A04.01_Perforance_Work_Statement_DRAFT_BendPro.pdf

Performance Work Statement (PWS) Installation of Replacement Controller System on the Existing Pipe Bender located at Puget Sound Naval Shipyard Bremerton, WA

JML #: 82066450

DD2276 #: N4523A18RC97681

Ship/Activity: Puget Sound Naval Shipyard – Building 107 Title: Installation of Replacement Controller System on Existing Pipe Bender - Asset #: 4523A11932 / Serial #: VB-80 HP LH 861132L Place of Performance: PSNS & IMF BLDG. 107 1st Floor Period of Performance: 09/26/2018 TO 11/30/2018

1. Background

An Eaton Leonard pipe bender (Asset #: 4523A11932 / Serial Number: Vb-80 HP LH 861132L) is installed at Puget Sound Naval Shipyard and Intermediate Maintenance Facility (PSNS & IMF). The existing controller needs to be replaced with a new BendPro style controller.

2. References

2.1. THE EATON LEONARD PIPE BENDER. Serial Number VB-80 HP LH 861132L Original Equipment Manufacturer Manual

2.2. THE CODE OF FEDERAL REGULATIONS

29 CFR 1910 Occupational Safety and Health Standards

(Application for copies should be addressed to Superintendent of Documents, Government Printing Office, Washington, DC 20402)

2.3. NATIONAL FIRE PROTECTION ASSOCIATION (NFPA)

NFPA 70 National Electric Code

NFPA 79 Electrical Standards for Industrial Equipment

(Application for copies should be addressed to National Fire Protection Association, 470 Atlantic Ave., Boston, MA 02210)

2.4. NATIONAL ELECTRICAL MANUFACTURERS’ ASSOCIATION (NEMA)

ICS Industrial Controls and Systems

MGI Motors and Generators

(Application for copies should be addressed to the National Electrical Manufacturers’ Association, 2101 L Street, NW, Washington, DC 20037)

2.5. INTERNATIONAL STANDARDS ORGANIZATION (ISO)

ISO 1940/1 Balance Quality Requirements of Rigid Rotors

(Copies available online at: http://www.iso.org/iso/iso_catalogue.htm or American National Standards Institute, 11 West 42nd St, New York, NY 10036)

3. Scope

This Performance Work Statement (PWS) supports service labor and parts for the replacement of existing controller on an Eaton Leonard pipe bender (Asset #: 4523A11932 / Serial Number: Vb- 80 HP LH 861132L) located in Building 107. The work needs to be accomplished by a factory authorized representative.

4. Deliverable Items

4.1. This document covers the minimum government requirements for procurement of installation of a replacement controller on the existing Eaton Leonard pipe bender (Asset #: 4523A11932 / Serial Number: Vb-80 HP LH 861132L) at PSNS & IMF located in Building 107.

4.2. GOVERNMENT RESPONSIBILITIES: The Government will be responsible for the following:

4.2.1. The contractor shall be granted access to the Government owned property, Eaton Leonard pipe bender (Asset #: 4523A11932 / Serial Number: Vb-80 HP LH 861132L) at PSNS & IMF located in Building 107.

4.2.2. The receiving activity point of contact will be the COR as listed in Section 10 and will serve as the contractor’s primary contact for all interaction with other Shipyard and Government activities.

4.2.3. Storage: Lay-down area will be provided within the vicinity of installation site for storage of contractor materials and tools. The Government does not accept responsibility for security of contractor’s materials or tools. The area must be kept clean and orderly, free of rags, paper and other debris. Failure to maintain area in a clean condition may result in the loss of the area. However, the contractor shall be responsible to restore the storage area to original condition after use.

4.2.4. The Government will provide all fluids, if needed, after installation.

4.2.5. The Government will provide material for equipment testing after installation at

PSNS & IMF.

4.3. CONTRACTOR RESPONSIBILITIES: The contractor shall be responsible for the following:

4.3.1. The contractor shall provide and install, the required components to replace the existing controller on the Government owned Eaton Leonard pipe bender (Asset #:

4523A11932 / Serial Number: Vb-80 HP LH 861132L).

