Performance Work Statement.pdf

Performance Work Statement (PWS) – Machinery Repair on the Plasma/Oxy Fuel Cutting Center at Puget Sound Naval Shipyard, Bremerton, WA

Ship/Activity: Puget Sound Naval Shipyard and Intermediate Maintenance Facility (PSNS & IMF)

BLDG 460

Title: Machinery Repair on the Plasma/Oxy Fuel Cutting Center

Place of Performance: PSNS BLDG. 460 1st Floor. Existing Profile Cutting System Plasm/Oxy Fuel

Cutting Center

PART 1

GENERAL INFORMATION

1. General:

This is a non-personnel services contract to provide Machinery Repair on the Plasma/Oxy Fuel Cutting Center.

The Government shall 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 Machinery Repair on the

Plasma/Oxy Fuel Cutting Center as defined in this Performance Work Statement except for those items specified as government furnished property and services. The Contractor shall perform to the standards in this contract.

1.2 Background.

The Profile Cutting System (PCS) Plasma/Oxy Fuel Cutting Center (Asset #: 4523AC1136 / Serial Number:

100535 A/B) was installed at Puget Sound Naval Shipyard and Intermediate Maintenance Facility (PSNS & IMF) in

2017. This machine was procured through the Capital Investment Program (CIP) to recapitalize an existing plasma/oxy fuel cutting center.

1.3 Objectives.

This Performance Work Statement (PWS) supports repairs on the Plasma/Oxy Fuel Cutting Center (Asset #:

4523AC1136 / Serial Number: 100535 A/B) at PSNS & IMF located in Building 460. It is the Government’s intent that a single contractor be awarded this contract and be responsible for the provision of equipment, and the accomplishment of all work detailed by this PWS.

1.4 Scope.

This PWS requires a single contractor to perform Machinery Repair on the Plasma/Oxy Fuel Cutting Center.

The Contractor shall be responsible for the engineering, removal, installation, components, and transportation to accomplish the work required in this PWS. The Contractor shall be responsible for all materials and labor services required to accomplish the work required in this PWS. At the completion performance, the entire plasma and oxy fuel cutting machine will be fully operational and will have an operational and accuracy test performed satisfactorily for acceptance. The Machinery Repair on the Plasma/Oxy Fuel Cutting Center shall be performed in two deliverables. The machine consists of a North Gantry (Serial Number 100535B) and a South Gantry (Serial Number

100535A). During the Machinery Repair on the Plasma/Oxy Fuel Cutting Center one of the two gantries shall be operational at all times.

1.5 Period of Performance:

The period of performance shall be one year from contract award.

1.6 General Information

1.6.1 Quality Assurance:

The Government shall evaluate the contractor’s performance under this contract in accordance with the operational and accuracy tests listed in Sections 5.1.4 and 5.2.4 of this document to the standards and capacities specified in

Table II and Table III. This plan is primarily focused on what the Contractor must perform satisfactorily for the

Government with the performance standards. It defines how the performance standards will be applied, the frequency of surveillance, and the minimum acceptable defect rate(s).

1.6.2 Recognized Holidays:

If the Contractor desires to work a recognized holiday, the Contractor shall submit a request to the receiving activity

COR for approval a minimum of four (4) business days prior to the anticipated work date.

Ten (10) PSNS & IMF recognized holidays read as follows:

1) New Year’s Day 6) Labor Day

2) Martin Luther King Jr.’s Birthday 7) Columbus Day

3) President’s Day 8) Veteran’s Day

4) Memorial Day 9) Thanksgiving Day

5) Independence Day 10) Christmas Day

1.6.3 Hours of Operation:

When on site, the Contractor is responsible for conducting business between the hours of 7:20 am to 4:02 pm, Monday thru Friday except recognized holidays or when the government facility is closed due to local or national emergencies, administrative closings, or similar government directed facility closings. The Contractor must at all times maintain an adequate workforce for the uninterrupted performance of all tasks defined within this PWS when the Government facility is not closed for the above reasons. When hiring personnel, the Contractor shall keep in mind that the stability and continuity of the workforce are essential.

If the Contractor desires to work on Saturdays, Sundays, holidays, or outside the regular or specified hours and/or days, the Contractor shall submit a written request to the receiving activity COR for approval a minimum of four (4) business days prior to the anticipated work date. In no event shall a Contractor carry on work outside the hours and/or days specified in the contract without prior approval.

1.6.4 Place of Performance:

The work to be performed under this contract shall be performed at Puget Sound Naval Shipyard and Intermediate

Maintenance Facility, 1400 Farragut Avenue, Bremerton, WA 98314-5001 in Building 460 and contractor facilities.

Work on disassembled equipment may performed an alternative work site when advantageous, with written approval from the COR.

1.6.5 Type of Contract:

The Government will award a fixed price contract.

1.6.6 Security Requirements:

Contractor personnel performing work under this contract must have or be able to obtain a PSNS & IMF GREEN

BADGE or a PSNS & IMF WHITE “ESCORT REQUIRED” BADGE at time of the proposal submission, and must maintain the level of security required for the life of the contract. The security requirements are in accordance with

Attachment A.

1.6.6.1 Physical Security:

The Contractor shall be responsible for safeguarding all government equipment, information and property provided for Contractor use. At the close of each work period, government facilities, equipment, and materials shall be secured.

