STATEMENT_OF_WORK_.pdf

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STATEMENT OF WORK FOR

FULL REPLACEMENT REMANUFACTURED OF TWO (2)

INGERSOLL RAND 600 HORSEPOWER CENTRIFUGAL AIR ENDS

FLEET READINESS CENTER EAST, MCAS,

CHERRY POINT, NORTH CAROLINA

1.0 Scope: This Statement Of Work (SOW) defines the Government’s minimum requirement for the full replacement of two (2) 600 horsepower (HP) Ingersoll Rand compressors [Building 133 compressor

(S/N: C12897, M/N: C70031M3) and Building 139 compressor (S/N: C11946, M/N: 2CV27M3)] air end and all other required operations. Minimum requirement is defined as the Contractor providing all required services (procurement, transportation, inspection, engineering, installation, removal, rigging, mechanical, electrical, welding, machining, alignment, programming, start-up, testing), parts, tools and materials to successfully perform and complete all required operations. The required operations on compressor and/or associated network components include: 1) a) Replace Building 133 existing

Ingersoll Rand compressor air end (M/N: C70031M3) with a remanufactured 600 HP Ingersoll Rand compressor air end (M/N: C70031M3). 1) b) Replace Building 139 existing Ingersoll Rand compressor air end (M/N: 2CV27M3) with a remanufactured 600 HP Ingersoll Rand compressor air end (M/N:

2CV27M3). Both remanufactured air ends shall have all new internal components., 2) Ensure all existing interface capabilities are maintained between the compressor and associated networks, 3)

Replace all condensate traps (M/N: 2CV27M3 has five (5) condensate traps and M/N: C70031M3 has three (3) condensate traps) and associated alarm level switches with new condensate traps and associated alarm level switches, 4) Replace existing bypass valve with new bypass valve on both compressors, 5) Replace local control panel Base Control Monitor (BCM) battery with new BCM battery on both compressors, 6) Replace two (2) oil coolers (two (2) oil coolers exist on each compressor) on each compressors, 7) Change and reconnect motor existing auxiliary connections to existing auxiliary spare connection on Building 139 compressor motor, 8) Replace and upgrade both buildings (Building 133 and Building 139) existing compressor CMC controllers with XE Controllers and 9) Repair and restoration of one (1) 600 HP compressor motor in Building 133. The two (2) 600

HP Ingersoll compressors [Building 133 compressor (S/N: C12897, M/N: C70031M3, EIN:

65923081060) and Building 139 compressor (S/N: C11946, M/N: 2CV27M3, EIN: 65923X30067)] required operations are located in Building 133 and Building 139 at Fleet Readiness Center East (FRC

East), MCAS Cherry Point, NC:

2.0 Applicable Documents: The following documents are a part of this SOW to the extent referenced herein:

(a) FRC East Instruction 5000.1B, Enclosure 1

3.0 Requirements:

3.1 General. Certain compressor components have had suspect performance, per Ingersoll Rand investigation e-mail on November 21, 2018.

3.2 Site Preparation: FRC East personnel will be responsible for preparing the site for the compressor. This site preparation will consist of providing accessibility to the compressors through FRC East maintenance.

3.3 FRC East will provide up to two (2) maintenance artisans to provide limited assistance (opening and closing valves, checking and maintaining utilities) in start-up and shutdown of the compressors. The

Contractor shall be the only one providing and implementing the adjustments and/or corrections to the compressor and the SOW parts. All adjustments and/or corrections shall be documented, in writing, and presented in the Contractors final report to Government.

3.4 In accordance with the estimate, the Contractor shall provide a qualified experienced technician to provide the required technical expertise to accomplish the following two (2) items: 1) Replace

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Building 133 existing Ingersoll Rand compressor air end (M/N: C70031M3) with a remanufactured

600 HP Ingersoll Rand compressor air end (M/N: C70031M3). 2) Replace Building 139 existing

Ingersoll Rand compressor air end (M/N: 2CV27M3) with a remanufactured 600 HP Ingersoll Rand compressor air end (M/N: 2CV27M3). Both remanufactured air ends shall have all new internal components. If during the repair visit, the Contractor finds that additional parts and/or services will be needed to complete this SOW, then it is the Contractors job to provide to the Government a complete itemized quote meeting the requirements stated in Section 3.4.20.3.

3.4.1 Replace existing Ingersoll Rand compressor air end with a remanufactured 600 HP

Ingersoll Rand compressor air end.

3.4.1.1 The remanufactured air end shall match existing air end model.

3.4.1.2 Prior to shipment, the remanufactured Ingersoll Rand air end shall be examined, tested, and be certified by Original Equipment Manufacturer

(OEM) Ingersoll Rand.

