulic system shall contain 1 ea. Pressure filter (rated at 3 microns w/glass fiber element), 1 ea. Return filter (rated at 10 microns w/glass fiber element), Loop filter (rated at 10 microns w/glass fiber element) for continuous oil cooling and filtration while test stand is operating and shall have additional operator manual controls, and 1 ea. Sink Return filter (rated at 10 microns w/glass fiber element).

3.12 PNEUMATIC SYSTEMS: Pneumatic systems shall conform to the requirements of the NFPA T2.25.1 R. Pneumatic systems operated from receiving activity supplied air shall be provided with regulators and filters and shall include dryers, if necessary for safe and efficient operation of system. Compressed air available for air actuated mechanisms is 90 pounds per square inch gauge and 100 cubic feet per minute (nominal). If the proposed system requires more air than indicated above, the excess capacity shall be provided as part of the equipment. Any proposed compressed air system shall include a regulator(s) and a filter(s) with an automatic drain.

3.13 ELECTRICAL DESIGN

3.13.1 ELECTRICAL EQUIPMENT: Electrical components including motors, starters, relays, switches, and wiring shall be in accordance with NFPA 79. Electrical system shall be installed withing NEMA style (4/12) enclosure. The equipment delivered and all accessory parts shall operate from a single source of primary power which is 460 VAC (+/- 10%), three-phase, 60 Hz. The contractor shall provide the peak electrical load (AMPS) required to support a fully configured, operational system including all accessories in its fully configured and operational state. Total electrical load requirement for test stand not to exceed 400 Amps. Electrical system shall be designed with 2 ea. emergency stop buttons.

3.13.1.1 ELECTRIC POWER DISCONNECT: A supply circuit disconnect device shall be provided and installed on the equipment.

3.13.1.2 MOTORS: Motors shall be rated for continuous duty and shall be equipped with ball bearings of the sealed and permanently lubricated type. Electric motor shall be rated 300 HP, 460 VAC, 3 Phase, 60 Hz, and 1750 rpm. Motors shall conform to the NEMA MG-1. Electrical system shall have motor starters for main pump, loop pump, sink pump and static pressure pump.

3.13.1.3 CONTROL CIRCUITS: Main and auxiliary control circuits shall operate on a circuit of 115 volts or less derived from isolation transformer(s) integral with the equipment.

3.13.1.4 CONTROL CONSOLE: The control console shall contain all necessary air, hydraulic, electrical connections, regulators, valves, test bed, sink, switches, lights, gages, dials, control valves and limit switches for testing accumulators, piping and mounting provisions for servo system, electronics test set and other accessories as required. All instruments shall be installed in front of the instrument panel and shall be readily visible from the test stand operating position and labeled as to the system being read. All connections to the instrument shall be back connected and arranged so that any single instrument may be replaced without disturbing other components. The control console base shall be welded structural steel construction with components secured to the frame by heavy steel mounting fixtures. Cover pan shall be not less than number 16-gauge sheet steel.

3.13.1.5 ELECTRICAL CONNECTIONS: Electrical connections within the equipment shall be complete and shall be made via terminals on the components, terminals, or circuit boards and bussing. Splices between terminations are not permitted. Connections and terminals shall be supported and spaced without dependence upon the wiring in the components and braced as necessary to assure withstanding the distortion forces associated with available short-circuit currents. Proper identification of wiring, bussing, terminals and circuits for function, polarity, phasing, etc., shall be adhered to throughout the equipment. Identification shall be in the form of wire markers, color coding, permanently engraved plates, and permanent markings on the devices. Adequate spacing shall be maintained throughout to avoid excessive bending of cabling and wiring, to maintain adequate separation and creepage distance between electrical potentials and between these potentials and ground, and to permit ease in disconnecting wiring and cabling during trouble-shooting and repair. In no instance shall clearances and creepage distances be less than those prescribed under NEMA ICS, Part ICS 1-111.