1.6.7 Post Award Conference/Periodic Progress Meetings:

The Contractor agrees to attend any post award conference convened by the contracting activity or contract administration office in accordance with Federal Acquisition Regulation Subpart 42.5. The Contracting Officer, Contracting Officers Representative (COR), and other Government Key Personnel, as appropriate, may meet periodically with the Contractor to review the Contractor's performance. At these meetings the Contracting Officer will apprise the contractor of how the Government views the Contractor's performance and the Contractor will apprise the Government of problems, if any, being experienced. Appropriate action shall be taken to resolve outstanding issues. These meetings shall be at no additional cost to the Government.

1.6.8 Contracting Officer Representative (COR):

The (COR) will also be designated by separate letter. The COR monitors all technical aspects of the contract and assists in contract administration The COR is authorized to perform the following functions: assure that the

Contractor performs the technical requirements of the contract; perform inspections necessary in connection with contract performance; maintain written and oral communications with the Contractor concerning technical aspects of the contract; issue written interpretations of technical requirements, including Government drawings, designs, specifications; monitor Contractor's performance and notifies both the Contracting Officer and Contractor of any deficiencies; coordinate availability of Government furnished property, and assist Contractor personnel to obtain access to the site. A letter of designation issued to the COR, a copy of which is sent to the Contractor, states the responsibilities and limitations of the COR, especially with regard to changes in cost or price, estimates or changes in delivery dates. The COR is not authorized to change any of the terms and conditions of the resulting order.

1.6.9 Identification of Contractor Employees:

All contract personnel attending meetings and working in other situations where their contractor status is not obvious to third parties are required to identify themselves as such to avoid creating an impression in the minds of members of the public that they are Government officials. They must also ensure that all documents or reports produced by contractors are suitably marked as contractor products or that contractor participation is appropriately disclosed. All contract personnel shall obtain and wear PSNS&IMF visitor badges in accordance with local site security requirements for Naval Base Kitsap (NBK) and the Controlled Industrial Area (CIA) of PSNS&IMF.

1.6.10 Contractor Travel:

The Contractor will be authorized travel expenses consistent with the substantive provisions of the Joint Travel

Regulation (JTR) and the limitation of funds specified in this contract. All travel requires Government approval/authorization and notification to the COR. The Contractor is responsible for arranging all travel and lodging requirements.

1.6.11 PHASE IN /PHASE OUT PERIOD:

To minimize any decreases in productivity and to prevent possible negative impacts on additional services, the

Contractor shall ensure the COR, KO and all Key Personnel are notified a minimum of 20 business days prior to any onsite work starts. The Contractor shall ensure one gantry cutting system is maintained operational; this ensures the phase in of the first gantry is completed before services to the second gantry phase out commences.

PART 2

DEFINITIONS, ACRONYMS, & APPLICABLE DOCUMENTS

2. Definitions and Acronyms:

2.1 DEFINITIONS:

2.1.1. CONTRACTOR. A supplier or vendor awarded a contract to provide specific supplies or service to the government. The term used in this contract refers to the prime.

2.1.2. CONTRACTING OFFICER (KO). A person with authority to enter into, administer, and or terminate contracts, and make related determinations and findings on behalf of the government. Note: The only individual who can legally bind the government.

2.1.3. CONTRACTING OFFICER'S REPRESENTATIVE (COR). An employee of the U.S. Government appointed by the contracting officer to administer the contract. Such appointment shall be in writing and shall state the scope of authority and limitations. This individual has authority to provide technical direction to the Contractor as long as that direction is within the scope of the contract, does not constitute a change, and has no funding implications. This individual does NOT have authority to change the terms and conditions of the contract.

2.1.4. DEFECTIVE SERVICE. A service output that does not meet the standard of performance associated with the

Performance Work Statement.

2.1.5. DELIVERABLE. Anything that can be physically delivered, but may include non-manufactured things such as meeting minutes or reports.

2.1.6. KEY PERSONNEL. Contractor personnel that are evaluated in a source selection process and that may be required to be used in the performance of a contract by the Key Personnel listed in the PWS. When key personnel are used as an evaluation factor in best value procurement, an offer can be rejected if it does not have a firm commitment from the persons that are listed in the proposal.

2.1.7. PHYSICAL SECURITY. Actions that prevent the loss or damage of Government property.

2.1.8. QUALITY ASSURANCE. The government procedures to verify that services being performed by the

Contractor are performed according to acceptable standards.

2.1.9. QUALITY ASSURANCE SURVEILLANCE PLAN (QASP). An organized written document specifying the surveillance methodology to be used for surveillance of contractor performance.

2.1.10. QUALITY CONTROL. All necessary measures taken by the Contractor to assure that the quality of an end product or service shall meet contract requirements.

2.1.11. SUBCONTRACTOR. One that enters into a contract with a prime contractor. The Government does not have privity of contract with the subcontractor.