3.4.2 Upon successful air end installation, the Contractor shall ensure all existing interface capabilities have been maintained between the compressor and associated networks.

3.4.2.1 The compressor shall interface with existing controls [Building 133 is connected METASYS and Building 139 Compressor Control

Corporation “Air Miser “system].

3.4.2.2 Both compressor shall interface with the existing Ingersoll Rand CMC controllers.

3.4.3 Per OEM guidelines/specifications, both compressors shall be tested and meet the following minimal performance requirements with manufactured air end installed:

3.4.3.1.1 At operating conditions of barometric pressure of 14.7 psia, 95° Fahrenheit air, 85° Fahrenheit cooling water the

Ingersoll Rand 600 HP compressor shall produce a minimum of 2,438 SCFM dry (+/- 4%) at 100 psig. Note, SCFM is based upon reference conditions of air at 14.7 psia, 60 °F at 0% relative humidity.

3.4.3.1.2 Natural Surge, PSIG 138 or more [The compressor shall be isolated from the compressor network during this natural surge test.]

3.4.4 Replace all condensate traps [M/N: 2CV27M3 has five (5) condensate traps and M/N:

C70031M3 has three (3) condensate traps] and all associated alarm level switches with new condensate traps and associated alarm level switches on both compressors.

3.4.5 Change and reconnect compressor motor existing auxiliary connections to existing auxiliary spare connection on Building 139 compressor motor (Building 139 compressor: S/N: C11946, M/N: 2CV27M3, EIN: 65923X30067).

3.4.6 The following actions shall be completed, by the contractor, in the repair and restoration of one (1) existing 600 HP compressor motor [Building 133 compressor

(S/N: C12897, M/N: C70031M3, EIN: 65923081060).

3.4.6.1 The motor shall be removed, transported, repaired, restored, and reinstalled (per motor Original Equipment Manufacturer (OEM) specifications), by the contractor, to and from a qualified motor OEM repair shop. All of the following actions shall be completed, per motor

OEM specifications, on the compressor 600 HP motor:

3.4.6.1.1 disassembly of motor for full internal inspections, PAGE 3 OF 7 PAGES

3.4.6.1.2 dip/spray windings with new resin,

3.4.6.1.3 balance rotor,

3.4.6.1.4 replace both bearings,

3.4.6.1.5 rewind motor,

3.4.6.1.6 reassembly motor,

3.4.6.1.7 perform all validation testing and test run the motor,

3.4.6.1.8 If required, provide all written Government approved and contract approved repairs noted during subject motor shop inspection and repair.

3.4.6.1.9 The contractor shall be responsible for all motor actions

(disconnect motor, removal of motor, remount motor, reconnect motor, rigging, mounting, aligning, removal, engineering services, shipping, repair, restoration, testing, commissioning, installation, handling) required to disconnect, remove, repair, restore, transport (to and from motor shop), reconnect, mount, set up and test for the subject 600 HP compressor motor at FRC East.

3.4.6.1.10 All findings and test reports on the compressor 600 HP motor shall be provided to the Government.

3.4.7 Replace existing bypass valve with new bypass valve on both compressors.

3.4.8 Replace local control panel BCM battery with new BCM battery on both compressors.

3.4.9 Replace both oil coolers on both compressors.

3.4.10 Replace and upgrade both buildings (Building 133 and Building 139) existing compressor CMC controllers with XE Controllers.

3.4.11 Evaluate operation of all condensate drains on both compressors.

3.4.12 Contractor has 20 working days from date of delivery for preparation, installation and testing of the components.

3.4.13 Contractor shall ensure proper alignment between existing drive train and air end.

3.4.14 The Contractor shall provide all tools required for repaired and evaluation.

3.4.15 Contractor shall verify proper hookup of all components (mechanical and electrical) during installation.

3.4.16 The Contractor shall remove oil from each compressor prior to installation and supply new compressor oil.

3.4.17 The electrical system installation and wiring shall be in compliance with applicable requirements of NFPA 70 and NFPA 79.

3.4.18 The Contractor OEM shall provide a written procedure for locking out all energy sources in accordance with 29 CFR 1910.147 after contract award and prior to start of any work. The written procedure shall be included in the equipment manual. The written procedure shall include color pictures of all energy sources and the associated lockout component.

3.4.19 At the completion of the evaluation and repair, the Contractor shall notify the

Government representative that the repair has been completed. The Contractor shall

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perform within 48 production hours (production hours: Monday through Friday, 0700 -

1500), the following tasks:

3.4.19.1 Contractor shall perform and record start up test of the compressor and ensure the following conditions have been met throughout all testing periods and while the compressor is in a loaded.

