Scope of Work.docx

STATEMENT OF WORK

BLUESTONE GEARBOXES AND COUPLINGS

SECTION I. GENERAL PROJECT INFORMATION

These specifications cover all work required to fabricate, paint and coat, test and deliver eleven (11) gearboxes, and eleven (11) flexible gear coupling. The Contractor shall provide all the necessary hardware and dowel pins to install the gearboxes. These items are being purchased as replacement parts for crest gate hoist machinery that is currently installed at the Bluestone Dam Project.

GENERAL. This contract is for the supply of goods only. The installation will be performed by the Government.

Bluestone Dam Location:

US Army Corps of Engineers 701 Miller Ave.

Hinton, WV 25951

SECTION II. GENERAL ADMINISTRATIVE ITEMS

1. Contract Overview The contract will have two phases:

Phase I – Prefabrication/manufacturing submittals Phase II – Fabrication, Assembly and Testing at Manufacturer’s Facility of eleven (11) gearboxes and eleven (11) couplings. Transportation and delivery of the eleven gearboxes and couplings are included in this phase. This phase also includes submission of all the required submittals during and post fabrication.

The maximum period for each phase will be:

Phase I – 60 calendar days. This phase will be considered complete once the manufacturer has Government approved premanufacturing submittals.

Phase II – 210 calendar days from the completion of Phase I. Completion of this phase is having Government approved post-delivery submittals.

A Notice to Proceed (NTP) will be issued after completion of phase I. Note that phases can be completed in less time than allowed by the contract.

The intention of Phase I is for the Government to review the gearboxes and couplings pre-fabrication submittals and shop drawings, and confirms it complies with the contact requirements. In addition, the schedule developed and provided by the contractor will allow the Government to plan for the necessary quality assurance work to minimize disruptions to the build schedule.

The intention of Phase II is for the contractor to build the gearboxes and couplings and demonstrate performance through successful testing at their facility. The contractor is also responsible for prepping and packaging for shipment the gearboxes and couplings for delivery at Bluestone Dam.

2. Submittals

All the Phase I, II submittals will be reviewed by the Government. The Contractor shall only begin any fabrication and manufacturing activities after having approved phase I submittals.

a. Submittal Classification

Government Approved (G)-Government approval is required for any variations from the Solicitation or the Accepted Proposal and for other items as designated by the Government.

For Information Only (F)-Submittals not requiring Government approval will be for information only.

b. Approved/ Accepted Submittals

The Contracting Officer's approval/acceptance of submittals shall not be construed as a complete check but will indicate only that the general method of operation, materials, detailing and other information are satisfactory. Approval/acceptance will not relieve the Contractor of the responsibility for any error which may exist, as the Contractor under the Contractor Quality Control (CQC) requirements of this contract is responsible for dimensions, the design of adequate connections and details, and the satisfactory completion of all work. After submittals have been approved/accepted by the Contracting Officer, no resubmittal for the purpose of substituting materials or equipment will be considered unless accompanied by an explanation of why a substitution is necessary. The Government shall receive a minimum of 30 days to review submittals. Failure of the contractor to plan their submittals with sufficient lead time (including the 30-day Government review period) in advance of their scheduled start date for each definable feature of work shall not be reason for the contractor to claim that they were delayed

c. Disapproved/Non-Accepted

The Contractor shall make all corrections required by the Contracting Officer and promptly furnish a corrected submittal in the form and number of copies specified for the initial submittal. If the Contractor considers any correction indicated on the submittals to constitute a change to the contract, a notice in accordance with FAR 52.212-4(c) - Changes shall be given promptly to the Contracting Officer.

Immediately after the award, (within sixty (60) calendar days), the Contractor shall prepare and submit the following digital items per the Contracting Officer’s Representative (COR) direction, via ENG Form 4025. The Government will use the requested drawings and deliverables to check the compliance with the contract specifications. ‘G’ means Government approval is required, and ECD-E is the Government section that reviews the submittal.

Shop Drawings: Completely detailed shop drawings, drawn to scale, for all components specified herein shall be submitted to the Contracting Officer for approval in accordance with section VII, ‘Shop Drawings’ prior to initiating fabrication. Drawings shall show complete details, including tolerances and proposed method of assembly. Shop drawings shall include completely detailed information on materials, including catalog cuts, and type, grade, and class of materials, as appropriate.

The following submittals shall be submitted by the Contractor. The Government will only use the requested drawings and deliverables to confirm the contract specifications.