2.1.12. WORK DAY. The number of hours per day the Contractor provides services in accordance with the contract.

2.1.12. WORK WEEK. Monday through Friday, unless specified otherwise.

2.2 ACRONYMS:

ACOR Alternate Contracting Officer's Representative

CFR Code of Federal Regulations

CNC Computer Numerical Control

CONUS Continental United States (excludes Alaska and Hawaii)

COR Contracting Officer Representative

COTR Contracting Officer's Technical Representative

COTS Commercial-Off-the-Shelf

DD250 Department of Defense Form 250 (Receiving Report)

DD254 Department of Defense Contract Security Requirement List

DFARS Defense Federal Acquisition Regulation Supplement

DMDC Defense Manpower Data Center

DOD Department of Defense

FAR Federal Acquisition Regulation

KO Contracting Officer

OCONUS Outside Continental United States (includes Alaska and Hawaii)

ODC Other Direct Costs

PIPO Phase In/Phase Out

POC Point of Contact

PRS Performance Requirements Summary

PWS Performance Work Statement

QA Quality Assurance

QAP Quality Assurance Program

QASP Quality Assurance Surveillance Plan

QC Quality Control

QCP Quality Control Program

TE Technical Exhibit

2.3 Applicable Documents

2.3.1 General.

The documents listed in this section are specified in this PWS. While every effort has been made to ensure the completeness of this list, document users are cautioned that they must meet all specified requirements of this PWS, whether or not they are listed.

2.3.2 Government Documents (Specifications, Standards, and Handbooks).

The following specifications, standards, and handbooks form a part of this document to the extent specified herein.

Unless otherwise specified, the issues of these documents are those cited in the solicitation or contract.

NAVAL FACILITIES ENGINEERING COMMAND (NAVFAC)

NAVFAC P-307 --------------------------------- Management of Weight Handling Equipment (June 2016)

(Copies available online at http://www.navfac.navy.mil/navfac_worldwide/specialty_centers/ncc/about_us/resources/p307.html)

PUGET SOUND NAVAL SHIPYARD AND INTERMEDIATE MAINTENANCE FACILITY

OSH-II-9(LOTP) -------------------------------- PSNS&IMF OCCUPATIONAL SAFETY AND HEALTH

MANUAL Hazardous Energy Control, Lock Out/Tags Plus

P5100 (14) ---------------------------------------- PSNS&IMF VISITOR AND CONTRACTOR HANDBOOK

Visitor and Contractor Handbook

(Copies available, to be provided by Government Key Personnel as required)

3. 2.3.2.2 Other Government Publications.

The following other Government documents, drawings, and publications form a part of this document to the extent specified herein. Unless otherwise specified, the issues of these documents are those cited in the solicitation or contract.

COMBINED FEDERAL REGULATIONS

29 CFR 1910 -------------------------------------- General Industry, OSHA Safety and Health Standards http://www.navfac.navy.mil/navfac_worldwide/specialty_centers/ncc/about_us/resources/p307.html

29 CFR 1915 -------------------------------------- Occupational Safety and Health Standards for Shipyard

Employment

(Copies available online at http://www.gpo.gov/fdsys)

3.6.1 Non-Government Publications.

The following documents form a part of this document to the extent specified herein. Unless otherwise specified, the issues of these documents are those cited in the solicitation or contract.

AMERICAN NATIONAL STANDARDS INSTITUTE (ANSI) B11 STANDARDS

ANSI B11.0 -------------------------------------- Safety of Machines; General Requirements and Risk

Assessment (2015)

ANSI B11.19 ------------------------------------ Performance Criteria for Safeguarding (2010)

ANSI B11.25 ------------------------------------ Safety Requirements for Large Machines (2015)

(Copies available from B11 Standards Inc, 7901 Westpark Dr, McLean, VA 22102)

INTERNATIONAL ORGANIZATION FOR STANDARDIZATION

ISO 4413 ------------------------------------------ Hydraulic Fluid Power - General Rules and Safety

Requirements for Systems and Their Components (2010)

ISO 4414 ------------------------------------------ Pneumatic Fluid Power - General Rules and Safety

Requirements for Systems and Their Components (2010)

ISO 9013 ------------------------------------------ Thermal Cutting - Classification of Thermal Cuts -

Geometrical Product Specification and Quality Tolerances

(2017)

ISO 17916 ----------------------------------------- Safety of Thermal Cutting Machines (2016)

(Copies available at http://webstore.ansi.org/ or American National Standards Institute, Dept. 969, 1430 Broadway, New York, NY 10018)

NATIONAL ELECTRICAL MANUFACTURERS ASSOCIATION

NEMA MG 1 ------------------------------------- Motors and Generators (2016)

NEMA Z535.4 ----------------------------------- Product Safety Signs and Labels (R2017)

NEMA 250 ---------------------------------------- Enclosures for Electrical Equipment (1000 Volts Maximum)

(2014)

(Copies available at http://www.nema.org or National Electrical Manufacturers Association, 1300 North 17th Street, Suite 1752, Rosslyn, VA 22209)

NATIONAL FIRE PROTECTION ASSOCIATION

NFPA 70 ------------------------------------------ National Electrical Code (2017)

NFPA 79 ------------------------------------------ Electrical Standard for Industrial Machinery (2018)

(Copies available at http://www.nfpa.org or NFPA, 1 Batterymarch Park, Quincy, MA 02169)

PROFILE CUTTING SYSTEMS (PCS) MAINTENANCE MANUAL

http://www.gpo.gov/fdsys http://webstore.ansi.org/ http://www.nema.org/ http://www.nfpa.org/

PCS ------------------------------------------------ Preventative Maintenance Schedule Serial Numbers 100535A and 100535B

(Copies available, to be provided by Government Key Personnel as required)

3.6.2 Order of Precedence.

Unless otherwise noted herein or in the contract, 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 has been obtained.