3.4.19.1.1 Confirm that the Cold Temperature Difference (CTD) limits are not exceeded:

3.4.19.1.1.1 First stage cooler CTD is less than or equal to

17° Fahrenheit.

3.4.19.1.1.2 Second stage cooler CTD is less than or equal to

21 ° Fahrenheit.

3.4.19.1.1.3 Third stage cooler CTD is less than or equal to

24° Fahrenheit.

3.4.19.1.2 Confirm that the lube oil temperature is between 100° and

115° Fahrenheit.

3.4.19.1.3 Confirm that the oil pressure is between 20 and 30 psig.

3.4.19.1.4 Confirm that the vibration level is below 0.6 mils for the first stage.

3.4.19.1.5 Confirm that the vibration level is below 0.5 mils for the second stage.

3.4.19.1.6 Confirm that the vibration level is below 0.5 mils for the third stage.

3.4.19.1.7 All instrumentation used, by the Contractor, for

quantitative measurements (vibration, pressure, temperature, etc.) shall be calibrated and traceable back to current National Institute of Standards and Technology

(NIST) standards.

3.4.19.2 Then the Contractor shall conduct a test, on each compressor, consisting of running each compressor for two (2) eight (8) hour FRC

East production shifts without any unplanned/ unexpected interruptions. The Contractor shall operate each compressor for the entire test period. The test period shall be during and in support of a production first shift(s) and/or second shift(s) on an FRC East approved production day(s) (Monday through Friday, 0700 -1500). The

Contractor shall operate the compressor for the entire test period without surge, safety (temperature, pressure, etc.), vibration or other unexpected compressor alert or alarm. Any unplanned, unexpected interruption in operation of the compressor and/or a related component(s). The Contractor shall record hourly readings on the compressor, recording all data currently listed on FRC East log sheet.

A copy of all readings, alarms, and a written summary of all corrections performed by the Contractor shall be provided to the Government within five (5) calendar days after Government acceptance.

3.4.19.3 Training shall be provided for a period of at least one (1) eight-hour day and shall thoroughly familiarize all personnel with operating and maintaining the compressor and associated accessories (compressor controls, bypass valve, traps, etc.). Due to fact the control package has been upgraded, the major emphasis of the training shall be on thoroughly familiarize (i.e., hands on training) the personnel with operating, maintaining, and troubleshooting the new XE controller.

The contractor shall provide all participants with technical manuals.

The technical manuals shall be used extensively as reference materials during this training.

3.4.19.4 Contractor shall provide three (3) hard copies and one (1) electronic copy of the list of recommended spare parts list. The spare part list shall clearly indicate the part number, recommended quantity, price, PAGE 5 OF 7 PAGES and recommended supplier name and contact information (contact name, address, phone number, e-mail address).

3.4.19.5 Final acceptance by the Government is contingent upon satisfactory completion of all requirements.

3.4.19.6 The Contractor shall warrant the compressor remanufactured air end and associated parts for a minimum period of one (1) year, to include all parts and labor. This warranty period shall begin after Government acceptance. The warranty shall cover all costs (i.e., labor, travel, meals, hotel, parts, freight, materials, rigging, equipment, supervision, engineering, and transportation expenses) associated with warranty repair and support. Upon notification of a discrepancy covered by the warranty, the Contractor shall arrive at the depot within 48 hours to initiate repairs.

3.4.20 The Contractor shall provide a final report that summarizes all of the evaluation findings, repairs, and any additional recommendations and suggested repairs. All implied repairs should be clearly defined, in writing to the Government, in the following manner:

3.4.20.1 What needs to be repaired to achieve original performance levels?

3.4.20.2 Clearly state why the repair is required.

3.4.20.3 State, in a quote, what repairs will be required. The quote shall be based on the Contractor providing turnkey repair. Contractor shall clearly identify the following, within the quote:

3.4.20.3.1 Provide the associated parts breakdown (part number, cost per part, quantity, availability time line for on-site installation).

4.0 Additional Notes:

4.1 The Contractor shall abide by all current Federal, State, and FRC East safety laws. Rules and regulations when performing work within the confines of FRC East. (Reference: 29 CFR

1926 and EM 385-1-1)

4.2 Contractor shall follow current FRC EAST INSTRUCTION 5090.1 for appropriate spill response procedures and proper handling and disposal of hazardous waste. Contractor shall be responsible for turnkey removal proper disposal of existing non-returnable compressor parts and/or trash. All parts that can be returned to Ingersoll Rand for monetary value shall be returned and the Government shall be compensated 100% of trade in value minus shipping and handling costs.

