M00146-15-T-9016_RFQ.doc

Section A - Solicitation/Contract Form

SUMMARY INFORMATION FOR VENDORS

1. Point of Contact:

Larry Davis/Contract Specialist

Phone: 252.466.7765

E-mail: larry.davis1@usmc.mil

2. Small Business Set-Aside: This requirement is 100% set-aside for small business concerns. The NAICS assigned to this requirement is 333994 with a corresponding size standard of 500 employees. Therefore, quotations from large business concerns will not be considered for evaluation.

3. Quotation due date/time: Quotations submitted in response to this requirement must be received at the location specified in paragraph 2) of Addendum to FAR 52.212-1 (See Section L) no later than 1:00 p.m. (EST) on 02 June 2015.

4. Address for submission of Vendor’s quote: Quotations submitted in response to this requirement must be submitted to the location specified in paragraph 2) of Addendum to FAR 52.212-1 (See Section L).

5. Advice to Vendors: Vendors are advised to read this document in its entirety, paying particular attention to the information provided in Section C – Purchase Description/Specification, Section L - Instructions, Conditions and Notices to Vendors, and Section M- Evaluation Factors for Award.

6. Content of Vendor’s Quote: At a minimum, the vendor’s quote must includeall of the information requested in paragraph 3) of the Addendum to FAR 52.212-1 located in Section L. Information must be presented in the same order as listed in the instructions.

7. Evaluation of Quotes: Quotes received in response to this requirement will be evaluated in accordance with the information provided in Section M- Evaluation Factors for Award.

8. Site Visit: A Site Visit relating to the above requirement is scheduled to be conducted on 06 May 2015 at 10:00 am EST at the Fleet Readiness Center (FRC) East, MCAS Cherry Point, NC. See paragraph 5 of the Addendum to FAR 52.212-1 located in Section L.

Section B - Supplies or Services and Prices

Oil Quench Furnace and Gas Generator

FFP

Integral Quench Furnace and Endothermic Gas Generator in accordance Purchase Description/Specification (Section C).

JON 5Y513ZD, SHOP 56300, COST CODE 5Y513ZD31300

MILSTRIP: N6592315SU00126

Section C - Descriptions and Specifications

Specification for an

Integral Quench Furnace and Endothermic Gas Generator

1.

Scope. This specification describes the minimum performance requirements for design, manufacture, delivery, installation, and acceptance testing of new, not used integral quench furnace and endothermic gas generator. The new furnace and generator will replace a GM integral quench furnace and gas generator (EIN 65923031655) in Shop 93553, Building 137, at the Fleet Readiness Center (FRC) East. A single contractor having experience in the design and manufacture of this type of equipment shall supply and integrate the requirements as specified herein to provide complete turnkey system including installation.

2.

Applicable Documents. The following specification, standards, drawings and other publications of the issue in effect on date of solicitation, or request for quotes, form a part of this purchase description to the extent specified herein. Unless otherwise noted the contractor shall ensure the latest edition is used.

2.1 Government Documents.

FLEET READINESS INSTRUCTION (FRCEASTINST)

FRCEASTINST 5000.1A – Visitor/Contractor Site Specific Rules and Compliance FRCEASTINST 5090.1 – Environmental Compliance

FRC East drawing – PE-21522F (Equipment layout) (Attachment 1) FRC East sketch – Existing Utilities Piping Schematic

(A copy of this instruction can be acquired by contacting the contracting office.)

MIL STANDARDS

MIL-STD-1472F - Human Engineering

(Copies may be ordered online at http://dodssp.daps.dla.mil/ or from DODSSP, Building 4D, 700 Robbins Avenue, Philadelphia, PA 19111-5094)

NAVAL AIR SYSTEMS COMMAND (NAVAIR)

NAVAIRDEPOTINST 4790.11B – Foreign Object Damage (FOD) Prevention Program

(A copy of these instructions can be acquired by contacting the contracting officer.)

NAVAL FACILITIES ENGINEERING COMMAND (NAVFAC)

NAVAIR P-307 – Management of Weight Handling Equipment (A copy of these instructions can be acquired by contacting the contracting officer.)

NC General Statutes Chapter 87-Article 4

(Copies are available from http://www.ncbeec.org. NC State Board of Examiners of Electrical Contractors)

US ARMY CORPS of ENGINEERS

EM 385-1-1 - US Army Corps of Engineers Safety and Health Requirements Manual

(A copy of this instruction can be acquired at http://www.publications.usace.army.mil/Portals/76/Publications/EngineerManuals/EM_385-1-1_2008Sep_Consolidated_2011Aug.pdf)

U.S. DEPARTMENT OF LABOR

29 CFR 1910 – Occupational Safety and Health Standards

29 CFR 1910.147 – Control of Hazardous Energy (Lockout/Tagout)

29 CFR 1910.331 through 1910.335 - Safety Related Work Practices

(U.S. Department of Labor, OSHA Publications, P.O. Box 37535, Washington, D.C. 20013-7535 “www.osha.gov”)

U.S. NAVY

OPNAVINST 5100.23 – Navy Safety and Health Program Manual (Ashore)

(“www.safetycenter.navy.mil/instructions/default.htm” or Commander, Naval Safety Center 375 A Street, Norfolk, VA 23511)

2.2 Industry Publications.

AMERICAN CONFERENCE OF GOVERNMENTAL INDUSTRIAL HYGEINISTS (ACGIH)

