RFP 2031ZA20R00031 (PVD).pdf

SOLICITATION/CONTRACT/ORDER FOR COMMERCIAL ITEMS

OFFEROR TO COMPLETE BLOCKS 12, 17, 23, 24, & 30

1. REQUISITION NUMBER PAGE 1 OF

2. CONTRACT NO. 3. AWARD/EFFECTIVE

DATE

4. ORDER NUMBER 5. SOLICITATION NUMBER 6. SOLICITATION ISSUE

DATE

7. FOR SOLICITATION

INFORMATION CALL:

a. NAME b. TELEPHONE NUMBER (No collect calls)

8. OFFER DUE DATE/

LOCAL TIME

9. ISSUED BY

13b. RATING

14. METHOD OF SOLICITATION

CODE

15. DELIVER TO 16. ADMINISTERED BY CODE

18a. PAYMENT WILL BE MADE BY CODE17a. CONTRACTOR/

OFFEROR

CODE

FACILITY

CODE

CODE

TELEPHONE NO.

17b. CHECK IF REMITTANCE IS DIFFERENT AND PUT SUCH ADDRESS IN

OFFER

18b. SUBMIT INVOICES TO ADDRESS SHOWN IN BLOCK 18a UNLESS BLOCK

BELOW IS CHECKED

RFQ IFB RFP

SEE ADDENDUM

19.

ITEM NO.

20.

SCHEDULE OF SUPPLIES/SERVICES

21.

QUANTITY

22.

UNIT

23.

UNIT PRICE

24.

AMOUNT

(Use Reverse and/or Attach Additional Sheets as Necessary)

25. ACCOUNTING AND APPROPRIATION DATA 26. TOTAL AWARD AMOUNT (For Govt. Use Only)

28. CONTRACTOR IS REQUIRED TO SIGN THIS DOCUMENT AND RETURN

COPIES TO ISSUING OFFICE. CONTRACTOR AGREES TO FURNISH AND

DELIVER ALL ITEMS SET FORTH OR OTHERWISE IDENTIFIED ABOVE AND ON ANY

ADDITIONAL SHEETS SUBJECT TO THE TERMS AND CONDITIONS SPECIFIED

29. AWARD OF CONTRACT: REF. OFFER

DATED . . YOUR OFFER ON SOLICITATION

(BLOCK 5), INCLUDING ANY ADDITIONS OR CHANGES WHICH ARE

SET FORTH HEREIN, IS ACCEPTED AS TO ITEMS:

30a. SIGNATURE OF OFFEROR/CONTRACTOR

30b. NAME AND TITLE OF SIGNER (Type or print) 30c. DATE SIGNED

31a. UNITED STATES OF AMERICA (SIGNATURE OF CONTRACTING OFFICER)

31b. NAME OF CONTRACTING OFFICER (Type or print) 31c. DATE SIGNED

AUTHORIZED FOR LOCAL REPRODUCTION

PREVIOUS EDITION IS NOT USABLE

STANDARD FORM 1449 (REV. 2/2012)

Prescribed by GSA - FAR (48 CFR) 53.212

10. THIS ACQUISITION IS UNRESTRICTED OR

NAICS:

SIZE STANDARD:

13a. THIS CONTRACT IS A

RATED ORDER UNDER

DPAS (15 CFR 700)

SET ASIDE: % FOR:

11. DELIVERY FOR FOB DESTINA-

TION UNLESS BLOCK IS

MARKED

SEE SCHEDULE

12. DISCOUNT TERMS

ARE ARE NOT ATTACHED

ARE ARE NOT ATTACHED

27a. SOLICITATION INCORPORATES BY REFERENCE FAR 52.212-1, 52.212-4. FAR 52.212-3 AND 52.212-5 ARE ATTACHED. ADDENDA

27b. CONTRACT/PURCHASE ORDER INCORPORATES BY REFERENCE FAR 52.212-4. FAR 52.212-5 IS ATTACHED. ADDENDA

8 (A)

EDWOSB

WOMEN-OWNED SMALL BUSINESS

(WOSB) ELIGIBLE UNDER THE WOMEN-OWNED

SMALL BUSINESS PROGRAM

SERVICE-DISABLED

VETERAN-OWNED

SMALL BUSINESS

HUBZONE SMALL

BUSINESS

SMALL BUSINESS

2031ZA20R00031

VALERIE M. CATLETT 202-874-0861

2031ZA

See Schedule

2031ZA

BEP-ACQUISITION

Bureau of Engraving and Printing Washington, DC 20228-0001

BEP-OFM

Bureau of Engraving and Printing Office of Financial Management 301 14th Street SW Washington, DC 20228-0001

Physical Vapor Deposition (PVD) Coating Systems Please see RFP for additional information

333244

07/30/2020

08/20/2020

2:00PM ET

BEP-ACQUISITION

Bureau of Engraving and Printing Office of Acquisition 301 14th Street SW Washington, DC 20228-0001

2031FY

STANDARD FORM 1449 (REV. 2/2012) BACK

19.

ITEM NO.

20.

SCHEDULE OF SUPPLIES/SERVICES

21.

QUANTITY

22.

UNIT

23.

UNIT PRICE

24.