3.13.1.6 ELECTRICAL TEST CIRCUIT: Electrical test circuit shall have DC and AC connector plugs with 2, 3, 4, & 5 (A, B, C, D, & E) pinholes two each. AC volts meter with adjustment of 0-150 volts. AC amperes meter 0-10 amperes. DC milliamps meter with adjustment of 0-90 milliamps. DC voltmeter with adjustment of 0-150 volts. DC amperes meter 0-10 amperes. DC positive and negative polarity switch. An ohms meter 0-200 ohm to read coil resistance on a solenoid with data that indicates it’s too low, high or no good. All electrical equipment shall have digital read out. DC/AC output and input measurement ports shall be RCA type female ports. DC power supply shall be able to supply 0-60 VDC and provide 6A (amps) per dual channels. DC multi meter shall contain digital read out and measure (0-1000 VDC, 0-750 VAC, 10mA to 10A DC current, 10A AC current and 100 to 100M ohm resistance range. Electrical test equipment (e.g., voltmeters, amp meters, etc.) shall have calibration/recalibration capability and removable.

3.13.1.7 GROUNDING: Exposed, non-current carrying metal parts on the equipment shall be maintained at common, zero ground potential. None of the primary circuits in the equipment shall be connected to ground. A ground stud or lug on the equipment shall provide means for grounding the equipment for safety to personnel. A NEMA type grounding plug that effectively grounds the equipment shall be acceptable for cord connected equipment.

3.13.1.8 SOLID-STATE COMPONENTS: Solid-state design shall be employed throughout for electronic components. Use of selenium and other similar aging devices shall be permitted only in the application of voltage surge protection to other solid-state components. Each solid-state device shall be selected and installed to have characteristics and withstand ratings compatible with its intended function and application in assuring long life and reliability. Solid-state components shall not be adversely affected when subjected to radiated and conducted power line transients and surges typically experienced in a production type, industrial environment. Series and parallel connections of solid-state devices without forced sharing circuitry for voltage and current, respectively, is not permitted. Cathode ray tubes are excluded from this requirement.

3.11 COMPRESSED AIR: Compressed air available for air actuated mechanisms is 90 pounds per square inch gauge and 100 cubic feet per minute (nominal). If the proposed system requires more air than indicated above, the excess capacity shall be provided as part of the equipment. Any proposed compressed air system shall include a regulator(s) and a filter(s) with an automatic drain.

3.12 INTERCHANGEABILITY: Replaceable parts shall be manufactured to definite standards, tolerances and clearances in order that such parts can be replaced or adjusted without modification of the equipment.

3.12.1 MAINTAINABILITY: The equipment shall be designed and constructed to permit maintenance personnel to service the equipment easily and effectively using a minimal number of tools. The contractor shall provide any special tools required to service the unit. The equipment shall have access covers, as necessary, to facilitate inspection, cleaning and repair or replacement of internal parts. A comprehensive warranty shall be included for a period of no less than 2 years to include manufacturing or material defects.

3.13 CONSTRUCTION: The equipment shall be constructed of parts that are new or refurbished without defects. The equipment shall be complete. When connected to the specified utilities, it shall be capable of any operation for which it is being purchased. The equipment shall be devoid of any defects or characteristics that will preclude conformance with any of the requirements herein. Test bed shall have a base plate constructed of 1117 steel or equal with electroless nickel plate finished in accordance with attached design drawing. The baseplate is designed to accommodate subplates and hoses connected to submarine type hydraulic accessories being tested on the test stand. Test bed construction shall allow for components to be lowered from overhead crane.

3.13.1 WELDING, BRAZING OR SOLDERING: Welding, brazing or soldering shall be employed only where those operations are included in fabrication of the original design. These operations shall not be employed as repair measures for defective parts.

3.13.2 SOLDERING: Solder connections shall show evidence of good bonding in metal-to-metal contact. Cold solder joints, incomplete joining of solder and metal, excess or insufficient solder or damaged insulation shall be considered reason for rejection of the equipment.