Phase I Submittals Pre-manufacturing

1. Fabrication Schedule, G ECD-E

2. Quality Control Plan, include all the test plans, G ECD-E

3. Existing gearbox information and dimension (FIO)

4. Parts and Material list, G ECD-E

5. Transportation Arrangements and Details (loading and off-loading), G ECD-E

6. Schematics for the lubricant system, G ECD-E

7. Paint Schedule, G ECD-E

8. Final Shop Assembly Procedure, G ECD-E

9. Shop Test Procedure, G ECD-E

10. Schedule of welding procedure, G ECD-E A complete schedule of welding procedures as described in paragraph Welding Procedure, shall be submitted to the Contracting Officer, and approved before fabrication is commenced.

Shop Drawings

11. Gearbox, G, ECD-E

12. Couplings showing bore tolerance, G, ECD-E

13. Drawings for All Fabricated Items; G, ECD -E

Within 60 days of notice to proceed drawings shall be submitted for approval in accordance with section VII. Drawings shall include templates, fabrication and assembly details and type, grade, and class of materials, for all parts being fabricated. Elements of fabricated items inadvertently omitted on contract drawings shall be detailed by the fabricator and indicated on the shop drawings.

Product Data

14. Gearboxes, G ECD-E

15. Couplings, G ECD-E

16. Lubricant oil and grease, G ECD-E

17. Catalog Cuts for Purchased Items; G ECD-E

Within 60 days of notice to proceed catalog cuts for all items to be furnished shall be submitted for approval in accordance with section VII.

Phase II submittals During Manufacturing

18. Material, Machinery, and Equipment Bill of Materials along with purchase orders or bill of lading, G (ECD-E)

19. Fabrication Photos, G (ECD-E), sufficient number of detailed fabrication photos showing the progress of fabrication shall be submitted for Government approval at different stages of fabrication such as equipment and machinery assembly, before and after painting, and photos during shop tests.

Post-Manufacturing

20. Shop Test Reports, G ECD-E

21. Gear Hardening Report, G ECD-E

Certificates

22. Material tests; G ECD-E Submit certificates for material tests

23. Material examinations; G ECD-E Submit certificates for material examinations

24. Welding Procedure; G ECD-E Submit certificates for welding procedures

25. Operator Qualifications; G, ECD-E Submit Operator Welding qualification certificates

26. Loading for Transportation Condition Certificate, G ECD-E

Post Delivery

27. Gearbox Parts Sheets, Shop drawings including Dimensioned Gearbox Assembly Drawing, G ECD-E

28. Operations & Maintenance Manual – two (2) printed sets of manuals in English that describe the full operation of gearboxes and couplings. The manuals shall also detail the frequency and specifications for maintaining and lubricating the equipment. An electronic copy of the manual set shall also be provided to the Government, G ECD-E

29. As-Built Drawings – two (2) printed sets of as-built drawings with a complete bill of materials. Electronic copies of the drawings shall also be provided to the Government, G ECD-E

30. Part Lists – two (2) printed copies of the parts lists available from the contractor. An electronic copy of the list shall also be provided to the Government, G ECD-E

3. Payments Base Contract

a. Phase I Submittals Payment will cover all the costs associated with the submission of submittals. No payment will be made for this line item until acceptance by the Contracting Officer or their representative. Successful completion of this line item is having approved submittals.

b. Phase II Submittals Payment will cover all the costs associated with the submission of submittals. No payment will be made for this line item until acceptance by the Contracting Officer or their representative. Successful completion of this line item is having approved submittals

c. Working "As-built" Documents Payment for preparation and submission of working "as built" drawings shall be made at the contract line-item price for "Working "As-Built" Documents”. Successful completion of this line item is having working as-built documents with the Contractor during fabrication and manufacturing and providing them during government visits.

d. Final "As-built" Documents Payment for preparation and submission of final "as built" drawings shall be made at the contract line-item price for "Final "As-Built" Documents”. Successful completion of this line item is having approved final as-built documents.

e. Fabrication and Assembly of eleven (11) gearboxes and eleven (11) couplings Payment will cover all the costs associated with the purchase of materials, fabrication, assembly, and testing of eleven gearboxes and couplings at the Manufacturer’s facility. No payment will be made for this line item until acceptance by the Contracting Officer or their representative. Successful completion of this line item is fabrication and manufacturing of the gearboxes and pass all the testing requirements as per the contract specifications.

f. Transportation and Delivery Payment will cover all the costs associated with the loading, submission of loading condition certification, transportation, delivery, submission of the off-loading condition certificate, and delivery inspection of gearboxes. No payment will be made for this line item until acceptance by the Contracting Officer or their representative. Success is completion of this line item as per the contract specifications.