4.3.1.1. All electrical components including motors, starters, relays, switches, and wiring shall conform to and be located in accordance with the applicable NFPA, NEMA, and ANSI standards for the intended application.

4.3.1.2. All electrical components, parts, and equipment required for the refurbishment shall be new parts. Rebuild or refurbished parts are not accepted and shall not be installed on the machine.

4.3.2. Work Requirements

4.3.2.1. The contractor shall disconnect the equipment from utility services (air, steam, steam condensate return, electrical power, etc.), as required.

4.3.2.2. The contractor shall remove or relieve any sources of stored energy (gravitational, mechanical, electrical, etc.) that remains within the equipment, as required.

4.3.2.3. Provide a factory authorized field service representatives that is thoroughly familiar with electrical motors and equipment, installation and repair procedures to complete the removal, installation and testing.

4.3.2.4. The contractor shall connect all utilities required for full equipment operation.

4.3.3. Remove existing Pipe Bender Controller Unit.

4.3.3.1. The contractor shall disconnect and remove the existing control and any unnecessary electrical components on the Eaton Leonard pipe bender (Asset #:

4523A11932 / Serial Number: Vb-80 HP LH 861132L).

4.3.3.1.1. Prior to removal, the contractor shall record and backup all the machine parameters stored in the existing controller for transfer to the new controller.

4.3.3.1.2. Prior to removal, the contractor shall cycle the machine to note any issues not related to the controller in the presence of the COR as listed in Section 10.

4.3.3.2. The contractor shall place the existing controller components in a designated laydown area for Government disposal.

4.3.4. Installation of new BendPro G2v2 controller.

4.3.4.1. Provide installation of the contractor furnished, operator console with industrial PC and BendPro G2v2 software to the existing Eaton Leonard pipe bender (Asset #: 4523A11932 / Serial Number: Vb-80 HP LH 861132L) at PSNS Building 107.

4.3.4.1.1. The controller shall be of new construction and the current OEM model; a rebuilt or refurbished controller shall not be accepted.

4.3.4.2. Provide a contractor representative that is thoroughly familiar with BendPro G2v2 controller installation procedures and applications on pipe benders.

4.3.4.3. The BendPro G2v2 controller shall be assembled for operation by the contractor in accordance with the manufacturer installation requirements.

4.3.4.4. The BendPro G2v2 controller shall be installed by the contractor with clearances and access points available as specified by the manufacturer.

4.3.4.5. The contractor shall connect all utilities required for full equipment operation as outlined by the manufacture’s installation and operations manual.

4.3.4.6. Provide a Factory Authorized Field Service Representatives to complete the Installation and Testing of the new controller/control systems.

4.3.4.7. The contractor shall measure and digitize the existing Eaton Leonard pipe bender (Asset #: 4523A11932 / Serial Number: Vb-80 HP LH 861132L) to create a 3D model of the machine to interface with the new controller.

4.3.4.8. The contractor shall maintain the following existing machine components on the Eaton Leonard pipe bender (Asset #: 4523A11932 / Serial Number: Vb-

80 HP LH 861132L);

4.3.4.8.1. Rexroth Indra C servo motors, drives, and cabling

4.3.4.8.2. Hydraulic pump motor, pump, and coupling

4.3.4.8.3. Main disconnect, fusing, motor starter, and overload protection

4.3.4.8.4. Keyence safety laser floor scanner

4.3.4.9. The vendor shall provide commissioning services.

4.3.4.9.1. Commissioning services shall consist of an inspection of the installation to ensure that the system has been installed properly, ensuring proper power connection, and check for compliance of OSHA safety requirements.

4.3.4.9.2. Commissioning services shall be performed in the presence of the COR as listed in Section 10.

4.3.4.10. Provide operational confidence testing after installation to verify the BendPro G2v2 controller is properly functioning and interfacing with the existing Eaton Leonard pipe bender (Asset #: 4523A11932 / Serial Number: Vb- 80 HP LH 861132L) at PSNS Building 107.