American Conference of Governmental Industrial Hygienists Industrial Ventilation Manual

(American Conference of Governmental Industrial Hygienists, 1330 Kemper Meadow Drive, Cincinnati OH, 45240-1634 or www.acgih.org)

AMERICAN SOCIETY OF MECHANICAL ENGINEERS (ASME)

ASME A13.1 – Scheme for the Identification of Piping Systems

(American Society of Mechanical Engineers, Three Park Avenue, New York, NY 10016 or www.asme.org)

NATIONAL FIRE PROTECTION ASSOCIATION (NFPA)

NFPA 70 – National Electrical Code (2014 Edition)

NFPA 70E – Standard for Electrical Safety in the Workplace (Current Edition)

NFPA 79 – Electrical Standard for Industrial Machinery

NFPA 86 – Standard for Ovens and Furnaces

(NFPA, 1 Batterymarch Park, Quincy, Massachusetts 02169-7471. “www.nfpa.org”)

SAE INTERNATIONAL - AEROSPACE MATERIAL SPECIFICATIONS

AMS 2750E- Pyrometry

(A copy of this instruction can be acquired from SAE Customer Service, 400 Commonwealth Dr., Warrendale, PA 15096; 877-606-7323; or online at www.sae.org)

SHEET METAL & AIR CONDITIONING CONTRACTORS NATIONAL ASSOCIATION (SMACNA)

Accepted Industry Practice for Industrial Duct Construction

(Sheet Metal and Air Conditioning Contractors’ National Association, 4201 Lafayette Center Drive Chantilly, Virginia 20151-1219 or www.smacna.org)

UNITED FACILITIES CRITERIA (UFC)

UFC 1-200-01 - General Building Requirements

(Whole Building Design Guide, National Institute of Building Sciences, 1090 Vermont Avenue NW, Suite 700, Washington, DC 20005 or www.wbdg.org)

AMERICAN NATIONAL STANDARDS INSTITUTE, INC. (ANSI)

ANSI B11.19 - Performance Criteria for Safeguarding

(American National Standards Institute, Dept. 969, 1430 Broadway, New York, NY 10018 or www.ansi.org)

2.3 Order of Precedence. In the event of a conflict between the 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 is obtained. The listed documents in this purchase description are a minimal list but not limited to regulations for industrial safety pertaining to industrial equipment design and installation. Under no circumstance shall these regulations not be applied to the manufacture and installation of the equipment.

3. REQUIREMENTS.

3.1 General. All quoted items shall be new and a current commercially available model. A current model is defined as the manufacturer’s currently produced model which, on the date this solicitation is issued, has been designed, engineered, sold or is being quoted for sale through advertisements or manufacturer’s published catalogue or brochures. Products such as a prototype unit, pre-production model, or experimental unit do not qualify as meeting the requirements specified herein. The equipment shall include all components, parts, and features necessary to meet the performance requirements specified herein. All parts subject to wear, breakage or distortion shall be accessible for adjustment, replacement, and repair.

3.1.1 Intended Use. The equipment will be used to perform automated heat treatment of 4000 series (4130, 4140, 4340, and others) carbon steels for use as shafts, liners, bearings, bushing, rod stock, etc. In addition, the furnace is used for carburizing steel such as 9310 and 8620.

3.1.2 Measuring and Indicating Devices. All measuring and indicating devices on the equipment shall be graduated in the inch/pound system as required.

3.1.3 Safety and Health Requirements. Covers, guards, and other safety devices shall be provided for all components of the equipment that present potential safety hazards. The safety devices shall not interfere with the operation of the equipment. The safety devices shall prevent unintentional contact with the guarded part(s) and shall be removable to facilitate inspection, maintenance, and repair. All parts, components, mechanisms, and assemblies furnished on the equipment shall comply with all applicable requirements of OSHA 29 CFR 1910 and ANSI B11.19.

3.1.3.1 Human Engineering. The equipment shall be ergonomically designed in accordance to MIL-STD-1472F, as to reduce/eliminate injury to the operator while operating the equipment. All points of operation shall be easily accessible to the operator with minimal motion and there shall be no overextending conditions. The system shall be designed and manufactured to minimize the possibility of human error or injury (i.e. back injury) and to ensure human/machine compatibility. Adequate access to support maintenance functions and personnel shall be provided as part of the design.

3.1.4 Noise Restriction. Noise transmitted from the equipment furnished shall not exceed 84 dBA at the source in accordance with OPNAVINST 5100.23. Noise generated by the work piece shall be excluded in determining compliance of the equipment with the 84 dB requirements.

3.1.5 Environmental Protection. The equipment shall meet all applicable US Environmental Protection Agency (EPA) and OSHA restrictions for materials classified as hazardous to the environment in effect on the date of contract. During the operation of the machine at the final location, the equipment shall comply with all applicable US EPA and OSHA regulations in effect on the date of contract regulating the emission of materials hazardous to the environment.

3.1.5.1 Mercury Restriction. The equipment shall not contain mercury or mercury compounds nor be exposed to free mercury during manufacture.

3.1.5.2 Asbestos Restriction. Asbestos and materials containing asbestos shall not be used on or in the equipment.

3.1.5.3 PCB Restriction. Equipment or materials containing polychlorinated biphenyl (PCB) shall not be used in the equipment.

