PWS for the Anodize Line.pdf

PERFORMANCE WORK STATEMENT

PREVENTIVE & EMERGENCY MAINTENANCE FOR

AUTOMATED ANODIZE LINE

Fleet Readiness Center Southeast (FRCSE), Naval Air Station, Jacksonville, Florida 32212-0016

Controlled By: Department of the Navy Controlled By: Fleet Readiness Center Southeast (FRCSE) CUI Category: CONTRACT Distribution/Dissemination Control: Distribution D POC: frcse_procurement_gr@navy.mil

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1. Scope: This is a non-personal services contract to provide maintenance and emergency repair services for the Automated Anodize Line located at the Fleet Readiness Center Southeast (FRCSE). The Government will not exercise any supervision or control over the contract service providers performing the services herein. Such contract service providers shall be accountable solely to the Contractor who, in turn is responsible to the Government.

1.1. Description of Services/Introduction: The Contractor shall provide all personnel, equipment, supplies, facilities, transportation, tools, materials, supervision, and other items and non-personal services necessary to perform Preventive and Emergency maintenance on the anodize line and support equipment located at the, building 794, FRCSE, Naval Air Station (NAS) Jacksonville, FL, as defined in this Performance Work Statement (PWS).

1.2. Background: The FRCSE, located in Jacksonville, FL, is an industrial facility that reworks, repairs, and overhauls various aircraft, engines, and components. The anodize line chemically changes the surface of aluminum components to improve corrosion resistance and hardness. The FRCSE does not have the capacity or ability to perform the required maintenance to keep this system maintained and ready to meet the fleet’s demand for these components and parts that need repaired. The FRCSE therefore requires contractor services for the Preventive Maintenance and Emergent Repairs of this anodize line to ensure they are ready and available to apply the Aluminum coating as required when required. This contract will enable FRCSE to continue the production line and ensure the anodize line is repaired in a timely manner if it breakdowns.

2. Applicable documents:

2.1 Attachment 1 – FRCSE Work Restrictions

3. Requirements

3.1 General Requirements

The Contractor shall be responsible for providing preventive maintenance and emergency repairs for the anodize line located at the Fleet Readiness Center Southeast (FRCSE), Naval Air Station, Jacksonville, Florida 32212-0016, Building 794.

3.3 Detailed Support Requirements: This section provides the detailed support to be provided by the contractor.

3.3.1 Preventative Maintenance

AUTOMATED ANODIZE LINE

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The below table list the anodize system and specific components that will need to be serviced:

3.3.1.1 The contractor shall be onsite to perform Preventive Maintenance (PM) every six

(6) months, totaling two (2) visits in a 12 months period. The following equipment list shall be inspected to identify any parts requiring replacement or repair. During the PM, the contractor shall identify which parts are recommended for replacement and submit the parts list to the TPOC. The TPOC will approve the list and provide written confirmation to replace the parts. PM Services shall also include inspection and preventative maintenance of the following equipment:

Anodize line:

� All Tanks C-1 thru C-14c � Resistance Temperature Detectors (RTDs) � Water fill solenoids � Spray solenoids � Steam components � Agitation system

ASSET

PLANT

ACCOUNT

NUMBER

MANUFACTURER PART NUMBER

Anodize Line 65886070984 George Koch Sons, LLC 01 (N/A)