4.3.4.10.1. The requirements of the operational confidence test are listed in Section 7.1.

4.3.4.10.2. Operational confidence test shall be performed in the presence of the COR as listed in Section 10.

4.3.4.10.3. The vendor shall provide an assessment report to the COR listed in Section 10 identifying any discrepancies, if found.

4.3.5. Provide three (3) days (24) hours total for (3) employees, of operator training onsite at bldg. 107 shop 56 on the operation and maintenance of the controller.

4.3.6. The vendor shall furnish all necessary labor, tools, and materials for removal and installation of the new controller on the Government owned Eaton Leonard pipe bender (Asset #: 4523A11932 / Serial Number: Vb-80 HP LH 861132L).

4.3.6.1. The contractor shall provide all materials, tools, equipment, gauges, instrumentation, lifting and handling gear, and safety equipment needed to perform the required work in Building 107 at PSNS.

4.3.6.2. The contractor shall dispose of all packing material for the new controller and electrical components.

4.3.6.3. All equipment installations shall be assembled for operation by the contractor in accordance with the manufacturer installation requirements or per standards identified in Section 2.

4.3.6.4. All equipment installations shall be installed by the contractor with clearances and access points available as specified by the manufacturer or per standards identified in Section 2.

The entire cost for providing the services described in this Performance Work Statement (PWS) (including travel, per diem, etc.) shall be covered by this contract.

5. Contractor Furnished Material

The Contractor shall be responsible for furnishing the following materials as required to complete the installation of a new replacement controller:

5.1. One BendPro G2v2 controller and supporting components with the following:

5.1.1. The controller shall be equipped with a minimum of:

5.1.1.1. Rolling operator console with a minimum connection cord length of 12-ft.

5.1.1.2. Installed one (1) gigabyte of memory

5.1.1.3. Installed 139 GHz Dual Core processor

5.1.1.4. PC Based Windows Operating System, Windows 7 or newer

5.1.1.5. Four (4) USB ports

5.1.1.6. Emergency Stop Button

5.1.1.7. 3D Simulation to allow for part development at bender controller

5.1.2. BendPro G2 Simulation 3D model of the Eaton Leonard VB80HD

5.1.3. BendPro G2 Office offline simulation of the Eaton Leonard VB80HD

5.1.4. BendPro CAD/STEP Interface

5.1.5. BendPro G2 Interface to Supravision (Romer, Faro, or Accurex) based CMM Dell Precision 7720 Ruggedized 17” Industrial Work Station Laptop (PC shall not have a camera)

5.1.6. BendPro Ghost Drive – Backup hard drive for system restore

5.1.7. Beckhoff I/O system and all wiring to exisiting I/O

5.1.8. Rittal operator console with industrial PC (PC shall not have a camera)

5.1.9. EtherCat drive LAN to replace existing Sercos control network

5.1.10. Bosch Rexroth Factory Engineer for drive start-up and commissioning

5.1.11. Programmable pressures: pressure die and pressure die assist

5.2. The vendor shall provide to the COR, one (1) hard copy and one (1) searchable/printable electronic copy of the updated electrical diagrams and user manual for the controller.

5.3. The vendor shall provide standard commercial OEM 1-year warranty on all parts and labor which have failed and have not been the result of an operator mistake of misjudgment nor neglect of recommended maintenance.

6. Government Furnished Property:

There is no GFP under this requirement. All work shall be performed within Building 107 at the machine. The machine is a permanent installation and cannot be readily removed to complete this work.

Manufacturer: Eaton Leonard

Asset #: 4523A11932 / Serial Number: VB-80 HP LH 861132L Model Number: VB-80 HP

7. Quality Assurance & Surveillance Plan (QASP)

PSNS&IMF is responsible for quality assurance - &- Contractor is responsible for quality control.