3.1.5.4 ODS Restriction. Equipment or materials containing Class 1 Ozone Depleting Substances (ODS) shall not be used except when approved in writing and a copy attached with the quote, by the Navy Senior Acquisition Executive, Assistant Secretary of the Navy for Research, Development, and Acquisition.

3.2 Assembly. The equipment shall be assembled of parts that are new, without defects, and free of repairs. The structure shall withstand all forces encountered during operation of the equipment to its maximum rating and capacity without distortion.

3.2.1 Fastening Devices. All screws, pins, bolts, and other fasteners shall be installed to prevent unintentional loosening. Fastening devices subject to removal or adjustment shall not be permanently installed.

3.2.2 Surfaces. All surfaces shall be clean and free of harmful or extraneous materials. All edges shall be either rounded or beveled unless sharpness is required to perform a necessary function. The condition and finish of all surfaces shall be in accordance with the manufacturer's commercial practice.

3.2.3 Welding, Brazing, or Soldering. Welding, brazing, or soldering shall be employed only where specified in the original design. None of these operations shall be employed as a repair measure for any defective part.

3.2.4 Materials. Direct contact between dissimilar metals, especially brass, copper, or steel in contact with aluminum or magnesium, shall be avoided. When dissimilar materials are used a barrier is required preventing the metals from contacting.

3.2.7 Painting. Where applicable the equipment shall be painted in accordance with the manufacturer’s standard commercial practice. Prior to painting, surfaces shall be properly prepared and primed. Manufacturer’s standard color shall be used. Machine guards shall be painted yellow. The inside of electrical panel doors shall be painted white and inside the electrical panels shall be painted white.

3.2.8 Workmanship. Workmanship of the equipment shall meet all requirements specified herein and shall be of a quality equal to that prevailing among manufacturers producing equipment of the type covered by this specification.

3.2.9 Standard Equipment. All standard equipment normally provided with the equipment shall be furnished.

3.3 Essential Characteristics. The contractor shall provide the following major components:

a. Integral quench furnace

b. Control system

c. Endothermic gas generator

3.3.1 Integral Quench Furnace. The integral quench furnace shall have a minimum workload area shall be 24 inches wide by 36 inches long by 20 inches high with a maximum weight capacity of 850 pounds. Temperature operating range shall be between 1450º and 1850ºF. Per AMS-2750 the temperature uniformity shall be ±25 ºF. The furnace shall comply with all applicable sections of NFPA 86.

3.3.1.1 Furnace frame shall be continuously welded and built from reinforced hot rolled steel plate. Hot zone cover plate shall be bolted on for easy access while maintaining the furnace. The basket load station shall extend beyond the exhaust hood for parts loading / unloading via the bridge crane.

3.3.1.2 Door shall be pneumatically operated. The door shall be lined with a minimum of 2300ºF ceramic insulation. Door shall include a propane gas flame curtain under the door to ignite any combustible atmosphere leaving the furnace and minimize air getting inside the furnace.

3.3.1.3 Quench tanks shall be a minimum of 850 gallons. Agitation shall be provided in the quench tank to circulate the oil through the workload area (see Paragraph 3.3.2.7). A level indicator shall be provided on the quench tank for ease in determining fluid level. High, low, and normal oil levels shall be identified. Normal quench oil temperature will be 120ºF, but the quench tank shall have heating elements capable of heating the oil to a maximum of 250ºF.

3.3.1.4 The chamber above the quench tank shall be double-walled and used for cooling the workload under a protective atmosphere. An atmosphere circulating fan shall be included in this chamber.

3.3.1.5 Workload transfer system shall be designed to move the workload from the load area to the quench zone and finally to the hot zone and back to the quench zone and out of the furnace upon completion of operation. Workload transfer system shall be designed to minimize the time when moving a work load from the hot zone to fully quenched. The time between the furnace door opening and the load entering the quench shall not exceed 30 seconds maximum.

3.3.1.6 The furnace shall include a separation system for removing contaminants and all solid particles from the quench oil to lengthen the life of the oil. In addition, the furnace shall include a quench cooling system that uses an air cooled heat exchanger and circulating pump to cool the quench oil to its normal temperature set point. The cooling system shall be capable of cooling the quench oil within 120 minutes maximum after quenching an 850 pound load at 1650ºF.

3.3.1.7 The furnace shall include burn-off and quench vents which shall ignite all combustible exhaust gas leaving the furnace. The furnace shall alarm if any of the burn off pilot blow out.

3.3.1.8 The furnace shall use electric heating elements.

3.3.1.9 The hot zone shall be line with a minimum of 2300ºF rated insulated fire brick with appropriate insulation located behind the brick.

3.3.1.10 A duplex type “N” thermocouple shall be installed in the rear wall of the hot zone for measuring the furnace temperature. One element shall be for the temperature controller and one for the over temperature protection. A port shall be located within three (3) inches of this thermocouple for system accuracy testing.

3.3.1.11 A carbon probe shall be used for measuring the oxygen concentration in the hot zone.

3.3.1.12 The contractor shall provide a minimum of two (2) 24 inch wide by 36 inch long by 8 inch high parts baskets. Baskets shall be stainless steel and a grade appropriate for the subject environment. The contractor shall also provide a minimum of two (2) 24 inch wide by 36 inch long cast alloy grids.