AMOUNT

32a. QUANTITY IN COLUMN 21 HAS BEEN

RECEIVED INSPECTED ACCEPTED, AND CONFORMS TO THE CONTRACT, EXCEPT AS NOTED:

41a. I CERTIFY THIS ACCOUNT IS CORRECT AND PROPER FOR PAYMENT

32b. SIGNATURE OF AUTHORIZED GOVERNMENT

REPRESENTATIVE

32c. DATE

41b. SIGNATURE AND TITLE OF CERTIFYING OFFICER 41c. DATE

42a. RECEIVED BY (Print)

42b. RECEIVED AT (Location)

42c. DATE REC'D (YY/MM/DD) 42d. TOTAL CONTAINERS

40. PAID BY

32d. PRINTED NAME AND TITLE OF AUTHORIZED GOVERNMENT

REPRESENTATIVE

32e. MAILING ADDRESS OF AUTHORIZED GOVERNMENT REPRESENTATIVE 32f. TELPHONE NUMBER OF AUTHORZED GOVERNMENT REPRESENTATIVE

32g. E-MAIL OF AUTHORIZED GOVERNMENT REPRESENTATIVE

33. SHIP NUMBER 34. VOUCHER NUMBER 35. AMOUNT VERIFIED

CORRECT FOR

PARTIAL FINAL

37. CHECK NUMBER

38. S/R ACCOUNT NO. 39. S/R VOUCHER NUMBER

36. PAYMENT

COMPLETE PARTIAL FINAL

2 2031ZA20R00031

Bureau of Engraving and Printing

SECTION B – SUPPLIES OR SERVICES AND PRICES/COSTS

The contractor shall provide facilities, labor, materials, fabrication, assembly, delivery, and all other efforts necessary for a turn-key installation and operation of Physical Vapor Deposition (PVD) Coating systems to electro-formed nickel Intaglio printing plates in accordance with Section C of this document, for the Bureau of Engraving and Printing (BEP).

This requirement will result in a firm fixed price contract for new equipment. Contractor shall provide one (1) PVD Coating System, with the option to purchase up to three (3) additional PVD’s.

Offeror is required to submit, at a minimum, an offer that conforms to the solicitation specifications with pricing for all Contract Line Item Numbers (CLINs). Contractor shall price each individual CLIN on a firm fixed price basis. Failure to submit an offer which conforms to the solicitation specification may render the proposal unacceptable. The Government will negotiate payments based on the deliverable schedule submitted by the contractor and agreed to by the Government.

PVD #1

CLIN SUPPLIES/SERVICES QUANTITY UNIT OF

MEASURE

UNIT PRICE AMOUNT

0001 Physical Vapor Deposition (PVD) Coating System (DCF)

1 EA

0002 Factory Inspection Testing (C.3.3.11)

1 EA

0003 Installation and Bureau Acceptance Testing (C.3.3.11)

1 EA

0004 Technical Support (C.3.3.12) 1 EA

0005 Contractor Provided Materials (C.3.3.14)

1 EA

0006 Spare Parts (C.4.2) NTE $58,000

0007 Travel The BEP will only pay for actual cost. All travel shall be in accordance with Federal Travel Regulations. (See Section H.37, Travel Costs)

NTE

0008 Training (C.3.3.10) 1 EA

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OPTIONAL PVD #2

CLIN SUPPLIES/SERVICES QUANTITY UNIT OF

MEASURE

UNIT PRICE AMOUNT

1001 Physical Vapor Deposition (PVD) Coating System

(WCF)

1 EA

1002 Factory Inspection Testing (C.3.3.11)

1 EA

1003 Installation and Bureau Acceptance Testing (C.3.3.11)

EA

1004 Spare Parts (C.4.2.) NTE $61,550

1005 Travel The BEP will only pay for actual cost. All travel shall be in accordance with Federal Travel Regulations. (See Section H.37, Travel Costs)

1006 Training (C.3.3.10) 1 EA

OPTIONAL PVD #3

MEASURE

UNIT PRICE AMOUNT

2001 Physical Vapor Deposition (PVD) Coating System #3

(WCF)

1 EA

2002 Factory Inspection Testing (C.3.3.11)

1 EA

2003 Installation and Bureau Acceptance Testing (C.3.3.11)

1 EA

2004 Spare Parts (C.4.2) NTE $62,781

2005 Travel The BEP will only pay for actual cost. All travel shall be in accordance with Federal Travel Regulations. (See Section H.37, Travel Costs)

2006 Training (C.3.3.10) 1 EA

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OPTIONAL PVD #4

MEASURE

UNIT PRICE AMOUNT

3001 Physical Vapor Deposition (PVD) Coating System #4

(DCF)

1 EA

3002 Factory Inspection Testing (C.3.3.11)

1 EA

3003 Installation and Bureau Acceptance Testing (C.3.3.11)

1 EA

3004 Spare Parts (C.4.2) NTE $64,037

3005 Travel The BEP will only pay for actual cost. All travel shall be in accordance with Federal Travel Regulations. (See Section H.37, Travel Costs)

3006 Training (C.3.3.10) 1 EA

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SECTION C – DESCRIPTION/SPECIFICATIONS/STATEMENT OF NEED

C.1 STATEMENT OF WORK

The BEP intends to procure one (1) PVD system with the option to procure three (3) additional systems. The first system will be installed at the BEP’s Washington, DC Currency Facility (DCF).

Optional systems will be installed at either the Western Currency Facility (WCF) located in Fort Worth, Texas or in the existing Washington, DC facility or at a future DC location.

This Statement of Work (SOW) is for the fabrication, assembly, delivery, installation, set-up, testing, commissioning and training for a Physical Vapor Deposition (PVD) Coating System that will apply a uniform protective coating, primarily chromium, to electro-formed nickel intaglio printing plates. All peripheral systems necessary to support this system (i.e. vacuum pumps, filtering systems, etc.) shall be provided. Additionally, the contractor shall provide remote and on-site technical support for the optimization of the PVD process during the first year of operation.

C.2 REFERENCES

The following are referenced under this contract; Documents, Government Furnished Materials (GFM) and Product Requirements. The equipment and services to be provided under this contract shall adhere to the requirements of these referenced materials.