C-8 Rectifier 65886071006 American Plating Power

LLC

D480 G75/3000 WR-

PFX

C-7 Rectifier 65886071005 American Plating Power

LLC

D480 G30/3000WRG-

TFRX

Chiller for C-8 65886071000 YORK YLAA0120S46XFB

Chiller for C-7 65886070999 YORK YCAL0028EE46XEB

Heat Exchanger for C-7 65886071002 Paul Mueller Company

9804186/AT10 ICLC-

Heat Exchanger for C-8 65886071003 Paul Mueller Company AT75XICB-150

C-Line LP Blower 65886071007 Spencer Turbine Co 30107B2

Material Transporter 65886071004 George Koch Sons, LLC MH-01

AUTOMATED ANODIZE LINE

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� Glycol heat exchangers � Steam heat exchanger � Filter Pumps � Acid Pumps � Rectifier for C-7 � Rectifier for C-8 � All Electrical � Programmable Logic Controller (PLC) Cabinet � Human Machine Interface (HMI) � Central Processing Unit (CPU) � Uninterruptible Power Supply (UPS) � Acid Pumps � Input/output (I/O) operations � Cabinet air conditioning unit � Flight Bar Transport System � C Line Blower � C Line Exhaust Fan � C-7 and C-8 Chillers � C-7 and C-8 Glycol Pumps � Plate heat exchangers

Replacement Work in Accordance with Over and Above Work. If the Contractor identifies repairs that are required during the semiannual maintenance that are beyond the items that are being replaced, the contractor shall submit a written listing of the work that is required to the TPOC within 48 hours of identification, pursuant to the Over and Above Work clause. The TPOC will verify the Contractor’s parts/materials and pricing for accuracy and adequacy before submitting the contractor’s estimate to the COR and Contracting Officer for authorization for the repair work. Any repair work completed (other than what is included in preventive maintenance) without authorization from the Contracting Officer shall be at the contractor’s expense with no reimbursement by the Government.

3.3.1.1.1 Semi Annual

3.3.1.1.1.1 Anodize Line. The contractor shall conduct the following:

• Clean out steam strainers on the 10-steam supply manifolds located along back of tanks.

• Blow-down the steam condensate strainers (10) for the heated anodize line tanks and the condensate return strainer at the end of the steam supply line to all of the tanks.

AUTOMATED ANODIZE LINE

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• Clean laser lens and pad. **Must use DI water and soft cloth, NEVER use any abrasive type cleaner**

• Check the Battery Status Light on the Allen-Bradley 1769 Series PLC to gauge Lithium battery condition. Replace the battery if needed. (Allen- Bradley Pt. # 1769-BA)

• Check the condenser cooling air filter on the Anodize Line main electrical enclosure cooling unit. Remove and clean the filter or replace it with a new filter. Utilize ½”, or ¾” disposable filter material if needed. Check the air-cooled condenser for accumulation of dirt or dust. Clean the coils and mechanical section of the condenser with a HEPA filtered vacuum and compressed air. Do not damage condenser or evaporator coils. Verify proper operation of cooling unit. Document any condenser and unit cleaning.

• Check all limit, over-travel, and position switches. Replace if needed.

• Check the cathode assemblies in the two plating tanks, C-7 & C-8 for damage or deterioration.

• Check cleanliness and operation of all sensors.

• Check the pull air inlet manifolds, exhaust ducting, and exhaust duct drains for leaks, clogging, or damage.

• Check the function of the tank overflow system on tanks C-2, C-4, C-6, C-

7, C-9, and C-11. Assure no debris is collecting in the overflow weir or piping.

• Check the pull air inlet and push air manifolds, exhaust ducting, and exhaust duct drains for leaks, clogging, or damage.

• Check the rim spray systems on tanks C-4, C-6 C-9, C-11, and C-13 for proper operation, damage, or poor spray pattern.

• Visually inspect the steam coils in tanks C-1, C-3 C-7, C-8, C-10, C-11, C-12, and C-14 (3) for signs of steam or condensate leaks, damage, or deformation.

• In tanks C-1, C-3, C-5, C-7, C-8, C-10, C-11, C-12, and C-14 (3), check the RTD probes and their associated electrical junction boxes and conduit for damage, chemical build-up, or degradation. Clean the RTD probes if needed.

• Check the cables and structure comprising the umbilical and the umbilical tray for damage and proper function.

• Visually inspect the electrified saddle assemblies on the two anodize tanks (C-7 & C-8) for any degradation, damage, dirt/debris, or corrosion build-

up. Clean the copper contact surfaces if needed, to ensure electrical continuity.