3.14 FASTENING DEVICES: Screws, pins, bolts, and similar internal and external parts shall be installed with means for preventing change of tightness. Parts subject to removal or adjustment shall not be swaged, peened, staked, or otherwise permanently installed. Fastening devices shall be tightened to torque limits as established by the manufacturer's standard for tightening to preclude loosening by normal operation or vibration.

3.15 PAINTING: The equipment shall be painted in accordance with the manufacturer's standard practice. Prior to painting, surfaces shall be properly prepared and primed. Painting shall provide a highly wear-resistant finish that guarantees continued protection to the surfaces covered against the specified environment under all service conditions. The manufacturer's standard color shall be provided. Lead or chromium base paints are prohibited.

3.15 DISSIMILAR METALS: Dissimilar metals shall not be used in direct contact with each other without suitable means for preventing electrolytic corrosion.

3.16 CONTROL PANELS, INSTRUMENTS AND PLATES: Wording and numbers on all control panels, instruments, charts and plates shall be permanently and legibly displayed in bold face, English language characters on a contrasting background.

3.17 CONTROLS AND INSTRUMENTATION: Operator controls, instrumentation and indicators shall be mounted convenient to operating personnel. Such devices shall be clearly and legibly marked for function and identification. Controls shall be fitted with suitable handles, pushbuttons, or control knobs, as applicable. Gauges and instruments shall be designed for recalibration. Gauges shall be calibrated in the U.S. system of measurement and shall be marked with a range of acceptable operating range (so that from a distance, the operator can clearly see if the machine is operating in range). List of calibrated equipment shall be provided prior to start of test stand fabrication.

3.18 INSTALLATION: Government shall be responsible for all equipment (forklifts, man lifts, etc.) and qualified personnel required for installation, anchoring and leveling the machine in place. Government shall also be responsible for compliance with attached Installation Responsibilities Table. Contractor shall be responsible for startup services following installation.

4 QUALITY ASSURANCE.

4.1 RESPONSIBILITY FOR INSPECTION: The contractor shall be responsible for the performance of all inspection requirements specified herein. The contractor may use his own facility or any other commercial facility suitable for the performance of the inspection requirements specified herein, unless disapproved by the Government. The machine and all ancillary equipment shall completely conform to the requirements specified herein prior to the contractor requesting origin inspection from Government. The Government reserves the right to perform any inspections set forth in the purchase description where such inspections are deemed necessary to assure supplies and services conform to prescribed requirements.

4.2 RESPONSIBILITY FOR COMPLIANCE: All items must meet requirements of section 3.

4.3 INSPECTION / ACCEPTANCE TESTING:

4.3.1 INSPECTION / ACCEPTANCE TESTING (ORIGIN): An inspection and operational acceptance test shall be performed on the machine at origin to ensure conformance with this purchase description. The machine shall pass the examination, all tests, and the final inspection to be accepted. The supplies offered for delivery shall be examined for design, construction, components, electrical equipment and workmanship to determine conformance with the requirements of this specification.

4.3.2 INSPECTION / ACCEPTANCE TESTING (DESTINATION): An inspection and operational acceptance test shall be performed on the machine at destination to ensure conformance with this purchase description. The machine shall pass the examination, all tests, and the final inspection to be accepted. The supplies offered for delivery shall be examined for design, construction, components, electrical equipment and workmanship to determine conformance with the requirements of this specification. An operational test shall be conducted and witnessed by receiving activity. The machine shall be operated in a manner and for a time frame suitable to properly demonstrate and verify the successful operation of the equipment and all its component parts, relative to the design, construction and performance. Included in this test, but not limited to, shall be modes of operation, all indicating devices, operator controls, hydraulic system, safety devices, and all elements of the control system.

5 ADDITIONAL REQUIREMENTS:

5.1 SERVICE: Shall be performed by United States of America citizens of good standing and repute.

5.2 SCHEDULING SERVICE: By mutual agreement, NNSY will schedule contractor services within 4 months of contract award.

5.3 TOOLS: The contractor shall bring all necessary tools to conduct work as described herein. Crane or forklift service will be provided by NNSY to lift heavy contractor tools and components. These lifts must be scheduled with shop supervision one shift in advance.