PART 3

GOVERNMENT FURNISHED PROPERTY, EQUIPMENT, AND SERVICES

3. GOVERNMENT FURNISHED ITEMS AND SERVICES:

3.1 Services.

The Government will provide a machine operator to move the gantry to final position designated by the Contractor prior to all work commencing. Upon gantry final position, the Government will not provide personnel, included but not limited to, machine operators and maintenance personnel, to electrically or mechanically disconnect or connect services or machine components. The Government will provide a machine operator to work alongside the

Contractor during the reinstallation and operational testing. At the completion of the gantry repairs, the Government will make personnel available for training.

3.1.1 Material Handling Equipment (MHE) Crane and Rigging Services

The Government (receiving activities) will provide overhead crane and rigging services limited to the removal, loading on the Contractor vehicle, unloading from the Contractor vehicle, and installation of all machine components. Should the Contractor desire to provide their own crane services, the contractor shall provide a lifting sketch, as described below, 30 days prior to arrival of equipment in accordance with NAVFAC P-307, “Management of Weight Handling Equipment”. Lifting sketches, as a minimum, shall identify the following:

a) The weight of the load.

b) The location of the center of gravity.

c) The minimum capacity/length of slings.

d) The minimum capacity of other standard rigging gear.

e) The attachment (lifting) points for the load.

1. The attachment point for multiple leg lifts shall be sized such that each attachment point can support half the load's weight at the anticipated lift angle.

2. The attachment point for single leg lifts shall be sized such that the attachment point can support the entire load's weight.

f) Limitations on allowable orientations for any parts making up the lifting assembly.

g) For single vertical lifts using twisted wire rope (wire or synthetic), two parallel ropes each capable of supporting the entire load alone shall be required unless a method is used to prevent unlaying the rope.

h) A minimum D/d ratio of 1 (one) shall be required where wire rope slings pass over any object, or in the eyes of wire rope slings. A minimum D/d ratio of 2 (two) shall be required where synthetic rope slings pass over any object, or in the eyes of synthetic rope slings.

1. "D" represents the diameter of the object the sling passes over.

2. "d" represents the diameter of the sling.

3. Table 14-3 of NAVFAC P-307 lists efficiency factors at the various D/d ratios.

i) Components in each handling assembly shall be sized based on the worst-case distribution of loads.

NOTE: When making a two-, three-, or four-point lift, the handling gear shall be sized so that two legs can support the load without exceeding the safe working (SWL) at the lift angle expected, unless equalizing method is used.

j) When the Contractor requires non-standard gear (i.e., round stock lifting bars) be provided, written instructions shall be provided to the designated shipyard official to ensure:

1. The proper material is being used.

2. The item is certified.

3. Any special requirements or dimensions are followed to ensure that engineering assumptions are met (i.e., eccentricity of the bearing points).

3.1.1.1 MATERIAL HANDLING EQUIPMENT (MHE) CRANE, RIGGING, FORKLIFT SERVICES FOR

PUGET SOUND NAVAL SHIPYARD & IMF.

Any lifting operations or use of additional equipment in support of Contractor removal and installation shall require prior approval through the Shipyard COR. If installer intends to use a mobile crane, a crane work plan as detailed and formatted by the COR shall be required. Any lifting operation in support of a Contractor installation shall require prior approval of the Shipyard; additional information for privately owned material handling equipment can be found in the Site Specific Requirements in Attachment A.

3.1.2 Control of Hazardous Energy (Lockout/Tag-Plus) Program

The Government 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. The Contractor shall meet with the Government Point of Contact to discuss lockout/tags-plus interface. The Contractor shall use the Receiving Activity's lockout/tags-plus procedures in accordance with 29 CFR 1915.89. Lockout/tags-plus procedures IAW 29 CFR 1915.89 shall be followed, where applicable. Contractors shall train their employees to Vol. II Chapter 9 of the Government

Occupational Safety and Health (OSH) manual or as directed by technical guidance from the Receiving Activity.

Audits, surveillances and incident investigations shall be performed per 29 CFR 1915.89 and the Receiving

Activity's OSH Manual Vol. II Chapter 9 requirements.

3.2 Facilities.

The Government COR and Key Personnel will provide the contractor with information and forms for items detailed in the Site Specific Requirements in Attachment A, as required.

3.2.1 Site Specific Requirements

Site specific requirements for PSNS & IMF, Bremerton, WA site are provided in Attachment A.

3.3 Utilities.

The Government will provide utilities within 100 feet of the machine. Table I list the utilities available.

Table I: Utilities

Electrical – North Gantry 480 VAC (+/-20 V), 60 Hz, 3 Phase, 600 Amps

Electrical – South Gantry 480 VAC (+/-20 V), 60 Hz, 3 Phase, 600 Amps

Table I: Utilities

Compressed Air 100 psi (+/- 10 psi)

Nitrogen 140 psi (+/- 15 psi)

Oxygen 135 psi (+/- 10 psi)

Propane 20 psi (+/- 5)

Water 1-inch supply line

Argon Bottle provided, not hard piped

Working Environment (Temperature) 40° Fahrenheit to 100o Fahrenheit

Working Environment (Relative Humidity) Up to 100% Non-Condensing

3.4 Equipment.

The Government Furnished Property (GFP), the PCS Plasma/Oxy Fuel Cutting Center (Asset #: 4523AC1136 /

Serial Number: 100535 A/B), is located and installed at Puget Sound Naval Shipyard and Intermediate Maintenance

Facility, 1400 Farragut Avenue, Bremerton, WA 98314-5001 in Building 460.

Materials: The Government will provide plate material for machine performance testing at destination after installation is completed.