C.2.1 DOCUMENTS

C.2.1.1 Non-Disclosure Agreement During the course of this contract, the contractor will require sensitive but unclassified information that is proprietary to the United States Government. A Non-Disclosure Agreement (NDA) shall be signed as part of the contract (Attachment A).

C.2.1.2 Referenced Documents Equipment to be delivered under this contract shall meet all current U.S. commercial codes and industrial standards, or equally stringent international standards, for manufacturing of high quality industrial equipment, commercial printing presses and finishing equipment to be utilized within an industrial environment. At a minimum, all equipment shall conform to National Electric Code (NEC) standards.

The following is a listing of specific standards that machinery supplied under this contract shall meet:

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• All applicable sections of American Conference of Government Industrial Hygienists (ACGIH) (www.acgih.org)

• All applicable documents related to Energy Policy Act of 1992 with specific reference to Executive Order 13123 (www.omb.gov)

• All applicable Occupational Safety and Health Administration (OSHA) standards with specific references to OSHA standards 29 CFR 1910 (www.osha.gov)

• All applicable codes and standards and environmental permitting of U.S.

Environmental Protection Agency (EPA) (www.epa.gov) and District of Columbia (DC) government (www.doee.dc.gov) and State of Texas (TX) government (www.tceq.texas.gov).

C.2.1.3 Attached Documents The following lists the documents attached to this SOW.

NOTE – Attachments identified with an asterisk (*) require a Non-Disclosure Agreement (NDA).

All NDA documents provided under this contract shall be considered proprietary and sensitive to the government. NDA documents shall not be copied, scanned or reproduced without written approval by the Contracting Officer. All NDA documents shall be returned to the BEP when no longer required.

NOTE – Some documents will only be made available in redacted versions. Request to have copies of the original versions must be made to the Contracting Officer with information on why the information is required.

Identifier Title/Description

B Plate Drawings*

C Facility Layout*

D IT Computer Attachments

DOJ Ref Mapping PIVCard Certificates to a Privileged Account Open Version

FIPS-PUB-199-final NIST.SP.800-53r4 USGCB-Windows-Settings

E Environmental and Safety Attachments

75D-07.0-04 EHS Contractor Requirements at DCF 75B-07.0-05 EHS Requirements for Purchased Materials at DCF 75D-07.0-06 EHS Requirements for Large Equipment Purchases http://www.acgih.org/ http://www.omb.gov/ http://www.osha.gov/ http://www.epa.gov/

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75D-07.0-07 Restricted Materials at DCF 75DW-08.0-02 EHS Contractor Requirements at WCF 75W-08.0-04 Restricted Materials at WCF

F Draft PVD Test Plan

C.2.2 GOVERNMENT FURNISHED MATERIALS

The BEP will provide uncoated electro-formed nickel intaglio printing plates. See Attachment B.

Any other materials required for successful operation of the equipment shall be specified by the contractor see C.3.3.14 - CONTRACTOR PROVIDED MATERIALS.

C.3 SYSTEM REQUIREMENTS

The following are the requirements of the PVD Coating System to be delivered to the BEP. The PVD Coating System shall consist of a machine capable of applying a protective coating, primarily chromium, utilizing Physical Vapor Deposition (PVD). All auxiliary or support equipment required for the PVD Coating System to perform shall be provided by the contractor with the system. The PVD Coating System shall utilize the Government Furnished Materials (GFM) (C.2.2) and produce finished plates.

C.3.1 SYSTEM FUNCTIONALITY

The PVD Coating System shall have the following functional capabilities:

C.3.1.1 Safety Requirements (Mandatory Minimum Element)

All equipment delivered to the BEP shall be designed to minimize all risks of injury to BEP employees. Furthermore, all equipment shall be in full compliance with government and commercial safety and health regulations and requirements. The following are specific safety and environmental requirements for major production machinery for the BEP.

(A) General Safety - Equipment shall be designed to prevent injury to operation and maintenance personnel at all times. Equipment shall be equipped with service access equipment; such as, catwalks, access platforms, access ladders, lifts, and other equipment for operation and maintenance. Fixed stairs shall be provided in compliance with OSHA 29CFR 1910.24, Fixed Industrial Stairs. All catwalks, access platforms, access ladders, lifts, hoists, and any other equipment that are furnished, shall be built and tested to comply with ANSI and OSHA standards.

Special attention shall be given in providing proper ‘angle of steps’ as indicated in paragraph (e)

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of the referenced standard. All press and service access equipment shall be guarded as required by applicable portions of OSHA Regulations.

B) Noise Level – The maximum noise produced by the operation of the equipment at full production rate shall not exceed 85 decibels A-weighted sound level (85 dBA) when measured at 914 mm (3 feet) distance along the plan view of the equipment and at an elevation of 1,524 mm (5 feet). These noise level limits do not affect the warning horn levels described in C.3.2.3.

(C) Machine Guarding – All covers and safety guards shall be interlocked with the equipment’s controls to prevent its operation while any cover or guard is open or absent. The location of opened switches shall be displayed on the Master Control Station. Only local jogging control at a reduced speed is allowable provided no other covers are opened or removed. Covers and guards shall be manufactured for easy removal by Bureau personnel to facilitate removing mechanical and electrical parts for repair. All rotating and reciprocating parts shall be guarded as specified by OSHA regulation 29 CFR 2910.212. All equipment and service access panels shall be guarded as required by applicable portions of OSHA Regulations.

(D) Mechanical Entrapment Response Procedures – The manufacturer shall provide mechanical entrapment response procedures for the emergency release of persons trapped in machinery. Training on the procedures shall also be provided. This requirement applies to equipment that has any potential entrapment point(s) where hands, fingers or any other body parts could become caught between moving parts.

(E) Sharp Edges – All sharp edges and corners, which present personnel hazards, shall be guarded or padded.