3.3.1.13 All pilots shall be lit automatically via push button.

3.3.2 Control System. All furnace controls shall be located in a NEMA 12 control panel.

3.3.2.1 The furnace shall use an Allen-Bradley PLC for all main furnace operations. Unless specified elsewhere these shall include motor control, pneumatic control, safety and operational permissives, and other automated or operator initiated actions such as heating and cooling.

3.3.2.2 Furnace chamber and quench oil heating control shall be done with a Honeywell temperature controller of appropriate complexity. All heating shall be electric in nature.

3.3.2.3 A Honeywell Carbon Potential controller shall be used to control carbon potential in the chamber.

3.3.2.4 A Honeywell over temp controller shall be used to protect the furnace chamber from high temperature damage. The oven shall have an audible and visible alarm for over temperature.

3.3.2.5 User interface shall be accomplished through the use of an Allen-Bradley PanelView touch screen product of sufficient size to display general conditions of the furnace and peripheral equipment.

3.3.2.6 The interface shall include specifically-purposed screens that include the following:

a. General furnace conditions with appropriate temperatures, movement, fan status, gas flow status, actuator status, solenoid status, percent heating power.

b. Recipe building and recall for no fewer than 50 recipes.

c. Troubleshooting screen with PLC input and output status.

d. Alarm history and handling.

e. Motor control and status.

3.3.2.7 The quench oil agitation shall be controlled by Allen-Bradley VFD and agitation speed shall be user-adjustable.

3.3.2.8 The system shall include a Honeywell MiniTrend digital data recorder. The MiniTrend recorder shall record hot zone temperature, quench oil temperature, carbon potential, and quench oil agitation speed.

3.3.2.9 The system shall include a networking PC to record data from the MiniTrend digital data recorder. The MiniTrend recorder shall be connected to the Ethernet data collection system located in the heat treat area.

3.3.2.10 The system shall include analog voltage and amp meters for heating elements, retort elements, and quench tank elements.

3.3.2.11 The furnace shall include a timer with alarm for keeping track of how long loads are in the work zone.

3.3.3 Endothermic Gas Generator. The contractor shall provide an electrically heated endothermic gas generator. The gas generator shall have one (1) reaction retort and be capable of generating a minimum of 1,500 CFH of endothermic gas.

3.3.3.1 The heating chamber shall be lined with appropriately rated firebrick insulation. The heating elements shall be silicon carbide and mounted horizontally between the retort and insulated wall.

3.3.3.2 A duplex type “N” thermocouple shall be installed in the rear wall of the hot zone for measuring the retort temperature. One element shall be for the temperature controller and one for the over temperature protection.

3.3.3.3 Propane ratio shall be selectable by the artisan. Propane gas and air flow rates shall be monitored via flowmeters. The gas generator shall have an automatic dewpoint control system and automatic turndown. An oxygen probe shall be used to continuously sample the endothermic gas generated. Main output pressure shall be controlled via a relief valve.

3.3.3.4 Gas generator controls shall be located in a NEMA 12 control panel. Honeywell controllers shall be used. Retort heat control, and over-temp control shall be incorporated.

3.3.3.5 Carbon dropout from the endothermic gas shall be prevented prior to exiting the gas generator. The gas generator shall be designed to safely shut down in the event of a gas supply or electricity supply failure.

3.3.3.6 All pilots shall be lit automatically via push button.

3.3.4 Electrical System. The new integral quench furnace and gas generator shall be designed to work with 480V, 60 Hz, 3 phase power, 400 Amp maximum. The contractor shall conform to the requirements of NFPA 79 and all electrical work shall be conducted in accordance with NFPA 70 and 70E.

3.3.5 Operating Conditions. The equipment shall be capable of 24 hours of continuous, efficient and safe operation in a factory environment of 80 degrees Fahrenheit ±20 degrees, atmospheric pressures between 25.5 and 30.5 inches of mercury, and relative humidity of 95% or less without exceeding the designed operating limits of any of its components.

3.3.6 Space Constraints. The equipment shall be designed to require the minimum amount of floor space possible. Available footprint for the new furnace and generator are shown on drawing PE-21522F (Attachment 1). The equipment shall be designed and positioned allowing access to all serviceable components.

3.4 Marking on Instruments, Control Panels, and Plates. All alphanumeric symbols on instruments, control panels, charts, and plates shall be in the English language. Characters shall be permanently marked in boldface on a contrasting background and shall be clearly and legibly marked for function and identification on a corrosion resistant material.

3.4.1 Lubrication Chart or Plate. A corrosion resistant lubrication chart or plate shall be permanently attached to the machine. The following information as a minimum shall be furnished: points of lubricant application, servicing interval, type of lubricant, viscosity, military or federal Specification for each lubricant (If applicable), and size and type of each lubricant filter.

3.4.2 Nameplate. A nameplate shall be permanently and securely attached to the equipment. The nameplate shall contain at a minimum the following information: nomenclature, manufacturer's name, manufacturer's model designation, manufacturer's serial number, power input (volts, total amps, phase, and frequency), and date of manufacture. If the equipment is a special model, the model designation shall include the model number of the basic standard machine and a suffix identified in the manufacturer's permanent records.

3.5 Technical Data. Technical documentation shall be provided to support the equipment. The manufacturer’s standard format shall be acceptable for all data items except where otherwise noted. Related data items may be submitted as a single document package as long as each data item is clearly indexed and identified.