5.4 FACILITIES: Electricity, water, and toilet facilities required during the installation will be provided by NNSY.

5.5 WORKING HOURS: The Government's regular working hours are from 07:00-16:00, five days per week, Monday through Friday, except observed Federal holidays. Contractor may conduct work on weekdays only and may work past 16:00 as long as shop supervision is informed of this in advance.

5.6 ON-SITE REGULATIONS: The installation site will be occupied at the time service is provided. The contractor shall comply with all regulations, including safety practices, environmental directives and security clearance restrictions governing the operation of the premises. Machine assessment shall be performed in a manner not to unreasonably interrupt or interfere with the receiving activity's normal business routine.

5.7 RESTRICTIONS ON USE OF YELLOW MATERIALS: Contractors shall refrain from the use of yellow or yellow-orange materials for the following purposes: sheeting, tarpaulins, polyethylene bottles or other containers, tapes, bags, raingear, banding of identification marks on tools and boundary markers such as ribbons. Contractor generated yellow waste materials such as torn foul weather gear shall be disposed of by the contractor off-yard. Shipyard dumpsters and trashcans shall not be used for disposal of these Contractor generated waste materials. Yellow colored items such as described above are of special significance within the shipyard and are subject to strict controls.

5.8 SAFETY REQUIREMENTS: The Contractor shall develop and maintain a safety program in compliance with U.S. Army Corps of Engineers Safety and Health Requirements Manual EM 385-1-1, Public Law 91-596 Occupational Safety and Health Act, OSHA standards, 29 CFR 1910, 29 CFR 1915, and NAVSHIPYDNORINST P 5100.56, VOLUME II, CHAPTER 4. Contractor personnel shall work in a safe manner and comply with all applicable safety regulations. The Contractor shall be subject to safety inspections of its work sites by the Government. Contractor safety records shall be available upon request by the TPOC. The contractor shall be responsible for its Subcontractor’s compliance with all of the aforementioned requirements.

5.9 MEDICAL TREATMENT: Only emergency medical care is available on Government facilities to Contractor employees who suffer on-the-job injury or disease. Care will be rendered under the conditions and at the rates in effect at the time of treatment. The Contractor shall reimburse the Naval Regional Medical Center Collection Agent promptly upon receipt of statement.

5.10 DANGER TAGS AND LOCKS:

5.15.1 Contractors and Non-NNSY Government Agencies (NNGAs) will work to NNSY’s Lockout/Tags-Plus (LOTP) program in accordance with NAVSEA OSHECM Chapter 250 Rev. I, and OSHA 29 CFR 1915.89, “Hazardous Energy Control”. Contractor/NNGA employees will affix appropriate lockout or Tags-Plus systems to energy isolating devices, and to otherwise disable machines, equipment, or systems (MES) to prevent unexpected energization, start up or release of hazardous energy in order to prevent injury to employees. For copies of OSHE 250, contact TPOC.

5.1.1

5.1.2 Before using appropriate Lockout or Tags-Plus systems, the contractor or NNGAs will provide a submittal confirming that all of their on-site personnel have been trained on the OSHECM Chapter 250 Lockout/Tags-Plus program, and 1915.89.

5.1.3 Contractors and NNGA employees will coordinate with NNSY designated Lockout/Tags-Plus Coordinators (LOTCs) and/or Facility Custodians before applying any HEC lock or Tags-Plus systems to machinery, equipment, and/or systems. Hazardous Energy Control locks will be provided by the contractor or NNGAs for their employees’ use. Hazardous Energy Control (HEC) tags will be provided by the cognizant NNSY LOTC if MES cannot be locked out. All HEC work under Tags-Plus controls will have an energy control procedure (ECP) directing hazardous energy controls for that work.