PART 4

CONTRACTOR FURNISHED ITEMS AND SERVICES

4. CONTRACTOR FURNISHED ITEMS AND RESPONSIBILITIES:

4.1 General.

The Contractor shall furnish all supplies, equipment, facilities and services required to perform work under this contract that are not listed under Section 3 of this PWS.

4.1.1 Environmental, Safety and Health Requirements for Puget Sound Naval Shipyard

Visitor and Contractor Handbook PSNS & IMF P5100 (14), handbook is designed to provide basic safety, health and environmental requirements while within PSNS & IMF. Additional information can be found in the Site specific requirements for PSNS & IMF, Bremerton, WA site provided in Attachment A.

4.1.1.1 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 to this PWS and their supervisors, including their sub-contractors, are familiar with the contents of “Contractor’s Guide to Environmental Compliance” PSNS & IMF P5090 (4).

4.1.1.2 Personal Health and Safety

4.1.1.2.1. 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.

4.1.1.2.2. Prior to Commencing Work: The Contractor representative(s) shall meet in conference with the COR, Key Personnel, 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.

4.1.1.3 Energy Control

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.

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.

4.1.1.4 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.

4.1.1.5 Safety Equipment

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

4.1.1.5.1. 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).

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

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

4.1.1.5.4. Abatement of violations will be the responsibility of the Contractor and/or the

Government as determined by the KO.

4.1.1.5.5. 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.

4.1.1.5.6. 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.

4.1.1.5.7. The Contractor shall ensure that any additional measures that the KO or the COR determines to be reasonably necessary for safety are taken.

4.1.1.5.8. 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.

4.1.1.6 Digital Media Equipment

The Contractor shall provide with all necessary digital media equipment required during the performance of work on this contract.

4.1.1.6.1 The Contractor shall be responsible for providing any necessary computer and digital media required during the performance of work on this contract.

4.1.1.6.2 The Contractor shall comply with all PSNS digital media and computer requirements.

The Contractor shall notify the COR of any planned use of digital media or computers during onsite work a minimum of five (5) business days prior to use.

4.1.1.7 Factory Authorized Field Service Technician

The Contractor shall provide a certified and authorized technician(s) to preform work on the Plasma/Oxy Fuel

Cutting Center (Asset #: 4523AC1136 / Serial Number: 100535 A/B) at PSNS & IMF located in Building 460.

4.2 Materials.

The Contractor shall provide all materials necessary to meet the requirements under this PWS. The machine and all components are required to operate in a stand-alone condition, no direct network cables or internet connections are allowed. The repaired system shall be independent and not utilize nor be compatible with the existing operating system; machine proprietary rights will not be granted.

4.2.1 Gantry Components (for each gantry)

4.2.1.1 Gantry Configuration. Each gantry supplied shall be configured as follows:

a. Two (2) Plasma Heads

1) One (1) Plasma Torch in the Fixed/Straight Position

2) One (1) Plasma Torch with Bevel/Articulating Capabilities

b. Plasma Plate Marking Capability or Independent Torch

1) One (1) Plasma Plate Marker (capability shall either be incorporated into either the

Fixed/Straight and/or Bevel/Articulating plasma torch(s) listed)

i. Plasma plate marking with the capability to generate etched lines and alpha-numeric characters in plain text using the CNC control. Marking and cutting shall use the same consumables.

c. Two (2) Oxy Fuel Heads

1) Two (2) each Oxy-Fuel Torches in the Fixed/Straight Position

d. One (1) Hand Oxy Fuel Torch – Maintained existing torch on gantry: Gas supply lines are mounted on machine. Includes 50-foot retractable hose reel, input pressure regulator system, and one (1) each cutting tip

e. Magnetic Breakaway Devices – Each cutting head shall be fitted with a magnetic breakaway device to protect the devices in case of a collision with plate material, including the oxy-fuel cutting heads.

f. Three (3) Laser or Optical Visual Alignment Devices. One each shall be located on the fixed plasma, bevel/articulating plasma, and one of the oxy-fuel cutting heads.

4.2.1.1.1 Laser or Optical Visual Alignment Devices.

Each gantry shall be equipped with an alignment device on the fixed plasma, bevel/articulating plasma, and one of the oxy-fuel cutting heads to locate the material edge as well as locate a fixed point that is not the actual edge of the material.

4.2.2 Gantry Travel

The Contractor shall ensure the gantries are equipped with anti-collision safety interlock to prevent collision. The current range of travel for each gantry shall not be reduced or altered.

4.2.3 Operator’s Work Stations.

Each gantry is equipped with an operator’s platform with a permanently mounted seat and railings. The operator platforms are mounted on the east side of each gantry and are a fabricated steel work platform mounted to the gantry allowing the operator to travel with the gantry during operations. The Contractor shall maintain the location of the operator platforms and work stations on each gantry. Each work station shall have the CNC controls, critical process monitoring gauges, and controls mounted on the station. The Contractor shall mount the CNC controller at each work station.