AUTOMATED ANODIZE LINE

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• Lubricate the two (2) Chilled Water Pumps Motor bearings with Mobil Polyrex EM grease.

• Lubricate the two Acid Pumps Motor bearings with Mobil Polyrex EM grease

3.3.1.1.1.2 Rectifiers. The contractor shall conduct the following:

• Remove and clean or replace the four (4) cooling air intake filters on the side of the smaller rectifier enclosure and check the eight (8) exhaust fans on the rear of the enclosure for cleanliness and proper operation.

• Check whether the fixing screws, terminal strips, and connections of the bus bars and all other components are tight. Re-tighten them, if necessary.

• Carefully clean the electrical built-in components as well as the electronic components and switchgear. While doing this, be careful not to change the position of adjustable components.

• Check the electrical switchgear for contact erosion at regular intervals;

Replace the contact pieces, if necessary.

• Check the contact pieces of the main contractor for erosion after having removed the arc chute. Replace the contact pieces, if necessary. Check whether the fixing screws of the contact pieces and the terminals are tight.

Check whether the bearings and friction surfaces are sufficiently lubricated. Re-lubricate them with Molykote, if necessary.

3.3.1.1.1.3 Chillers. The contractor shall conduct the following:

• Verify that compressor oil sump heaters are connected tightly around the compressor.

• After the chiller has been operating for approximately 15 minutes and the system has stabilized, check the operating pressures and temperatures.

• Check the compressor oil levels on the two (2) Anodize Line Chillers.

When the compressor is running at stabilized conditions, the oil level must be between 1/4 and 3/4 in the oil sight glass. At shutdown, it is acceptable if the oil level falls to the bottom limit of the oil sight glass.

• Check the control system for any error or fault messages and proper operating parameters.

• Measure and record the evaporator superheat.

• Measure and record the system sub-cooling.

• Check the operation of the condenser fan motors. Note any noise, vibration, or loose fasteners.

• Check for any glycol leaks and repair.

3.3.1.1.1.4 Heat Exchanger. The contractor shall conduct the following:

AUTOMATED ANODIZE LINE

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• Check to confirm the plate pack is tightened.

• Check Heat Exchanger gaskets for cracks, holes, and swelling.

• Clean the heat exchanger plates.

3.3.1.1.1.5 Blowers. The contractor shall conduct the following:

• Lubricate the exhaust blower motor bearings with Mobil Polyrex EM grease. Remove grease relief plugs, slowly pump the grease until new grease appears at grease discharge hole. Allow motor to operate for up to 30 minutes to allow new grease to expand and be expelled from the vents.

Clean-up excess grease and reinstall grease relief plugs.

• Lubricate the Low Pressure Blower motor with Mobil Polyrex EM grease.

Remove the grease relief plugs and slowly add 1.5 cu inch of grease to each bearing. Run the motor for at least 15 minutes to allow the grease to warm and expand. Clean-up excess grease and re-install grease relief plugs.

• Replace filter on LP blower, Spencer Part # FIL-90335.

• Check the Exhaust Blower belt condition, tension, and alignment. Four

(4) each 5VX1230 belts required.

• Inspect the Exhaust Blower belt sheaves for wear. Correct any discrepancies. Replace belts or sheaves if needed. Assure proper alignment and tension.

3.3.1.1.1.6 Material Transporter. The contractor shall conduct the following:

• Lubricate grease fitting for worm housing with three pumps Shell Oil Co.

Albida LC Ep #2 (Shell Product Code 70311).

• Lubricate grease fitting for tube guide bushing with three (3) pumps of

Shell Oil Co. Albida LC Ep #2 (Shell Product Code 70311).

• Lubricate Clevis pins using anti-seize compound or extreme pressure grease.

• Grease the Baldor motor.

• Lubricate the cam roller rails on the lift cart with white Lithium based grease.