(F) Heated Surfaces – Prevent heated surfaces from causing burns to personnel during operation.

(G) Prohibited Materials – Some materials shall not be used in the equipment. These materials are noted in 75D-07.0-07 Restricted Materials at DCF and 75W-08.0-04 Restricted Materials at WCF . (Attachment E)

(H) Hazardous Emissions – Operation of the equipment shall not result in worker exposure to airborne contaminations exceeding current maximum allowable concentrations established by (OSHA) and the American Conference of Governmental Industrial Hygienists (ACGIH) standards. When the standards differ, the most stringent shall apply.

(I) Equipment Locking Arrangement – The equipment shall be equipped with a locking arrangement that will prevent unauthorized manual or power operation. An electrical interlock shall be provided to prevent accidental starting with the mechanical lock engaged.

(J) Safety Data Sheets – Safety Data Sheets (SDS) for all contractor supplied and specified chemicals that are part of the process shall be supplied by the contractor to the BEP’s WCF EHS Branch or DCF (OEHS) Office of Environmental, Health and Safety prior to their bringing the

9 2031ZA20R00031

material onto the respective site. The SDS shall comply with the OSHA, as listed in standard 29 CFR 1910.1200, with particular emphasis on paragraphs (g) and (i).

(K) Overload Protection – Equipment shall be equipped with overload protection and power factor correction devices to prevent damage to its components and operating personnel.

(L) Safe-Ready – All control stations shall include a "safe-ready" collar or equivalent. Upon turning the collar to the safe position, it shall be impossible to start the machine from any other station. Console shall indicate that the particular interlock including emergency stop buttons causes the machine to start or not.

(M) Emergency Stop – An Emergency Stop may be initiated due to the machine’s internal control logic detecting an emergency situation, activation of personnel safety devices (i.e. safety curtains, cover interlocks or other devices designed to protect personnel), or by personnel manually activating an Emergency Stop Button.

Emergency Stop Buttons shall be provided at strategic locations, including any drive side of the machinery in the areas of the drive motors and delivery, to minimize the time required to reach them. Emergency Stop Buttons shall be of the pronounced mushroom type, red in color, with no raised guards to prevent accidental depression. Emergency stop buttons shall remain activated once depressed until manually reset.

(N) Inching Interlock – Whenever an inching of the machine occurs, only the control station from where the inch was performed shall be able to cause the machine to move until the safe-ready is activated and deactivated.

(O) Energy Isolation – Disconnect or lockout devices shall be provided and identified with signage for all sources of energy on the machine. This includes electrical, hydraulic, pneumatic, and kinetic sources of energy. All isolating devices (levers, breakers, valves, etc.) for all associated energy sources (electrical, hydraulics, pneumatics, gravity, etc.) shall be identified by a color coded tag which indicates the type of energy source, the magnitude of the energy and an ID number. All isolating devices shall be capable of being locked out with a standard locking device and/or padlock. Stored sources of energy such as pneumatic and hydraulic forces shall be automatically bled and returned to a zero energy state when an interlocked device (i.e. a guard or a door) is opened.

(P) UV Curing/Exposing Equipment – All equipment with ultraviolet radiation systems shall be designed such that no operator is exposed at or above permissible threshold levels established by the ACGIH.

(Q) Hydraulic and Pneumatic Systems – All hydraulic and/or pneumatic systems shall have functional isolation, i.e., when part of a system is operating, no other part of the system shall be adversely affected by pressure drop, flow transients, etc. All hydraulic and pneumatic equipment

10 2031ZA20R00031

employed in the system shall conform to the Joint Industrial Council (JIC) standards. Hydraulic and pneumatic pumps shall be energy efficient.

(R) Laser Systems – All equipment with laser systems shall comply with the latest version of the Laser Institute of America’s ANSI-Z136.1 standard, American National Standard for Safe Use of Lasers, and 21 CFR 1040 and shall be designed such that no operator is exposed at or above permissible threshold levels established by the ACGIH.

(S) Illumination – Machine areas requiring regular operational or maintenance activities shall include illumination of at least 20 foot-candles of luminance by the equipment manufacturer, in accordance with the latest version of ANSI RP-7.

(T) Industrial Ventilation – Equipment which emits airborne contaminants which exceed permissible exposure concentrations as established by OSHA, ACGIH and National Institute of Occupational Safety and Health (NIOSH) shall be equipped with local exhaust ventilation (LEV).

LEV shall be designed in accordance with the ACGIH Industrial Ventilation: A Manual of Recommended Practice for Design, (latest edition). All industrial ventilation system parameters and design shall comply with the OSHA Ventilation Standard, 29 CFR 1910.94.

(U) Material Handling Assistance – The equipment shall include ergonomic lifting aids for any lifting of more than 32 pounds by the operators.

C.3.1.2 Environmental Protection (Mandatory Minimum Element) All equipment installed at the Bureau shall meet all local, state, and federal environmental regulations. Including but not limited to air quality, industrial solid waste, hazardous waste, and wastewater.

The equipment installed at the Bureau shall comply with the following regulations:

• Federal Regulation: Environmental Protection Agency, EPA Clean Air Act Amendments of 1990, Section 112-Air Toxics (http://www.epa.gov/air/oaq_caa.html);

• 40 CFR 403-General Pretreatment Regulations for Existing and New Sources of Pollution (http://www.epa.gov/docs/epacfr40/chapt-I.info/subch-N.htm);

• 30 TAC (Texas Administrative Code) - Chapters 101, 115, and 116 for Air Quality Rules and air permitting

• City of Fort Worth Code – Chapter 12.5 for Industrial Wastewater

• 30 TAC – Chapter 335 for Industrial Solid Waste and Municipal Hazardous Waste

C.3.1.3 Plating Size Capability The system shall have the capability of processing variable plates up to a maximum size of 870 mm wide by 860 mm long (34.25” by 33.85”). See Attachment B.

http://www.epa.gov/air/oaq_caa.html http://www.epa.gov/docs/epacfr40/chapt-I.info/subch-N.htm

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C.3.1.4 Coating Thickness and Uniformity

The PVD Coating System shall be capable of applying a protective coating of a minimum thickness of 2 micron (0.002 mm) with a uniformity across the plate of +/- 1 micron. The coating shall be free from particulates or contaminants.