3.5.1 Technical Data and Manuals. Two (2) complete printed sets and one (1) electronic copy (CD-ROM) of the Operation and Maintenance manuals shall be provided with delivery of the equipment. Documentation shall include at a minimum, operations, installation, maintenance, routine service schedule, calibration, preventive maintenance, lockout/tagout procedures, illustrated parts break down, recommended spare parts list including part numbers, vendor’s literature, mechanical design drawings, pneumatic schematics, electrical/electronic schematics, and piping layout. The maintenance procedures section of the technical manuals shall address procedures required for the corrections of faults. The manuals shall contain diagnostic procedures for isolating faults, correcting the faults, and replacing parts. The technical manuals shall provide an engineering approach to the determination of preventive maintenance tasks. Preventive maintenance tasks shall be clearly outlined, with specified periods/cycles for performance of tasks. Technical data packages shall be provided for all special fixtures, tooling, gauges, and master setting equipment. All technical data, drawings, and prints furnished shall be written in the English language. The contractor shall provide preliminary as built drawings of the equipment and piping layout to be included with the manuals. Technical data and manuals shall be provided at the start of installation and review by the Government of all technical data and manuals furnished will be accomplished during installation. Feedback from the Government will be provided within 10 days and any corrections shall be made by the contractor. Final manuals and final as built drawings shall be provided to the Government within 30 days of installation completion.

3.5.2 Operator Manual. The contractor shall provide an operator manual that includes a pre-operational checklist of all items that shall be checked or verified prior to using the furnace and endothermic gas generator. This manual shall give step by step procedures for starting the furnace and endothermic gas generator cold (i.e. after a weekend shut down) as well as day to day start up procedures when the furnace and/or generator are already hot. This manual shall also include step by step shut down procedures for the furnace and endothermic gas generator. In addition, complete burnout procedures for both the furnace and the endothermic generator shall be provided.

3.5.3 Software Documentation. The contractor shall provide electronic copies of the interface program as well as the PLC ladder project file including labels and comments. In addition, the contractor shall provide all software necessary to connect to the equipment and view, modify, and load programs to the PLC and interface. License for all software shall be transferred to the FRC East after award of the contract and before final acceptance of the equipment. A complete hardcopy of the PLC project file shall be included in the technical manuals.

3.5.4 Site Preparation and Installation Plan. The contractor shall provide a clear and concise site preparation and installation plan. The plan shall include a detailed description of all installation work, a detailed site layout, general equipment specification (i.e. size, weight, etc.), any required structural modification or additions, utility requirements and location, pertinent electrical details, and any other details required for site preparation and layout. As part of the site preparation and installation plan the contractor shall include facilities preparation instructions, including detailed information concerning any equipment that applies a load to a facility structure, wall, or roof. There is no crane available is this area for contractor use. Included with this submittal the contractor shall prepare and submit shop drawings of the equipment and piping. The site preparation plan and installation plan shall be submitted at least 60 days prior to installation for review and approval.

3.5.5 Post Award Conference. The Post Award Conference (PAC) shall be held at customer facility no later than 30 days After Contract Award (ACA). Representative(s) from the contractor’s plant who are familiar with both the equipment to be furnished and the requirements of the PD shall attend the PAC. During the PAC a Plan of Action and Milestone (POA&M) chart shall be submitted to the Government in hard copy and electronic format. During the PAC the contract and all requirements regarding equipment, layout, delivery, installation, disposal, training, and warranty shall be discussed.

3.5.6 Control of Hazardous Energy (Lock-out/Tag-out). A written procedure for locking out all energy sources shall be provided by the contractor in accordance with 29 CFR 1910.147. The contractor shall submit draft copies to the Government in accordance with the contractor submitted and Government approved Plan of Action and Milestones (Section 3.5.7) and final copies are due at start of equipment installation. The contractor shall provide an electronic copy of the procedure in Microsoft Word to the Government as well as include the procedure in the technical manuals.

3.5.7 Plan of Action and Milestones. The contractor shall provide a Plan of Action and Milestones (POA&M) to identify contractor performance dates of all major events from contract award to completion of all contract requirements. The POA&M shall be delivered 30 days ACA. The milestones shall be prepared using a recognized project management technique (preferably Microsoft Project). The Government and the contractor shall review the report on a monthly basis. The contractor shall notify the Government prior to making any changes to the POA&M. All changes to the POA&M must be approved in advance by the Government. The POA&M shall detail such items as equipment design concept, equipment development, software design concept, software development, engineering, procurement of major hardware, assembly, operational debug, factory acceptance, shipment, installation, training, and final acceptance test.

3.5.8 Acceptance Test Plan. The contractor shall prepare an acceptance test plan. The plan shall be a step-by-step written instruction on how to verify that the equipment is in accordance with this specification. The contractor shall submit draft copies to the Government in accordance with the contractor submitted and Government approved POA&M (Section 3.5.7) and final copies are due 30 days prior to installation.

3.5.9 Joint Requirements Review. The purpose of the Joint Requirements Review shall be to review and comment on the contractors proposed solutions. Reviews are not approvals and are no way binding to the Government. However, it is in the best interest of the Government and the contractor to review the work periodically. There will be no set dates for the subject review but they will be held when deemed necessary by either the Government or the contractor. This is intended to help eliminate potential problems before they have a chance to arise, or before much time, effort and cost is accrued. They are performed as a courtesy at various levels of depth. Acceptance of the equipment shall only be obtained through meeting the requirements of Section 4.0 of this specification.