4.2.4 Machine Component Specifications

Machine components require the following characteristics:

a) AC servo lifter

b) Magnetic torch breakaway

c) Integrated laser pointer

d) 360-degree infinite rotation without unwind sequence

e) Rotary actuators

f) Bevel up to 50-degrees – K, V, A, Y, X

g) Capability to change from plasma to oxy/fuel within 10 seconds

h) Automatic gas pressure adjustment to within 0.01 psi

i) Remote pressure monitoring

j) Pierce rate adjustment

k) 100% of adjustments made at controller

l) Optical edge finding system

m) Safety pull cord

n) All Hypertherm components

o) Gearboxes with 0-3 Arc minutes of backlash

p) 0.002” positional accuracy

q) 0.001” repeatability

4.2.5 Plasma System Specifications

The plasma cutting system associated with the cutting center shall have the following characteristics:

a) Mild steel cutting capacity and performance:

1. Dross free up to 1.5”

2. Production pierce up to 2”

3. Maximum cutting capacity (edge start) 3.2”

b) Stainless steel cutting capacity and performance:

1. Production pierce up to 1-3/4”

2. Maximum pierce 3”

3. Severance (edge start) 3.2”

c) Aluminum cutting capacity:

1. Production pierce up to 1-1/2”

2. Maximum cutting capacity 3.2”

d) ISO Range 4-5 cut angle (ISO 4: 1.68-3.34 degrees; ISO 5: 3.35-5.33 degrees)

e) 100% duty cycle

f) ISO 9001 registration

4.2.6 Computer Numerical Controller (CNC) Specifications

Each gantry of the plate cutting system shall be equipped with its own CNC. The CNC shall have on-board CAD functionality to model parts and create tool paths on the CAD geometry. The control shall automatically shut down if an over temperature condition is detected. The CNC controls shall be capable of independent operations and shall have, at a minimum, the following features and characteristics:

a) 1 GB RAM

b) 32 bit minimum PC based dual processor

c) Runs Windows 10 based operating system

d) Hard drive with minimum 250 GB storage capacity

e) 2 each USB Ports

f) Integrated Ethernet port

g) 4 hour power back-up using lithium rechargeable battery

h) Can bus I/O controller

i) I/O switching interfaced via programmable logic controller (PLC)

j) 19.5 ” LCD touch screen color display

k) Emergency stop

l) Machine power on/off

m) Power supply on/off

n) Cycle Start/Stop

o) Joystick jog control, 3-axis

p) Positioning hand-wheel with 3-axis selection

q) Controls for 6 process stations, expandable to 12

r) Mode selector (manual/automatic)

s) Single block

t) Optional stop

u) Feed rate override

v) Cutting head selection

w) Feed hold

x) Axis Home

y) Means/Ability to change axis home/reference

z) Laser or optical alignment device (see paragraph 4.2.1.1.1)

aa) Axes Set Zero

bb) Cutting head on/off

cc) Oxy-Fuel Controls

dd) Plasma Power Controls

ee) Display axes position (switchable Absolute/Incremental)

ff) Display axes distance-to-go

gg) 2-axis linear interpolation

hh) Multi-quadrant circular interpolation

ii) Axis over-travel protection

jj) Power fail recovery (return axes to last known position)

kk) Sensor torch height control

ll) Customizable cut charts for the plasma process

mm) Automatic torch spacing

4.2.7 Programming/Software Specifications.

The cutting system shall have the following minimum programming capabilities:

a) Direct importation of DXF, DWG, CAM, DGN, and standard shapes

b) Integrated 2D CAD program to create and edit CAD files

c) Interactive graphical preview of part

d) Process preview with path animation

e) Raster to vector conversion of static images to CAD

f) Importation of Bill of Materials from CAD files

g) Automatic CAD file correction and error notification

h) Automatic spline/ellipse smoothing and reduction

i) Automatic mapping of CAD layers to process

j) Automatic update of nest for part revisions

k) Automatic part corner radiusing

l) Material database

m) Auto nesting

n) Interactive manual nesting

o) Color parts according to part property

p) Group parts into clusters for nesting

q) Move, mirror, or drag to rotate parts

r) Prohibit or permit nesting within a part

s) Part interference detection

t) Edit lead-in/lead-out position and properties within a nest

u) Animated cutting sequence simulation

v) Control cut direction and cut sequencing on a part-by-part basis

w) Part library

x) Remnant plate library

y) Custom remnant creation

z) Plate list

aa) Assembly database

bb) Multi-head cutting

cc) Separations for part, plate, and pierce spacing

dd) Kef compensation and federate

ee) Lead-in/lead-out style optimized for part geometry

ff) Pre-pierce and edge pierce

gg) Ability to disable automatic height control based on part geometry

hh) Pre-heat timing for oxyfuel

ii) Cut sequencing (automatic or manual)

jj) Plate cropping

kk) Part estimating

ll) Pan and Zoom

mm) Multi-torch support

nn) Notch, Chamfer, Fillet, Bevel editors

oo) Kerf Offsets with override

pp) Copy

qq) Reverse Cutting Path

rr) Background editor

ss) Management and shop reports

tt) Export reports directly to PDF, Excel Spreadsheets

uu) Automatic nesting

vv) Common line cutting

ww) Collision avoidance

xx) Chain and bridge cutting capability

yy) Skeleton cut-up capability

zz) The controller will also contain pre-programmed settings for the following materials:

a. Mild steel

b. HY-80

c. HY-100

d. Stainless steel

e. Aluminum

f. Copper/nickel

g. Monel

If items listed above are not part of the standard pre-programed library, the Contractor will work with the government to develop the appropriate settings and add to the library.

4.2.8 Maintenance Diagnostic System.

Maintenance diagnostics software shall be furnished either in the control or as a separate program that is compatible with the input media specified herein. The diagnostic software shall test, exercise, and display errors to assist maintenance personnel in the event of machine failure. The system shall monitor operating conditions and stop operations to prevent damage when malfunctions are detected.