C.3.1.5 Coating Materials

The PVD Coating System shall be capable of applying chromium and/or chromium-nitride coatings to plates. The ability to apply other materials is desired (i.e. Titanium).

C.3.1.6 Processing Rate

The PVD Coating System shall demonstrate a minimum processing rate of fifteen (15) plates with at least 2 micron coating within an five (5) eight (8) hour operational shifts.

The system shall be capable of running overnight without operator supervision. Day shift personnel will load, initiate program and return the next day to remove finished plate(s).

Each system shall include at least two (2) additional plate fixtures to preload plates for coating.

C.3.1.7 Coating Programs (Recipes)

The PVD Coating System shall allow the operator to select from a menu of programs (recipes) depending on substrate. At a minimum, the system shall allow for the creation and storage of at least fifty (50) programs (recipes).

The system shall only allow BEP personnel with the proper BEP defined permission to create, modify and/or store recipes to the system.

Individual recipes shall allow for differences in the hardness, thickness and composition of the chrome plating applied to the plates to optimize the longevity of the plate in operation.

C.3.1.8 Unscheduled Maintenance

An unscheduled corrective maintenance event is considered any time maintenance personnel must be called by the operators or when the machine is unable to operate within conformance to the product, functional or performance requirements for more than fifteen (15) minutes.

The mean time between unscheduled corrective maintenance is defined as the Mean-Time- Between-Failure (MTBF). The PVD Coating System shall be designed for a MTBF of components of at least 150 hours. The MTBF will be measured during the extended operation of the system after Bureau Acceptance Test (BAT) and Training.

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The mean time required to perform corrective maintenance on the system is defined as the Mean- Time-To-Repair (MTTR). The machine shall have a MTTR of less than 2 hours. The MTTR will be measured during the extended operation of the system after BAT and Training. If during the extended operation of the system, the system fails to successfully demonstrate the required MTTR, the contractor shall make any and all corrective actions necessary to decrease the time required to perform maintenance or repair activities.

C.3.1.9 Fault Recovery

The PVD Coating System shall detect whenever a fault or error occurs that would cause damage to the equipment, produce unsatisfactory product or operation would pose a safety hazard to personnel. The machine shall take appropriate actions when a fault is detected to stop and notify the operators. The machine shall display specific detailed information on operator stations for trained operators to locate and take corrective actions to correct the fault.

The machine shall have provision to recover from all faults. A fault shall not create a hazard to personnel.

If the operator determines that product was damaged or unacceptable for further processing from an error/jam, the machine shall allow the operator to remove the product from the production stream.

The contractor shall provide detailed plans on each operator station detailing the step-by-step activities the corrective actions required to correct the fault condition and return to production.

C.3.1.10 Preventative Maintenance

The yearly average for time utilized for preventative maintenance on the system shall not exceed 3% of the operational time for the system. Major components shall have a Mean Time Between Maintenance (MTBM) of no less than 250 plates.

All Preventative Maintenance work shall be detailed within the Maintenance Manual, including all check-lists, procedures and recommendation for the time to perform based on a single 8 hour production shift over five days.

C.3.1.11 Manning The PVD Coating System shall require the labor of no more than one (1) individual to prepare, load and unload plates.

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C.3.2 DESIGN REQUIREMENTS

The following are the design requirements for the PVD Coating System:

C.3.2.1 System Life (Mandatory Minimum Element)

The PVD Coating System shall have a service life of not less than twenty (20) years, 240 working days per year, 1 twelve (12) hour operation per day. It is anticipated that the BEP will operate the equipment for one (1) – eight (8) to twelve (12) hour shift per day, four to five days per week.

C.3.2.2 Production Site

The machine shall meet the following requirements:

(A) Size – See Attachment C drawing for DCF site location.

The area provided shall be sufficient for the operation and maintenance of the equipment including material handling based upon maximum production rate. Access to any area of the equipment to support part replacement shall not be less than 36” (915mm); Contractor is to propose layout of the system within the designated area.

(B) Ambient Conditions – Machinery shall be designed for normal operations under the following ambient conditions at the installation site:

• Temperature: 72 +/- 3 oF (22.8 +/- 1.7 oC) (WCF is held to +/- 2 oF)

• Relative Humidity: 50 +/- 5 %

(C) Utilities – The equipment shall operate with the following BEP provided utilities:

• Electrical power: 480 volts, 3 phase, 60 hertz, four wire alternating current

• Compressed Air: (DCF) 94 psig, Max dew point of 37.4 F, Max oil content is below

0.1 mg/m3, filtered to 1.0 micron; (WCF) 120 psig, maximum oil content is below

0.01 ppm, filtered at 0.1 microns

The contractor shall provide and install devices such as, transformers, filters, dryers, surge suppressors, etc., to make these BEP provided utilities compatible with proper functioning and operation of the system. The contractor shall be responsible for utilities connections from disconnect points. The BEP will furnish all utilities to within 6 meters (20 feet) of the installation site for the machine. The utilities shall be connected overhead.

(D) On-Grade Installation – The machine shall be installed on a flat slab. It shall be designed to use no trenches, pits, floor covers or decking. Piping and wiring shall be connected internally in the system, and as necessary, routed via overhead troughs.