3.6 Disassembly and Disposal. The contractor shall be responsible for removal of the existing equipment that is being replaced by the new equipment. The contractor shall notify the Government at least two (2) weeks prior to the start of installation to allow the Government Hazmat personnel to drain the quench oil from the existing furnace. The contractor shall be responsible for all dissassembly necessary for execution of this installation.

a. Prior to installation and/or removal of any equipment, the contractor shall lockout/tagout all energy sources In Accordance With (IAW) OSHA 29 CFR 1910 and then notify the Government for final approval. In addition, the Government may also choose to dual lockout/tagout the equipment.

b. The contractor shall disconnect all utilities from existing furnace. If existing piped utilities are not to be re-used for the new system, then the contractor shall remove the utilities back to the closest isolation valve, tee, or source. Tees shall have an appropriate sized isolation valve installed. All isolation valves shall be plugged on the downstream side of the valve.

c. The contractor shall also clean up and dispose of any and all waste in accordance with all local, state, and federal regulations that was generated in the installation of the equipment at the facility. The area shall be kept clean at all times to prevent Foreign Object Debris or FOD in accordance with NAVAIRDEPOTINST 4790.11B.

d. The contractor shall move all removed components to the Hazardous Waste Berm (Building 4466) which is located behind Building 133. The contractor shall give the hazardous waste personnel a minimum of 24 hours notice prior to moving any equipment to the Berm. Relocation of equipment shall be performed only on normal working days Monday-Friday, 6:30 AM to 3:00 PM, excluding holidays. In addition, the contractor shall ensure NO metal is removed from the FRC East. All metal shall be recycled at the FRC East.

e. The contractor’s disassembly work shall be in accordance with EM 385-1-1, Subpart 23.

3.6.1 Installation. The contractor shall be responsible for the complete installation of the equipment including reconnection of any disconnected utilities. Unless otherwise specified herein, or where the Government gives special approval, all resources (e.g. labor, material, tooling, and equipment) required and/or used during unloading and installation shall be provided by the contractor. All assembly required to install the new equipment shall be performed in accordance with UFC 1-200-01. Electrical installation shall consist of the following:

a. All electrical work shall be completed by a contractor holding a current electrical contractor’s license issued by the North Carolina Board of Examiners of Electrical Contractors in accordance with the provisions and requirements of Chapter 87, Article 4 of The General Statutes of North Carolina. The contractor shall provide proof of license as part of their quote.

b. All work shall be completed in strict compliance with the articles and requirements of NFPA 70 and in strict compliance with the requirements set forth in the CFR 1910.331-335 OSHA “Safety Related Work Practices”.

c. The contractor shall be responsible for the complete installation of the equipment including all electrical utility service requirements.

d. All switches, receptacles, and other wiring devices shall be commercial grade or better. The contractor shall contact the Facilities Infrastructure Planning and Engineering Branch, Code 6.3.1.3 after completion of work for inspection and approval.

e. Unless otherwise specified herein, or where the Government gives special approval, all resources (e.g. labor, material, tooling, and equipment) required and/or used during unloading and installation shall be provided by the contractor. All assembly required to install the new equipment shall be performed in accordance with UFC 1-200-01.

f. The contractor shall be responsible to determine suitability of existing industrial ventilation systems currently in use for the new Furnace and Endothermic Gas Generator. If the existing exhaust fan for the Endothermic Gas Generator is determined to be sized appropriately, then the contractor may re-use the exhaust fan. If the exhaust fan is determined not to be appropriate and non-reusable with the vendor’s technical approach, the existing exhaust fan for the Furnace shall be removed and disposed of. The contractor shall determine requirements for a new replacement exhaust fan for the furnace, and install the new exhaust fan in same location and configuration, using existing power source (including electrical power disconnect). If the existing capture hood(s) and ductwork are determined to be sized appropriately, then the contractor may re-use the hood(s) and ductwork. If either or both of the industrial ventilation systems are determined to be in-appropriate, then the contractor shall be responsible for the disassembly of the system(s), and the contractor shall be responsible for the design and installation of the new ventilation system(s). The contractor shall utilize the American Conference of Governmental Industrial Hygienists Industrial Ventilation Manual to determine required capture velocities, ducting design, hood design, and installation practices. If new ductwork is necessary, the contractor shall re-use existing roof penetrations for new ventilation system(s). All ductwork, either new or modified, shall be fabricated and installed in accordance with SMACNA Accepted Industry Practice for Industrial Duct Construction.

g. Currently, there is a Quench Oil Cooler for the existing furnace system. The cooler is mounted on a structural steel frame on the roof above and adjacent to the furnace. The top of the frame is approximately 35 feet above the finished floor. If the contractor chooses to re-use the steel frame for any component, the maximum weight allowed to be mounted on the steel frame is 500 pounds. The contractor shall not transport loads greater than 300 pounds across Building 137 roof without prior approval of a contractor supplied rigging plan by the MCAS Cherry Point engineering office. If any installation work leaves holes in the roof, the contractor shall be responsible for patching the roof deck.

h. If Required, all roof patching shall be performed by a certified roofing contractor that is approved by both the roof manufacturer and FRC East in order to retain the existing roof warranty. The existing roof covering is Hydrostop coating over 3 ply built up roof. The Hydostop warranty number is 1000571. The contractor shall coordinate work with the roof manufacturer before modifying the roof or installing equipment on the roof to maintain the roof warranty. The warranty expires 12 October 2020. All roof and wall penetrations shall be sealed using flashing (hood, drip cap, drip edge, cant strip, etc) and sealant to prevent entry of water and blowing rain into the building. All flashing and counter flashing shall be stainless steel in accordance with the latest SMACNA Sheet Metal Manual.