4.2.9 Post Processor and Machine Definition.

The post processor shall provide a cutting and beveling file. The post processor shall include all files necessary to generate tool paths and output ASCII format NC files for all available functionality of the CNC Plasma/Oxy Fuel

Cutting System. Backup and restoration files of the machine parameters shall be provided and are to be delivered on removal media (i.e. compact disk, removable hard drive, USB, etc.) for storage.

4.2.10 Electronic Oxy Fuel Controls.

The following automated oxy fuel system operational features shall be provided under numerical control:

a) Proportional gas valve pressure control

b) High and Low flame settings to minimize fuel and oxygen consumption

c) Programmable initial height for preheat

d) Pierce rate control and ramping ability

4.2.11 Cutting Head/Torches.

The machine shall be provided with all cutting heads, torches, and components necessary to make the cutting systems complete.

4.2.12 Plasma Cutting Torches.

The plasma torch shall be outfitted with an automated ignition system and assist gas regulation controls. The operator shall also have the capability to adjust the automated features manually. The system shall be provided with any piping and regulators required for using the utilities identified in Table I. The system shall incorporate system protection or shielding from Radio Frequency (RF) inference internally generated by the plasma system installed on this machine. The additional following features and capabilities shall be provided:

a) Kerf compensation

b) Arc voltage digital display at operator’s station

c) Proximity sensors or equivalent on each cutting torch to detect and avoid a torch collision

d) Edge quality cutting requirements: Use of industry standard of ISO 9013 using the appropriate sections for the different materials to be cut

e) Automatic Torch Height Control (THC)

1. Sensor technology

2. Heavy duty ball screw

3. Linear guide bearings

4. Lifter stoke

f) Magnetic torch breakaway system

g) Quick change system for remote consumable change out on:

1. 3-Axis Torch

2. 5-Axis Torch

h) Bevel Plasma Torch includes

1. Bevel cutting ranging from 0 to 50 degrees from vertical

2. Required bevel types K, Y, V, and X

3. 5-Axis full contour

4. 360-Degree rotation without unwind sequence

5. Two harmonic drives

i) Plasma torch(s) spare parts and consumables shall be commercially and readily available.

4.2.13 Plasma Automatic Gas Console.

The cutting system shall utilize a fully automatic gas control console which allows the control unit to select the correct gas and flow for the process. Two (2) Hypertherm HPR-400 plasma power sources shall be provided for each gantry to ensure compatibility and commonality with existing equipment, and with the current range and duty cycle necessary to perform all cutting operations described in this PWS.

4.2.14 Oxy Fuel Cutting Torches.

The oxy fuel cutting torches shall be outfitted with an automated self-ignition system and gas regulation controls.

The operator shall also have the capability to adjust the automated features manually. The system shall be provided with any piping and regulators required for using the existing system manifolds and gas bottle storage racks that currently support the existing system. The additional following features and capabilities shall be provided:

a) Kerf compensation

b) Automatic Torch Height Control

c) Proximity sensors or equivalent on each cutting torch to detect and avoid a torch collision

d) Oxy fuel torch(s) spare parts and consumables shall be commercially and readily available.

e) Magnetic breakaway feature in the event of collision

1.1 Water Tables Compatibility

The Contractor shall ensure all systems provided, plasma and oxy fuel, are compatible with existing water table configuration. The Contractor shall provide information for acceptable water table fluid that prevents corrosion and bacteria growth that is compatible with all system provided.

4.2.15 Hydraulic System.

The hydraulics system shall conform to ISO 4413, and shall be complete, including all pumps, valves, piping, cylinders, and pressure controls including protection from over-pressurization.

4.2.16 Pneumatic System.

The pneumatic system shall conform to ISO 4414, and shall be complete, including all pumps, valves, piping, cylinders, and pressure controls including protection from over-pressurization.

4.2.17 Electrical System.

The existing electrical power source available at the installation site shown in Table I. Electrical connections made to the facility electrical system shall conform to NFPA 70. The machine shall conform to NFPA 79. All electrical components shall conform to applicable NEMA ICS 1 standards. The machine’s electrical system shall be tolerant of voltage fluctuation of ± 10 percent. The electrical system shall be complete, including transformers required to modify the existing source voltage to the proper operating voltage of the equipment. A properly rated and fused single disconnect device, controlling all electrical power to the equipment, shall be utilized on the machine with means of lockout in the off position only.

4.2.18 Motors.

Motors shall be rated for continuous duty and shall have ball or roller bearings of the sealed and permanently lubricated type. Alternating-current (AC) motors shall be designed to operate on 60-Hz and each motor enclosure shall meet the requirements for a drip-proof enclosure. All motors shall meet the requirements of NEMA MG-1.

Each motor shall have an identification plate to identify manufacturer, model identification, serial number, voltage, amperage, horsepower, phase, frequency and frame number. Motor horsepower shall be the manufacturer’s standard, unless otherwise specified herein.

4.2.19 Solid-State Components.

Solid-state design shall be employed throughout for electronic components. Use of selenium and other similar aging devices shall be permitted only in the application of voltage surge protection to other solid-state components. Solid-state components shall not be adversely affected when subjected to power line transients and surges typically experienced in industrial environments. Series and parallel connections of solid-state devices without forced sharing circuitry for voltage and current, respectively, is not permitted. Solid-state devices shall be capable of handling the electrical load imposed by operation of the machine to its maximum capability.