Quality assurance shall include but not limited to; inspection of the equipment installation to ensure that the controller has been installed properly, ensuring proper power connection, check for compliance of OSHA safety requirements, and an operational confidence test of the functionality.

7.1. Operational Confidence Tests

The replaced controller on the Eaton Leonard pipe bender (Asset #: 4523A11932 / Serial Number: Vb-80 HP LH 861132L) shall perform the following operational confidence test.

7.1.1. Test 1: The controller on the pipe bender shall cycle through the machine and demonstrate all movements.

7.1.2. Test 2: The machine shall demonstrate standard bending jobs suitable for machine capacity with material provided by the Government.

Quality Assurance Surveillance Plan (QASP):

Requirement PWS Performance

Standards Allowable Deviation Surveillance

M e t ho d Correction Procedures

Storage area; contractor shall maintain area in a clean condition

4.2.3 The Contractor shall be

required to maintain a clean designated storage area.

The contractor shall be given 8 hours to correct COR reported deficiencies.

COR will visually inspect Government provide area

COR will notify Contractor of 8 hours to correct safety/cleanliness of storage area.

COR will notify KTR and KO off any failures to correct cleanliness of storage area. KO will address issue with KTR.

Government will seek an equitable price reduction or other adequate consideration for acceptance of nonconforming services.

Vendor shall remove existing controller.

4.3.3 Contractor shall

remove existing controller and place in a Government designated location.

Prior to removal, vendor shall backup all machine parameters and cycle the machine.

KTR will coordinate with COR for required locations.

The contractor shall comply with all PWS requirements and communicate to the COR if any of the requested performance characteristics cannot be met by system prior to delivery.

COR will be present during cycling the machine and machine parameters backup.

COR tracks vendor completed cycling machine and placement removed existing controller in designated Government area.

Contractor may be required to re-perform/correct any non-PWS Compliant performance at no cost. The COR will report any deviations to the KO. The government will determine on a case by case basis as to the acceptability of non-conforming supplies.

Government will seek an equitable price reduction or other adequate consideration for acceptance of nonconforming services.

Vendor shall install a new controller on existing machine.

4.3.4 Contractor shall

perform installation of new G2V2 Controller within standards stated in the PWS.

The contractor shall comply with all PWS requirements and communicate to the Government if any of the requested performance characteristics cannot be met prior to delivery.

COR visually tracks services were completed with requirements in

PWS.

Contractor may be required to re-perform/correct any non-PWS Compliant performance at no cost. The COR will report any deviations to the KO. The government will determine on a case by case basis as to the acceptability of non-conforming supplies.

Government will seek an equitable price reduction or other adequate consideration for acceptance of nonconforming services.

Vendor shall commission newly installed controller and complete operational tests.

4.3.4 Contractor shall

perform within requirement stated in the PWS and completed the operational tests defined in PWS.

The contractor shall comply with all PWS requirements and communicate to the COR if any of the requested performance characteristics cannot be met by system prior to the start of operator training.

COR will be present during operational test of machine. COR will monitor and document operational test were completed without deficiencies for acceptance.

Contractor may be required to re-perform/correct any non-PWS Compliant performance at no cost. The COR will report any deviations to the KO. The government will determine on a case by case basis as to the acceptability of non-conforming supplies.

Government will seek an equitable price reduction or other adequate consideration for acceptance of nonconforming services.

Vendor shall provide operator training on new installed controller.

4.3.5 The contractor shall

complete 24 hours of operator training for up to three operators as detailed in the PWS.

The contractor shall not deviate from the 24-hour training schedule.

Contractor will communicate with COR for any delays in training. In the event of Government caused delays, contractor shall communicate issues to the

COR.

Operators will report to COR when training has been completed on operation and maintenance requirements in accordance with OEM manuals.

Contractor may be required to re-perform/correct any non-PWS Compliant performance at no cost. The COR will report any deviations to the KO. The government will determine on a case by case basis as to the acceptability of non-conforming supplies.