3.6.2 Installation Responsibilities. The contractor shall be responsible for:

a. Locating the equipment as shown on drawing PE-21522F (Attachment 1).

b. Removing existing furnace and gas generator and disposing of per Paragraph 3.6.

c. Furnishing all labor and material handling equipment for off-loading and placing equipment into position.

d. Providing fluids and filling all reservoirs with the manufacturer’s recommended fluid.

e. Providing MSDS sheets on all fluids and any other hazardous materials brought into the facility, including paint.

f. Pipe labeling per ASME A13.1. The contractor shall include the pressure of gases or fluids at or over 100 PSI in labeling. Labels shall be Dura Label Premium Vinyl Tape. Labels shall be applied to clean dry surfaces.

g. Connecting the furnace, gas generator, and any other accessories to the existing utilities, including but not limited to: compressed air, argon, propane, etc.

h. Providing all necessary tools, gages, and instrumentation necessary to perform the tests.

i. Providing continuous air monitoring for CO concentrations if engines powered by propane are used within the facility buildings. Gasoline engines shall not be operated inside any building at the facility at any time. The contractor shall provide a written plan for controlling potential hazards a minimum of 10 days prior to the start of installation. For any additional information please contact the FRC East Safety Office.

j. For any work requiring burning/welding/soldering, the contractor shall obtain a hot work permit from the MCAS Cherry Point Fire Department. The contractor shall provide the person’s name, company name, and contact number for the contractor performing the work. The contractor shall post a fire watch during and for two (2) hours after all hot work.

k. Supplying all tools and equipment to provide services required in this specification. The contractor shall NOT, at anytime, borrow or use any of the Government’s tools or equipment, including but not limited to forklifts, ladders, man lifts, motorized lifts, cranes, electric carts, and hand tools. All contractor’s forklifts, cranes, man lifts, hoists, and lifts of all types shall comply with 29 CFR 1926 Subpart N. The contractor may use the air source, water, and electrical power to remove and install the equipment.

3.6.3 Electrical Installation. Electrical connections made to the facility electrical system shall conform to NFPA 70 and performed in accordance with NFPA 70E and UFC 1-200-01. The following notes and requirements apply to the electrical installation:

a. Electrical Disassembly. The contractor shall be fully responsible to completely remove all the existing electrical connections for the existing equipment back to source (480 volts and/or 208/120 volts) located in the shop including all conduits, conductors, disconnect switches, junction boxes, and associated mounting hardware.

b. Electrical Installation. The contractor shall be fully responsible to provide the turn-key electrical installation to new equipment requirement. The contractor shall be responsible for the complete electrical installation of the equipment including providing appropriate busway enclosure and suitable busway circuit breaker for new electrical service from busway to new equipment. Busway circuit breakers shall be minimum 35kAIC symmetrical interrupting rating. All outdoor conduits shall be galvanized rigid conduit (RMC). All EMT conduits shall be used with compression fitting. A separate, new fusible heavy duty safety disconnect switch of the appropriate size, types and fuses shall be provided for new equipment. The fusible disconnect switch shall be installed adjacent to the motor controller to serve as a primary disconnecting means for equipment. The fusible disconnect switch shall be sized to carry the entire electrical load and lockable in the off position only.

c. The contractor shall clean up and dispose of any and all waste in accordance with all local, state, and federal regulations that was generated in the construction at the facility. The area shall be kept clean at all times to prevent foreign object debris (FOD).

d. Connection boxes, outlet boxes, junction boxes, and similar devices and fixtures exposed to the weather, condensation, or excessive dampness shall comply with NEMA ICS-6. Enclosures in interior locations exposed to dripping liquids or falling objects must meet as a minimum NEMA 250 Type 2. Enclosures in interior locations exposed to water spray, mist or splashing water must meet NEMA 250 Type 3R as a minimum. Watertight distribution panel cabinets should be cast or welded assembly with external mounting lugs and externally operable switches. Any penetration into an enclosure shall not affect the degree of protection of the enclosure.

e. Corrosion Protection. Ferrous components of equipment subject to corrosion shall be galvanized or similarly treated before painting. Painting is an acceptable corrosion resistant treatment for switchboard panels, distribution cabinets, and similar enclosures.

f. Labeling. The contractor shall provide 3” x 5” (W x L) engraved identification placard for fusible safety disconnect switch and motor controller with the following information: equipment name, volt, amp, hertz, and power source feed from. Placard shall be black lettering on a white background and attached with rivets to the center of the motor controller, main disconnect and all disconnect cover. Also, provide all power feed information if the motor controller has multiple power sources (120VAC, 208VAC, and 480VAC etc.). The contractor shall provide 5”x7” (W x L) engraved identification placard for new busway plug-in enclosure and the ampere rating label for new busway plug-in unit. The label shall be 7/8” x 2-1/4” (W x H) size, black letter with yellow background color, vinyl film or similar material type.

g. Any works related to fire alarm system, the contractor is responsible to coordinate with MCAS Public Work Dept. (Work Center 70, 252-466-5607) prior to installing and testing new fire alarm devices. All fire alarm devices shall be UL listed and shall be suitable for the installation and compatible with the existing fire alarm system.