• Lubricate the casters by applying two (2) pumps of lithium-based grease at each grease fitting.

• Inspect the wire rope on the lift cart for kinks, corrosion or fraying. If wire rope is damaged, replace the wire rope.

• Inspect the clasps on the lift cart to confirm they are tight. If the clasps are not functioning properly, replace the clasps.

• Inspect casters for proper operation and treads for any damage or flat spots. If casters or treads are damaged, replace the casters.

AUTOMATED ANODIZE LINE

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• Inspect the cam followers for damage and that they roll freely. If the cam rollers fail to operate properly or appear to be damaged, replace the cam followers.

• Inspect the wire rope heavy duty steel pulley for proper alignment, smooth operation, and cracking. If the pulley is misaligned, does not operate smoothly, or is damaged, replace the pulley if it cannot be properly aligned.

• Inspect the wire rope pulley for proper alignment, smooth operation, and cracking. If the pulley is misaligned, does not operate smoothly, or is damaged, replace the pulley if it cannot be properly aligned

• Check all connections on the Multipurpose Brake for tightness and signs of overheating. If electrical connections are not tight or there are signs of overheating, replace the defective item.

• Check Multipurpose Brake for cracked or damaged insulators and terminal blocks. If the insulators or terminal blocks are cracked or damaged, replace the damaged item.

• Inspect Multipurpose Brake heat sinks for cleanliness and remove dirt buildup to maintain proper ventilation.

• Remove dust and any remaining dirt from the Multipurpose Brake by vacuuming. Do not wash or use solvents.

• Check the four 3” dia. rubber bumpers on the flight bar transporter trolley for damage or deterioration.

• Inspect the function and condition of the four (4) cam followers mounted to the transfer trolley frame. Maximum total clearance is 3/16”. Adjust if needed. If the cam followers are worn, damaged, or seized, replace.

• Inspect the lift straps on the flight bar transporter for any signs of worn or broken strands or chemical deterioration. Replace if needed.

• Inspect the drive and idler wheels on the transfer trolley frame for wear, tread separation, or damage. Minimum frame to track clearance is 3/16”.

• Lubricate the flange bearings on the flight bar transporter and trolley (11 ea.) with a high quality NLGI 2 lithium grease.

• Check lift strap drums

• Drum surface should be free from wear and strap should lay evenly in the drums. Replace if drum flanges are worn away or strap has cut a groove into the drum surface.

• Check for worn strap drum key-ways. If key, drum, or shaft are worn, replace affected parts. Tighten setscrews.

• Check ends of lift straps where they connect with the strap drums. Assure no damage and a secure connection.

AUTOMATED ANODIZE LINE

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3.3.1.1.2 Annual In addition to the semiannual maintenance, the contractor shall conduct the following maintenance once a year:

3.3.1.1.2.1 Anodize Line. The contractor shall conduct the following:

• Check the UPS for the HMI. Life span of the UPS is three (3) years and shall be changed at on that interval. (last changed May of 2021)

3.3.1.1.2.2 Rectifiers. The contractor shall conduct the following:

• Ensure all readings are accurate.

3.3.1.1.2.3 Chillers. The contractor shall conduct the following:

• Wash condenser coils with water only, interior, and exterior.

• Remove and clean entering glycol strainers and clean and reinstall.

• Test entering and leaving glycol delta T.

• Perform corrosion control.

3.3.1.1.2.4 Heat Exchangers. The contractor shall conduct the following:

• Back flush the heat exchangers

• Check to confirm the plate pack is tight

• Check Heat Exchanger gaskets for cracks, holes, and swelling.

• Clean the heat exchanger plates.

• First year full replacement option for plate heat exchangers

3.3.1.1.2.5 Blowers.

• Not required for annual maintenance.

3.3.1.1.2.6 Material Transporter. The contractor shall conduct the following:

• Replace lift straps on the flight bar transporter.

• Lubricate the two gear motors on the flight bar transporter and trolley assemblies with one (1) teaspoon of Mobil Polyrex EM grease in each bearing.