Government will seek an equitable price reduction or other adequate consideration for acceptance of nonconforming services.

8. Security Requirements:

8.1. See Security Attachment.

9. Travel Requirements

9.1. The contractor is responsible for arranging all travel and lodging requirements.

10. Government Representative

10.1. PSNS Contracting Officer Representative (COR):

Ron Jackson, Equipment SME PSNS & IMF, Shop 11 and Shop 17 1400 Farragut Avenue Bremerton, WA 98314-5000 Phone: (360) 340-2148 ronald.r.jackson@navy.mil

10.2. WAWF Inspector

Derek Dunlap, Overhead Planner PSNS & IMF, Shop 11 and Shop 17 1400 Farragut Avenue Bremerton, WA 98314-5000 derek.dunlap@navy.mil Phone: (360) 476-2736

11. Other Considerations

11.1. All work is to be performed during PSNS & IMF’s regular work hours from 8:00 a.m. to 4:00 p.m., Monday through Friday except for Federal Holidays.

11.1.1. If the contractor desires to work on Saturdays, Sundays, holidays, or outside the regular or specified hours/days, the contractor shall submit a request to the receiving activity POC for approval a minimum of two (2) working days prior to the anticipated work date.

11.1.2. In no event shall a contractor carry on work outside the hours and days specified in the contract without prior approval.

11.2. All technical clarifications will be coordinated through the COR.

11.3. Environmental, Safety and Health Requirements for Puget Sound Naval Shipyard.

11.3.1. Environmental

Contractors working at the receiving activity are required to perform their work in compliance with all Federal, State, and local regulations pertaining to the environment. Contractors shall ensure all their personnel working on this installation and their supervisors, including their sub-contractors, are familiar with the contents of “Contractor’s Guide to Environmental Compliance”

PSNS & IMF P5090 (4).

11.3.2. Personal Health and Safety

11.3.2.1. The proposed work described herein will be performed in and industrial manufacturing area under the guideline of OSHA and the receiving activity’s Environmental, Safety and Health Office.

11.3.2.2. The contractor shall conduct all work in a safe manner and shall provide all necessary safety equipment.

11.3.2.3. The contractor shall make the maximum use of low-noise emission equipment as certified by the Environmental Protection Agency (EPA).

Applicable regulatory requirements for maximum environmental noise levels are WAC 173-60. The contractor shall provide hazardous noise signs and label equipment, wherever work procedures and equipment produce sound-pressure levels greater than 84 dB(A) stead state and/or 140 dB peak sound pressure level for impact or impulse noise, regardless of the duration of the exposure.

11.3.2.4. Prior to Commencing Work: The contractor representative(s) shall meet in conference with the Shipyard Point Of Contact, shop supervision, and/or other necessary Shipyard personnel to discuss and develop mutual understandings relative to environmental, safety, methods and schedules, security, waste management and any other subject necessary for a smooth and successful operation.

11.3.3. Energy Control

The COR will provide the contractor with a copy of the lockout and tag out controls used by the Government facility where the equipment is to be installed. After contract award and prior to commencement of work, the contractor and/or their subcontractor(s) shall submit and exchange lockout/tag out program procedures with the Government’s representative. The contractor is required to meet with the Government representative to discuss lockout/tag out interface. The contractor shall use their lockout/tag out procedures in accordance with (IAW) 29 CFR 1910.147.

NOTE: Lockout/Tags-plus procedures IAW 29 CFR 1915.89 shall be followed, where applicable, when it becomes law. When 29 CFR 1915 is implemented, contractors shall train their employees to Vol. II Chapter 9 of the Government Occupational Safety and Health (OSH) manual.

Audits, Surveillances and Incident Investigations – Audits, surveillances and incident investigations shall be performed per Vol. II Chapter 9 requirements when 29 CFR 1915.89 is invoked.

11.3.4. Compliance with OSHA

Contracting personnel shall perform all work in accordance with the latest OSHA rules and regulations issued by the Department of Labor, 29 CFR Parts 1910, 1915, and 1926 as applicable.