(E) Floor Loading/Vibration – The vibration produced by the operation of the machine at any speed within the specified limits and its impact to the building shall be minimized. Vibration

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isolation devices shall be provided to prevent vibrations from entering the facility. The maximum floor loading shall not exceed 200 pounds per square foot.

C.3.2.3 Control Stations

Control stations shall be provided at all strategic locations to maximize the safe and efficient operation of the machine. All controls shall be clearly and permanently marked in English or universally recognized symbols. Each control station shall include emergency stop and stop-and-lock buttons.

C.3.2.4 IT Components, Configurations and Controls

All computers provided shall be in compliance with the following as applicable:

(A) Managing Cybersecurity Risks – BEP reserves the right to request the Contractor provide information related to the non-embedded IT components and how the Contractor solution may be configured or implemented for supporting management of cyber risks in accordance with FAR 39.10; compliance with Federal Information Security Management Act (FISMA) (44 U.S.C.

3544); OMB’s implementing policies including Appendix III of OMB Circular A-130; and guidance and standards from the Department of Commerce’s National Institute of Standards and Technology (NIST). To assist with scoping, BEP has identified the following Federal Information Processing Standards (FIPS) that are applicable to the non-embedded IT components that may be present within the Contractor solution:

• FIPS 200: Minimum Security Requirements for Federal Information and Information Systems for a FIPS 199 LOW Baseline system (Reference:

http://csrc.nist.gov/publications/PubsFIPS.html);

• FIPS 201-2: Personal Identification Verification (PIV) of Federal Employees and Contractors; and

• (Attachment D)

(B) Operating Systems (OS) and Third Party Applications (TPA) – For host operating systems (OS) of non-embedded IT components, the components shall utilize software under mainstream support by the OS Contractor. For example, if the OS is Microsoft Windows Workstation, then the solution must use a version of the operating system that is still supported by Microsoft. Similarly, if the OS is Linux based, then the solution must use a version that is actively supported by the distribution being utilized (e.g. RedHat, SUSE, Debian, etc).

The OS shall be configured using the configuration standards in accordance with NIST SP 800-70 Rev 3. Relevant configuration standards are found at <https://web.nvd.nist.gov/view/ncp/repository> with preference given to Tier 3 and 4 (SCAP

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validated) configuration standards with the exception that Windows 7 may only utilize the US Government Security Baseline (USGCB).

BEP recognizes that the configuration standards may not be compatible with full system functionality. To this end, the Contractor shall identify the standard selected for the OS and document any deviations from the standard required for normal operations. The Contractor shall provide baseline deviations as part of the response package or within agreed upon number of days after contract award to provide sufficient time to assess and coordinate remediation actions to minimize impact to contract schedules and efforts. The requested deviation(s) shall include the justification for the need to deviate from the setting, and identify any risk mitigation either existing or planned to compensate for the deviation. BEP IT Security shall review all deviation requests and make a risk-based determination to allow or reject the request. Depending on the associated risk level for rejected deviation requests, the Contractor shall address the rejected deviation requests prior to or during the first maintenance period after system deployment.

For third-party applications (TPA) running on non-embedded IT components, the components shall utilize software under mainstream support by the TPA Contractor. For example, if the solution required the use of Microsoft Office, then the solution must use a version of Microsoft Office that is still supported by Microsoft.

For third-party hardware and peripherals of non-embedded IT components, the components shall utilize hardware and peripherals that are supported and maintained by the third-party equipment or hardware Contractor. This shall include being able to obtain replacement or spare parts for the components from the Contractor.

For components identified as obsolete, the contractor shall coordinate the replacement or upgrade such that the process is completed a minimum of 6 months prior to the expected date of obsolescence. For these special cases, the contractor shall provide the procedures to execute in order to perform the replacement or upgrade or the identified obsolete component(s) and return the system to operational capacity.

Obsolete shall be interpreted as no longer supported by the hardware or software Contractors or third-parties to include but not limited to hardware components no longer being manufactured, or software end-of-life.

Computer systems located in production or hazardous areas shall be housed in NEMA-12 rated enclosures to protect equipment from dust (and splashing liquid).

(C) Standard Operating Processes/Procedures – Non-embedded IT hardware and software components shall be included in the overall equipment preventive and operational maintenance (O&M) processes and schedules to include replacing or upgrade obsolete and worn components.

For normal hardware and software preventive and O&M processes, the contractor shall provide standard operating procedures (SOPs) that include, at a minimum, the procedures for backup and

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recovery, installation and configuration of TPA’s, and the deployment patches and updates for the OS and TPA’s.

Notes: For workstation-class components, backup processes may leverage the BEP Acronis application to make images of system and data drives. For server-class components, backup processes may leverage the enterprise commvault backup services.

(D) Network Connection – All components attached to the BEP Local Area Network (LAN) shall support Gigabit Ethernet (10/100/1000Mb/sec) and TCP/IP protocols. Network interface cards (NIC) shall support 10/100/1000Base-Tx/RJ-45 connections. If utilized, Simple Network Management Protocol (SNMP) enabled equipment shall support SNMPv.3.

All physical network connections and addressing to and from the BEP network (not within networks of embedded systems) shall be initiated and maintained by the Office of Information Technology (IT) Operations. The Contractor may assume that they will be provided IP addresses within the same class C network for connectivity to the BEP Network. If a secondary, internal network is used, the contractor shall not utilize addresses in the 10.0.0.0/8 range but shall use IP addresses that are compliant with RFC 1918 for IPv4/IPv6 addresses. The contractor will coordinate with OITO on this address space assignment to verify that the addresses and networking configuration do not conflict with existing network configurations. In accordance with BEP Directives, this acquisition requires all functionality, capabilities and features of non-embedded IT components to be supported and operational in both a dual-stack IPv4/IPv6 environment and an IPv6 only environment. Any IT component or system utilizing a second internal network for connecting to a machine network must use a separate NIC for such a connection and is considered an embedded IT component or system; as such this component is exempt from the “IPv6 only” requirement as it relates to this separate NIC because the machine network may use “IPv4 only” or a proprietary protocol.