• Inspect flight bar transporter trolley wheels. Replaces if damage is seen or material is becoming brittle.

• Change the oil in the two (2) gearboxes on the flight bar transporter and Trolley. The flight bar transporter gearbox takes 4.7 pt. of oil and the trolley gearbox takes 16.3 pints of oil. Use Mobilgear 600 XP 220 mineral oil or Mobil SHC630 Synthetic oil. Both are compatible and do not require flushing to interchange.

AUTOMATED ANODIZE LINE

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3.3.1.1.2.7 HMI. The contractor shall conduct the following:

• Run a system check on the AUCUS system and update the system if needed.

• Clean the computer fans.

3.3.1.1.3 Optional Replacements

3.3.1.1.3.1 Glycol Heat Exchanger Plate Replacement.

This option shall include new heat exchanger plates for C-7 and C-8 heat exchangers. This option shall include cleaning the frame of the heat exchanger and making any repairs that need to be made in order to make functional heat exchangers. New gaskets shall also be provided during the install of the new plates.

3.3.1.1.3.2 Acid Pump Replacement for C-7.

This option shall include a new acid pump and installation for C-7.

3.3.1.1.3.3 Acid Pump Replacement for C-8.

This option shall include a new acid pump and installation for C-8.

3.3.1.1.3.4 Cathode system replacement for C-7.

This option shall include replacing the cathode buss bars, cathodes, cathode shields, and all associated hardware for the cathode system on tank C-7. The contractor shall leave an open space between cathodes to lower the cathode to the component ratio. Cathode shields shall have a modified securing method to stop them from drifting into the tank.

3.3.1.1.3.5 Cathode system replacement for C-8.

This option shall include replacing the cathode buss bars, cathodes, cathode shields, and all associated hardware for the cathode system on tank C-8. The contractor shall leave an open space between cathodes to lower the cathode to the component ratio. Cathode shields shall have a modified securing method to stop them from drifting into the tank.

3.3.2 Emergency Maintenance

Emergent Repair Services: Contractor shall provide Emergency repair services having a one-day response via teleconference or online support. If an on-site visit is required, the Contractor shall be required to be on-site within 3-5 calendar days. All labor and travel shall be included in the price of emergency services and shall not be billed separately.

AUTOMATED ANODIZE LINE

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3.3.2.1 Replacement Parts in Accordance with Over and Above Work. If the Contractor identifies parts that require replacement (other than those parts included in routine preventive maintenance) during emergency maintenance inspections, the contractor shall submit a written listing of the parts required along with associated costs to replace to the TPOC within 48 hours of identification, pursuant to the Over and Above Work clause. The TPOC will verify the Contractor’s parts/materials and pricing for accuracy and adequacy before submitting the contractor’s estimate to the COR and Contracting Officer for authorization to replace parts. Any parts replaced (other than those included in routine preventive maintenance) without authorization from the Contracting Officer shall be at the contractor’s expense with no reimbursement by the Government. If repair parts must be ordered, the Contractor may leave the site temporarily and return within five (5) business days after the parts arrive to complete repairs.

3.3.3 Deliverables

3.3.3.1 After maintenance completion, the contractor shall provide a written service report for the Anodize line and its support components. Service reports shall consist of dates of services, serial number of system, services performed, parts provided, and contractor employee’s point of contact information.

3.3.3.2 The contractor shall provide Material Safety Data Sheets (MSDS) for all solvents, grease sealants, and lubricants utilized or incorporated in Anodize Line that the contractor will use.

3.3.3.3 The contractor shall provide a spare parts list for the Anodize Line. This shall include any parts that could need replaced on the anodize line along with the parts that will be replaced on a schedule. This list shall make a clear distinction of what items will be changed at each scheduled PM and what items are replaced on an as-needed basis. All replacement parts shall be of equal or greater quality as determined by the TPOC if a change from OEM components is requested.