5.0 Contractor Performance Requirements:

a. Safety, Environmental, Quality, Security Requirements: All personnel who enter or work in assigned spaces of this facility are required to comply with all federal, state, local, and site specific safety, environmental, quality and security requirements. FRC East has adopted and implemented additional safety programs to improve safety, quality, environmental, and security measures. Any individual found to not comply with this effort will be asked to immediately halt work.

Supervisors, managers, and employees are to report issues of non-conformance through the proper chain of command. Any individual or entity not willing to comply will state such and shall not be authorized to enter the facility. FRC East may take actions that result in removal of individuals or entities from this facility due to issues of non-compliance with stated instructions.

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b. Documented proof of all required certification training/licensing listed in the contract shall be available upon request by their Contracting Officer Representative or any auditor.

c. All personnel working on site at the FRC East under this contract shall document their receipt and review of the information listed in reference (a) annually.

d. All Contractors performing work on FRC East behalf and who have 10 employees at any time during the past calendar year, whose employees worked 1,000 or more hours in any quarter shall furnish FRC East their Total Case Incidence Rate for recordable nonfatal injuries and illnesses and their Days Away from

Restricted work activity, and/or Job Transfer Rate for the past three years.

e. Foreign Object (FO) is defined as any article or substance alien to the aircraft or assembly which is allowed to invade the product. Foreign Object Damage (FOD) is the damage that occurs due to these FOs.

All FRC East work sites shall be maintained in such a manner as to prevent FOD to aircraft and/or aircraft components. Work sites shall be kept clean at all times. All debris, scrap material, tools, and equipment will be cleared from the work site as work progresses. At no time shall hoses, power cords, materials, etc.

be permitted to create tripping hazards in areas of the work site.

f. In those cases where a Contractor supervisor determines that solving a safety or health problem is beyond their control, but within the control of the FRC East, the Contractor shall notify the appropriate point of contact identified in the contract.

g. All Contractor employees performing work on site at FRC East shall immediately report any safety, security, or environmental violation to their Contractor supervisor, as well as the cognizant FRC East

Safety/Security/Environmental Office provided in reference (a). The initial FRC East notification can be made via phone or e-mail and should include as many applicable details as possible (date, time, identification numbers, tags, company, etc.). This initial notification shall be made as soon as possible. A safety incident will require the Contractor to complete and submit an incident memo to the appropriate point of contact identified in the contract, with a copy to FRC East Safety Office within twenty-four hours of accident/incident). This incident memo will include the full name of the person involved in the incident, age, sex, job title, the name of the employing company and the contract number and title. In addition, this memo will include the severity of the illness or injury, indirect cause(s) or the accident and whether personal protective equipment was available and used.

h. All Contractors and sub-contractors working within FRC East shall develop and operate effective safety and health programs. (CSS contracts only).

i. Contractors are required to wear Personal Protective Equipment (PPE) consisting of hearing protection, eye protection, and safety shoes. PPE will not be provided by the facility. Contractor representatives without the appropriate PPE will not be allowed access to the facility.

j. Work areas utilized by Contractors will be provided an FRC East 5000/10, Contract Work Notice by their project manager before mobilization at the work site. This work notice requires the Contractor to notify a point of contact in the shop where they will be accomplishing work and document this notification on the appropriate portion of this notice. One completed notice shall be posted conspicuously in the area prior to performance of work. A copy of this notice will be available by the Contractor upon request at all times.

Contact project managers will address any issues regarding completion or duplication of this form.

k. Work above or anywhere near aircraft or passageways shall be avoided whenever possible. If this is not possible, the cognizant shop supervisor shall be informed so arrangements can be made to protect, move, or evacuate assets from the area to minimize foreign object debris potential. The area below the elevated work area shall be adequately marked and barricaded at all times. Under no circumstances shall work be performed over unprotected spaces. Standards listed in the Department of the Navy Fall Protection Guide for Ashore Facilities shall be complied with.

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l. Work being performed is in critical areas, therefore constant control of tools and materials are required at all times. Tools and hardware will be controlled at all times to prevent migration out of the work site. Lost tools shall be reported to the tool control manager at 252-464-9741. Tools found unattended will be confiscated and reported to the contracting officer.7.0 Labor Hour Reporting: In accordance with the Navy

Marine Corps Acquisition Regulation Supplement (NMCARS) Part 5237.102-90 relating to Enterprise-wide Contractor Manpower Reporting Application (ECMRA):