4.2.20 Electrical Enclosures.

Electrical components of the equipment shall be contained in enclosures of drip-proof construction and of minimum size consistent with good design practices and ventilation of components, meeting the requirements of NEMA 250

Type 12.

4.2.21 Power Tracks.

All flexible power lines, cables, conduits, and hoses necessary to connect the linear sliding, powered, assemblies to stationary utilities and controls are contained within a flexible power track arrangement. The contractor may reuse the existing flexible power tracks to contain the required hoses. All necessary flexible power lines, cables, and hoses shall be replaced with new equipment. Drawings of the existing power tracks and cable/conductor configurations are available upon requests from the contractor. All conductors shall be of sufficient length to allow full travel of connected components and shall be connected at both ends to junction boxes and manifolds in proximity to the track ends to facilitate replacement of conductors. Updated drawings of all conductors shall be provided. Installation of the power tracks in the overhead position is not allowed.

4.2.22 Hour Meter.

The CNC Plasma/Oxy fuel Cutting System is equipped with an analog hour meter mounted on the main electrical panel visible from the outside. The hour meter displays accumulated operating time of the main drive motor. The hour meter shall remain as installed and not be reset. The Government will record the hours when the system is removed from operation.

4.2.23 Size and Capacity

The size and capacity of the Machinery Repair on the Plasma/Oxy Fuel Cutting Center shall be not less the information detailed in Table II, unless otherwise stated.

Table II Size and Capacity

Work Tank Height From Finished Floor 32-36 inches

Material (Work Piece) To Be Cut Mild Carbon Steel, Stainless Steel, and Aluminum, HY-80, HY-100, Copper-Nickel, Monel

Material Size (maximum) 10 Ft. x 33 Ft.

Material Weight (maximum) 30,000 lbs.

Plasma Cutting Thickness – Straight (Mild Carbon

Steel)

0.1875-inch to 3-inches

Plasma Pierce – Mild Carbon Steel 2-inches

Plasma Pierce – Stainless Steel and Aluminum 1.75-inches

Plasma Cutting Thickness – K-Bevel (Mild Carbon

Steel)

½” landing +0” - .0625” at 22.5 to 25 degrees from center or 50 degrees total for material thickness of 2-

Table II Size and Capacity inches

Plasma Cut Bevel Range +/- 50 degrees

Plasma Cutting Torch Rotation Full 360 degrees without unwind sequence

Plasma Process Amps 30 amps to 400 amps

Oxy Fuel Cutting Thickness (maximum) 8 inches

Torch Vertical Lift Height (minimum) 9 inches

1.2 Speed and Accuracy Tolerances

The speed and accuracy tolerances of the Machinery Repair on the Plasma/Oxy Fuel Cutting Center shall be as specified in Table III.

Table III Speed and Accuracy

Cut Angle ISO Range 4-5 (1.68-3.34 deg; 3.35-5.33 deg)

Edge Tolerance 0.015-inch to 0.025-inch

Positioning Accuracy (maximum) 0.002-inch

Positioning Repeatability (maximum) 0.001-inch

4.3 Equipment.

The Contractor shall provide all necessary equipment to meet the requirements under this PWS. Equipment includes but is not limited to, truck and trailer for transportation, hand tools, lighting, testing apparatus, and computer; with exception of MHE as supplied through the government. Attachment A contains site specific information for

Contractor equipment.

4.3.1 Digital Media and Computer Equipment

The Contractor shall comply with all local PSNS & IMF requirements for contractor supplied computer and digital media necessary to complete the services in this PWS. The Contractor shall request the local PSNS & IMF requirements from COR.

4.3.2 Tools and Instrumentation

The Contractor shall provide all necessary tools and instrumentation to meet the requirements under this PWS.

PART 5

SPECIFIC TASKS

5. Specific Tasks:

The North Gantry (Serial Number: 100535 B) system and components within this PWS shall be completed first.

The Government intends to exercise an option to commence work required within this PWS on the South Gantry

(Serial Number: 100535 A) 60-days after the completion and Government acceptance of the North Gantry assuming suitable performance on the North Gantry Tasks and compliance with specifications listed. The work required within this PWS will comply with ISO 17916.2016, ANSI B11.0, ANSI B11.19, and ANSI B11.25.

5.1 North Gantry Tasks (Serial Number: 100535 B).

The Contractor shall provide services for the following tasks in support of the North Gantry repairs on the plasma and oxy fuel cutting center.

5.1.1 Engineer and Design to Repair Gantry Systems

The Contractor shall engineer and design system to complete the machine repair. The system is required to meet the size and capacities listed in Table II and accuracies listed in Table III. The Contractor shall ensure the gantry works with existing water tables. The system shall be compatible and complete to operate with the Government available utilities listed in Table I. The system shall meet the required quantity of torches and supporting infrastructure identified in Section 4. The Contractor shall perform the engineering and design repairs offsite at vendor facility.

5.1.2 Removal of North Gantry and Supplemental Components

The Contractor shall remove the North Gantry and all associated components needed for the repairs. The Contractor shall not remove the cutting tanks, unnecessary metal machine structures, and oxy fuel hand torch. The Contractor shall ensure the South Gantry machine remains operational and can be utilized on the South and Middle tanks.

The Contractor shall disconnect the CNC controller and the two plasma power units.