(E) Database Connection – The Contractor solution shall provide for the ability to send data to the BEP Database management systems (DBMS). The DBMS is currently Oracle version 12.1 as of this writing. The Contractor solution shall support data transfers to Oracle 12.1 or later;

and shall be Open Database Connectivity (ODBC) compliant.

(F) Backup and Recovery – All production systems shall be specified with backup and recovery mechanisms and standard operating procedures. The contractor shall provide SOP and support to allow BEP to establish at a minimum backups capability consisting of at least three separate backups, Grandfather, father, son; two (2) copies of each backup, one of on-site storage and one for off-site storage; store on non-volatile media. The contractor shall assume that BEP is responsible for coordinating the storage of the off-site backups.

(G) Fault Tolerant System Design – All Computer systems critical to the continuous operation of the equipment (i.e. the equipment will not operate without it running) whether internal or external to the equipment, should have some form of high availability built in to the design of the systems. High Availability describes a computer system or component designed in a manner to

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maintain a high degree of uptime and ease system restoration in a failure. Specifically, systems are designed in a way to ease the replacement of entire systems or system components in the event of a failure. (i.e. hard drives are easily accessible and replaceable; computer systems are easily accessible for inspection or replacement).

C.3.2.5 General Electronic and Electrical Requirements

All electronic and electrical components, especially Programmable Logic Controllers (PLCs), network communications hardware and any embedded computers, shall be of the latest version available on date of fabrication of the systems. All components shall be commercially available within the United States. All motors shall be of Alternating Current (AC) design unless individually approved by the Contracting Officer’s Representative (COR).

Control of the machine shall be performed via Programmable Logic Controllers (PLC) or industrial rated Personal Computers (PCs). The model of PLC used on the machine shall be uniform. The PLC shall be commercially available and supported within the United States. Communication ports shall allow access of a programming panel and peripheral devices such as modem, printer, and Programmer Interrogator (PI).

The power supply(s) shall contain circuitry for the orderly shutdown of the machine in the event that the incoming power does not meet the requirements. The power supply shall be capable of operation with voltages +/-15% of the normal supply. The machine shall be capable of restarting following return of the power to normal supply without problems or resetting. An Uninterrupted Power Supply (UPS) shall be provided on the machine for all computers and control systems to ensure against the loss of data or operational setting during power variations.

All electrical and electronic components shall be designed to operate in an industrial environment without the use of external fans, air conditioning, or electrical filtering. All electronics shall be free from undue electromagnetic radiation and shall be unaffected by normal emissions The electrical system shall be capable of handling Radio Frequency Interference (RFI) surges of one

(1) KV peak to peak with a pulse frequency of less than 10 KHz.

PLC Programs shall be stored in non-volatile memory. All program memory of the machine shall be protected from loss during power interruption. All data shall be retained during loss, spikes or dips in power supply. Data retention shall be provided for a minimum of 14 calendar days. Key type protection or software password protection shall be provided to ensure software memory protection from unauthorized changes, access, or deletion.

All controllers shall perform internal error checking to ensure reliable data transfer. Detection of internal communication faults shall occur via watchdog timers. In the event that a communication fault is detected, then controllers shall turn off all outputs (i.e., fail-safe). Indication lights shall be provided at all diagnostic points. All Input/Output modules shall have lighted status indicators.

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To the maximum extent possible, all software programs shall be commercially available. All programs shall include sufficient documentation to allow maintenance personnel to debug the program. All software to modify, install, or perform diagnostic on the operating software shall be furnished with the machine. All software comments shall be in English language.

Configurations settings, randomly determined sampling plans, counters and other operational variables shall not be lost when the equipment is shut down, rebooted, re-initialized or a general reset of the electronics occurs. The machine shall retain knowledge of the configuration settings, sampling, counters and other variables to enable a return to operation in the quickest possible time.

LED lighting shall be from commercially acceptable fixtures for their intended locations. Lighting shall be provided at all points where fine adjustments are to be performed. A minimum lighting of 1076.4 lumens per square meter (100 foot-candles) on these working areas shall be provided with 5000 degree K light color. Individual switches to control these lamps shall be provided. The lights shall be operable without powering on the system.

Lighting provided for the purpose of manual inspection of product shall be in accordance with Commission International de l’Eclairage (CIE) Standard D65 for daylight as specified in American Society for Testing and Materials (ASTM) Standard D1729. All light fixtures and bulbs shall be in standard sizes available in the United States.

All components such as power rectification equipment, control components, etc., shall be mounted on the back panel of the electrical cabinet and not on the sides or the doors of the electrical cabinet for easy access and safety. Mounting of power supplies on the bottom of cabinets is allowable.

C.3.2.6 Uniformity

All equipment delivered to the BEP under the terms of this contract shall be of the same type, model, software version etc. Any changes that are made to the machine or support systems, including software shall be retrofitted onto previously accepted system(s) under this contract. The installation of changes on a machine previously accepted shall not occur until after the change has been proven during a BEP Acceptance Test.

C.3.2.7 Component Access Components that require regular service, such as motors, pumps, etc., shall be located to facilitate maintenance and repair. Access to these parts shall not take more than 15 minutes by no more than two (2) persons. All enclosures, which conceal gears, shafts, bearings, etc., shall be accessible without the requirement of dismantling or removing of sub-units or components.

Sub-assemblies that require frequent adjustment, maintenance, replacement and repair, shall be of modular design to facilitate easy and quick replacement.