3.6.4 Contractor Crane Usage at FRC East. When contractor supplied cranes are used to install, remove or unload equipment, such usage shall comply with OSHA 29 CFR 1926.550 and NAVFAC P-307. Provide the Facilities Engineering & Acquisition Division (FEAD) Crane Inspector, (252) 466-4738, in accordance with paragraph 3.5.4. The crane may travel to the work site and set up, but no lifting shall occur until the crane has been inspected. The contractor shall submit a completed FRC East 11262/1A “Certificate of Compliance” to the FEAD Crane Inspector for approval. Once approved, the Certificate of Compliance shall be posted in the crane cab or with the P-307 Chapter 14 rigging gear being used. The FEAD Crane Inspector or the FRC East Weigh Handling Equipment (WHE) Certifying Official, upon successful inspection of the contractor’s crane, shall complete the FRC East 11262/1, “Contractor Crane or Rigging Operation Checklist.” Lifts may proceed once this checklist is completed, provided that no deficiencies are noted. A copy of this form shall be provided to the FRC East WHE Certifying Official, the FEAD Crane Inspector as well as the contractor. The crane operator shall provide accident reports and critical lift plans to the project manager as required IAW P-307. Contractors desiring to rig off the FRC East building structures (with or without cranes being used) shall follow this same approval process. Additionally, the contractor shall provide, at their expense, professional engineering evaluations that demonstrate the building is capable of supporting the proposed loading. No lifts from building structure shall take place until these engineering evaluations have been reviewed and approved by the FEAD. These procedures also apply to material handling equipment (i.e. forklifts) when used as cranes for lifting with P-307 Chapter 14 gear. Contractors shall be entirely responsible for cost of repairs to cranes, structures, buildings and equipment incurred during their operations.

3.6.5 Government Responsibilities. The Government will:

a. Evacuate all fluids from equipment before removal. The contractor shall notify the Government at least two (2) weeks prior to the start of installation to allow the Government Hazmat personnel to drain the quench tank prior to contractor installation and delivery to the hazmat berm.

b. Provide unobstructed of the following utilities within 50 feet of the proposed installation site for hook-up by the contractor:

Shop air: If compressed air is required, the contractor shall be responsible to determine suitability of existing compressed air for use. Currently, there is a three-quarter inch pipe at the proposed installation site of the furnace that is 85 +/-5 psi. Reference “Existing Utilities Piping Schematic” sketch.

Propane Gas: If propane gas is required, the contractor shall be responsible to determine suitability of the existing propane gas system supplied to the installation site. Currently, there is a one inch propane gas supply pipe at the proposed installation site of the furnace with 13 psi supply pressure regulated at the outside propane storage tank. If the furnace requires a lower pressure to operate correctly, the contractor shall provide and install a new pressure reducing regulator prior to the furnace. There is a three-quarter inch propane gas supply pipe at the proposed installation site of the Endothermic Gas Generator with 13 psi supply pressure regulated at an outside propane storage tank. If the Endothermic Gas Generator requires a lower pressure to operate correctly, the contractor shall remove and dispose of the existing pressure reducing regulator; and provide and install a new pressure reducing regulator prior to the generator. Reference “Existing Utilities Piping Schematic” sketch.

Argon: If argon is required, the contractor shall be responsible shall be responsible to determine suitability of the existing argon system supplied to the installation site. Currently, there is a three-quarter inch argon supply pipe at the proposed installation site of the furnace with 100 psi supply pressure. If the furnace requires a lower pressure to operate correctly, the contractor shall provide and install a new pressure reducing regulator prior to the furnace. Reference “Existing Utilities Piping Schematic” sketch.

Foundation: The existing floor is six inch thick concrete. There is no design information or floor load data available.

c. Not perform any work on the equipment during installation and initial start-up.

3.6.6 Utility and Foundation Capacity. If floor or any existing utility capacity is inadequate for the equipment to function properly, then the contractor shall be responsible for providing the necessary upgrades/equipment/re-configurations/labor needed for the new equipment to operate correctly. Utility modifications shall not impair any of the existing operations or processes at the customer facility.

3.6.7 Installation Work Schedule. All installation work shall occur during the Government’s normal daily work hours. Hours are between 6:30 am and 3:00 pm Monday through Friday, except Federal holidays. If the contractor desires to perform work outside of these hours the installation work schedule must be approved in advance by the Government. The contractor shall coordinate the work to minimize impact on facilities production operations.

3.6.8 Utility Shutdowns. Utility connection shutdowns shall be scheduled during weekends, or other non-normal Government hours, and shall be approved by the Government two (2) weeks prior to the requested shutdown.

3.7 Warranty. The contractor shall warrant all equipment, components, etc. to be provided hereunder for a minimum period of one (1) year to begin upon the Government's final acceptance of the equipment at the FRC East, Cherry Point. The warranty shall cover all parts, labor, and travel expenses related to the warranty repair/support.

3.8 Reserved

3.9 Training for Government Personnel. The contractor shall furnish the services of competent instructor(s), fluent in the English language, who shall give full instruction to designated personnel in operation, maintenance,…