6 WORKER ACCESS TO THE WORK SITE:

6.1 INITIAL ENTRY: Companies seeking access to the shipyard must provide to the technical representative a request under the company’s letterhead, detailing the full name, social security number, gender, race, place and date of birth of each worker, the job’s start to completion date, and the contract number. This letter must be signed by a company officer. This will be endorsed by the TPOC and forwarded to the NNSY Pass Office.

6.2 No employee or representative of the Contractor will be admitted to the site of work unless satisfactory proof of citizenship is furnished, or, if an alien, legal residency within the United States is confirmed. Generally, an I-9 form from the Office of Homeland Security must be presented at the pass office for each worker. Each worker must attend a 45-minute training video prior to entering the shipyard’s Controlled Industrial Area (CIA) for the first time, but one viewing allows entry for ONE year. An entry badge will be issued. Each Contractor employee shall be required at the time of issuance of a personnel badge to complete a Special Access Determination Form. Requested information shall be furnished. Individuals who have felony convictions (e.g., murder, rape, drug offenses, of theft) or who are deemed untrustworthy by the NNSY Security Department will be denied access to the shipyard and their personnel badge will be recalled.

6.3 VEHICLE ENTRY: The Company name shall be displayed on each of the Contractor's vehicles in a manner and size that is clearly visible. All vehicles shall display a valid state license plate that complies with State Vehicle Code. Vehicles shall meet all other requirement of the State Vehicle Code, such as safety standards, and shall carry proof of insurance and state registration. Passes issued in the Inspection Area, (across Effingham Street from the Shipyard Pass Office) will be required for vehicles to enter the shipyard. A separate pass is required for parking near the work site. Work site parking may be further addressed with the TPOC.

7 TRAINING:

7.1 TRAINING: After satisfactory completion of acceptance testing of the system, training shall be provided to familiarize receiving activity personnel with the equipment and to help ensure reliable performance and maximum service life, during normal usage. The training shall be performed at the customer facility and shall be as stated in paragraphs below. Training shall occur between 7:30 am and 3:30 pm excluding weekends and any federal holidays. The course shall utilize training manuals for each of the operator and maintenance training students, as-built drawings and manuals provided under this contract, and shall include both classroom and hands on portions. All printed training aids shall be supplied at no additional cost to the government and be in the English language.

7.2 OPERATOR ON-SITE TRAINING: Training shall be provided at the receiving activity. Training shall include preparation of part programs, and preparation of equipment for safe operation. The trainees shall be provided instruction for all aspects of machine operation. Trainees shall be provided instruction for the care, use and operation of all attachments and accessories. Training shall be provided for three (3) operators/programmers.

7.3 MAINTENANCE PERSONNEL: Maintenance training with respect to controls and related components shall include troubleshooting and methods of correction should the equipment malfunction, with emphasis on minimizing equipment down time. Training shall be provided for two (2) maintenance personnel. Training shall be timed for completion of the acceptance testing of equipment and shall be accomplished at the receiving activity.

8 WARRANTY / SERVICE SUPPORT:

8.1 MACHINE: Machine shall be guaranteed by a twenty-four (24) month warranty from date of installation. Machine original equipment manufacturer (OEM) technicians shall be capable of responding to a service call on a warranty item within 48 to 72 hours of notification.

8.2 SERVICE SUPPORT: Machine service support shall be readily available within the continental United States (CONUS). Machine original equipment manufacturer (OEM) technicians shall be capable of responding to a service call within 48 to 72 hours of receiving a purchase order for support. Machine specific replacement parts and consumables shall be readily available from an OEM warehouse located within the continental United States.

8.3 MAINTENANCE PERSONNEL: Maintenance training with respect to controls and related components shall include troubleshooting and methods of correction should the equipment malfunction, with emphasis on minimizing equipment down time. Training shall be provided for two (2) maintenance personnel. Training shall be timed for completion of the acceptance testing of equipment and shall be accomplished at the receiving activity.

INSTALLATION RESPONSIBILITIES TABLE

Manufacturer’s design requirements

and placing item on foundation

necessary to perform the required tests

accordance with manufacturer's instructions