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C.3.2.8 General Design and Construction Requirements

(A) Bearings – Bearings shall be selected to a minimum American Antifriction Bearing Manufacturers Association (AABMA) L10 life of fifty thousand (50,000) hours. Bearing load capacity, including applicable safety and life factors as recommended by the bearings manufacturer, shall be equal to or greater than the maximum bearing load under specified operating conditions of the system.

(B) Castings – All castings shall be of uniform quality, free of blowholes, porosity, hard spots, shrinkage defects, cracks, or other injurious defects. Materials, strength, and other physical properties of castings shall be adequate for the intended use. Under no circumstances shall a defective casting be used.

(C) Welding, Brazing and Soldering – Welding, brazing, and soldering shall be performed in accordance with American Welding Society (AWS) standards and codes. These operations shall not be employed as repair measures for defective parts.

(D) Surface Treatments – All equipment surfaces subject to rust, corrosion, galvanic action, or other deterioration shall have an appropriate protective treatment (surface finish) such as painting, plating, lacquering, anodizing, etc. This treatment shall be done in accordance with American Society for Testing and Materials (ASTM) standards.

(E) Gears – All gears shall be designed for a minimum service life of fifty thousand (50,000) hours, and shall be in accordance with American Gear Manufacturers Association (AGMA) standards. Provisions shall be made to ensure that the gears are aligned prior to meshing of any gear set.

(F) Lubrication – The system shall utilize an automatic lubrication system(s). All automatic lubrication systems shall operate according to an adjustable time cycle, based on the running of the system. Automatic lubrication systems shall have indicators and interlocks to indicate the need for service and filling. Recommended lubricants shall be identified within the maintenance manual. All bushings and other surfaces with sliding contact shall have provisions for lubrication.

Lubrication points shall be available for servicing without the removal or disassembly of components. Effective means shall be provided to ensure against the contamination of the production environment by lubricating and/or hydraulic oil.

C.3.3 SUPPORT MATERIALS AND SERVICES

The Contractor shall provide the following materials and perform the following services under this contract to support the installation, testing, startup and placement into operations the PVD Coating System.

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C.3.3.1 Security Requirements

The Contractor shall comply with all policies, regulations, requirements and instructions from the Bureau’s Office of Security. In addition to those requirements within section H, the contractor shall:

(A) Non-Disclosure Agreement – The Contractor shall sign and a Non-Disclosure Agreement (NDA) prior to the Government’s release of proprietary and/or sensitive information. The NDA will cover all work to be performed under this contract and shall apply to all contractor personnel as well as any subcontractors.

(B) Safeguarding Government Furnished Materials – Under the performance of this contract, the BEP will provide Government Furnished Materials that are considered items of security. The contractor shall abide by all requirements and instructions of the BEP’s Office of Security during the performance of this contract.

C.3.3.2 On-site Services

All services to be performed on-site within the BEP shall be performed in a manner consistent with the BEP’s Environmental, Health and Safety (EHS) policy and applicable EHS laws, regulations and other applicable requirements. The contractor shall abide by all applicable requirements within the attached document, EHS Contractor Requirements for WCF (75.W- 08.0-02) or 75D-07.0-04 for DCF Attachment E.

C.3.3.3 Spare Parts Listing A listing of all parts that the contractor recommends the BEP carry in stock to support operation of the machine shall be provided at 2nd design review meeting. The listing shall be provided in MS-Excel format. The listing shall include the manufacturer’s part number, detail description of the part, function, lead time for delivery, estimated mean time for failure/maintenance, recommended quantity and unit price. The contractor shall identify all electronic and electrical parts with a risk analysis including possible time to obsolescence.

Parts that are common to other production machinery made by the contractor shall be identified on the spare parts listing.

Proprietary spare parts shall be identified on the spare parts listing. Proprietary is defined within the Merriam Webster Dictionary as: (i) used, made, or sold only by the particular person or company that has the legal right to do so, (ii) something that is used, produced, or marketed under exclusive legal right of the inventor or maker.

The BEP recognizes that the initial list may not be complete, as the machine design may not be final. The contractor shall provide any changes or additions to the original list prior to delivery of the equipment to the BEP.

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C.3.3.4 Technical Documentation The contractor shall provide the BEP with accurate, complete and current technical documentation of the machine, including all supporting equipment. The documentation shall include engineering drawings, bill of materials, operation and maintenance manuals, and purchase component information.

One (1) complete set of documentation shall be provided in PDF format upon delivery of the first machine to the BEP. The files shall enable the BEP to copy the data onto servers for access not only on the machinery but also for engineering, maintenance and operations personnel via the BEP’s intranet.

The contractor shall also be responsible for providing updates, whenever changes or modifications occur during the term of this contract. The contractor shall supply technical data covering the system, support equipment, optional equipment (if exercised), and any other equipment/items delivered to the BEP under this contract.

In the event the equipment is to be furnished by firms whose standard technical documentation does not use the English language or engineering terminology commonly used in the U.S., the aforementioned technical documentation shall be modified as follows:

• All documentation shall be provided in the English language, including drawing titles, part names, material specifications, manufacturing processes, heat treatments, finishes, or any other notations necessary for manufacturing the part. It will not be necessary to translate metric (SI) measurements into inch or foot measurements.

• If standard systems are employed to designate dimensional tolerance, surface textures, heat treatments, or coatings, comprehensive explanations of systems shall be in sufficient detail to be readily understood by American manufacturers.

• Any international standards (ISO and DIN) referenced shall be provided translated into the English language.

(A) Engineering Drawings – Drawings covering the entire machine, support equipment and any other equipment delivered under this contract shall be provided; mechanical, electrical, hydraulic and/or pneumatic; and shall include individual parts,…