11.3.5. Safety Equipment

The contractor shall provide their employees with all necessary safety equipment during the performance of work on this contract.

11.3.5.1. All contractor personnel shall have in their possession and shall properly wear OSHA approved personnel protective safety equipment (i.e. hard-hats, steel-toe safety shoes, safety glasses, hearing protection and fall protection, as required).

11.3.5.2. The contractor shall provide all appropriate safety barricades, signs, and signal lights required to properly isolate the area of work.

11.3.5.3. Safety Inspections: The contractor’s work space may be inspected periodically for OSHA violations.

11.3.5.4. Abatement of violations will be the responsibility of the contractor and/or the Government as determined by the Contracting Officer.

11.3.5.5. The contractor shall provide assistance to the Safety Office escort and the federal OSHA inspector if a complaint is filed. Fines levied on the contractor by federal OSHA offices due to safety/health violations shall be paid promptly.

11.3.5.6. Failure to comply with or repeated violations of OSHA safety requirements can result in the violator(s) losing their access to the Government facility or the operation being suspended until the contractor can provide properly trained personnel. Certification of training shall be presented upon request by the Contracting Officer.

11.3.5.7. The contractor shall ensure that any additional measures that the Contracting Officer or the Government Representative determines to be reasonably necessary for safety are taken.

11.3.5.8. Additional safety and health requirements shall be as specified in other paragraphs of this specification.

11.3.5.9. Safety Signs and Labels – Safety signs and labels in accordance with ANSI Z535.4 shall be securely attached to the equipment in visible locations, with any safety precautions to be observed by the operator or maintenance personnel permanently marked on the signs, as applicable.

11.3.6. Safety Data Sheets (SDS)

In accordance with 29 CFR 1910.1200, contractors are required to submit Safety Data Sheets (SDS) whenever the supplies being acquired or supplies used during performance are identified as hazardous materials. Hazardous Materials shall include any material which, by virtue of its potentially dangerous nature (e.g., toxic, flammable, corrosive, oxidizing, irritating, sensitizing, reactive), requires controls in its use, packaging, handling, storage, or stowage, to assure adequate safety to life and property. This definition is intended to apply to proprietary industrial, commercial, or locally prepared blends, mixtures, formulations, or compounds of gases, liquids, and solids intended for use at the job site. Any other material that has been designated by a Government technical representative as potentially hazardous and requiring safety controls shall also be supplied with a SDS. SDSs are to be available at work sites where materials are being used.

11.3.7. Fire Protection

The contractor and his employees shall know where the fire alarms are located and how to activate them. The contractor shall handle and store all combustible supplies, materials, waste, and trash in a manner that prevents fire or hazards to persons, facilities, and materials.

Contractor employees operating critical equipment shall be trained to properly respond to a fire alarm or fire.

11.3.8. Accident Reporting

The Contractor shall submit to the Contracting Officer or COR in the manner and on the prescribed forms exposure data and all accidents resulting in death, trauma, or occupational disease.

11.3.8.1. Accident reports shall be submitted within 24 hours of their occurrence.

11.3.8.2. The Contractor shall submit to the Contracting Officer or Contracting

Officer’s Representative a full report of damage to Government property or equipment by contractor employees. Damage reports shall be submitted within 24 hours of the occurrence.

11.3.9. EMERGENCY MEDICAL CARE

Only emergency medical care is available in Government facilities to Contractor employees who suffer on-the-job injury or disease. Care will be rendered at the rates in effect at the time of treatment. Reimbursement shall be made by the Contractor to the Naval Regional Medical Center Collection Agent upon receipt of statement.

11.3.10. Laydown and Utilities Requirements

Laydown, if needed, will be provided in the vicinity of the work site. Reasonable amounts of compressed air (80-90 psi) and electricity (120 Volt) will be made available adjacent to the work site. The contractor shall be responsible for any costs incurred in connecting, converting and transferring the utilities to the work.