4. Progress Payments

Payments will be made upon submission of invoices as per the schedule on Table 1, or at such other times as they may be mutually agreeable to the Contractor and Contracting Officer. The Contractor must bill Other Direct Costs as a total and not as a percentage of completion. Upon approval and acceptance of work by the Contracting Officer, payment shall be made to the Contractor as soon as practicable. Submit ENG Form 93 (Payment Estimates), to the Huntington District’s A-E Design Management Section at the following e-mail address: CELRH-ECD-A-AE@usace.army.mil

In addition, copy the following staff:

Kristina Goff - Kristina.L.Goff@usace.army.mil, The pay estimate shall include a detailed narrative giving descriptions of the work performed during the billing period to include:

· The work items being invoiced (task)

· The negotiated amount

· The percentage of work completed for the billing period

· And earnings to date

Additionally, the invoice shall be clearly associated with a Contract Line Item for which payments are explicitly permitted, and the Contractor shall submit evidence such as photographs, documentations, etc.

At the completion of work, the Contractor shall prepare and submit a Contract Release of Claims form (format provided by USACE), to USACE with the final payment request.

Table 1: Payment Schedule

5. Combatting Trafficking in Persons

Both as part of its QC Plan, and in each monthly report to the COR, the contractor shall document by narration that it and its staff, subcontractors, and other contractor-controlled entities involved in this award are in compliance and have read and continues to follow the requirements of FAR 52.222-50. Included in this narrative shall be the actions the Contractor must take against employees or agents for violations of FAR 52.222-50(b). Such actions for employees shall include, but are not limited to, removal from the contract, reduction in benefits, or termination of employment. Additionally, the written verification shall include a statement that the Contractor has notified its employees and their agents of the policy prohibiting trafficking in persons and of the actions that will be taken by the Contractor for violations. The Contractor shall ensure FAR 52.222-50 is in its subcontracts and agreements with subordinate entities.

a. Deliverable – As part of each invoice or pay estimate Contractor shall report on its compliance with FAR 52.222-50.

6. Applicable Publications The following publications of the issues listed below, but referred to thereafter by basic designation only, form a part of this specification to the extent indicated by the reference thereto or as required.

American Society for Testing and Materials (ASTM)

Steel Structures Painting Council (SSPC)

American Welding Society, Inc. (AWS) Code

American Society of Mechanical Engineers (ASME) ASME B4.1-09 Preferred Limits and Fits for Cylindrical Parts

ASME B46.1-02 Surface Texture (Surface Roughness, Waviness, and Lay) American Gear Manufacturers Association (AGMA)

Military Specifications (MIL-DTL) MIL-DTL-24441C General Specification for Type IV Paint, Epoxy-Polyamide

SECTION III. GEARBOX AND COUPLING SPECIFICATIONS

Quality Control. The Contractor shall establish and maintain a quality control system to assure compliance with the contract requirements and shall maintain records of his quality control of all operations covered by these specifications. Quality control records shall be made available to the Contracting Officer upon request at the Contractor’s facility and shall remain in possession of the Contractor.

1. Products

a. Worm Speed Reducer The existing worm gear reducer is a Western Gear Works Type WB- 17, 40:1 ratio, with an input speed of 1660 RPM according to the original name plate data and original OEM information. The original order number was Order Number 62515 and the Serial Number for one of the eleven (11) identical original units is 171. The original box was fabricated and installed in the 1940s. The new gear reducer shall match or exceed the existing in all aspects including service factor, ratio, input rating, speed, class of service, footprint, and shaft centerlines. The new reducer shall have the same mounting footprint and shaft configurations to ensure installation to existing equipment without any modifications being required. The existing gearbox is equipped with a pipe tap for an immersion heater. The mechanical input rating, thermal input rating, input torque rating, output torque rating, and operating efficiency shall be clearly identified on the Gearbox Shop Drawings. The appropriate AGMA or other industrial standard used to calculate these parameters shall also be clearly identified.

The existing motor is a 10HP General Electric motor, and the rated full load speed is 1660 RPM. Photograph of the name plate is included in appendix A.

Bearings shall be of the anti-friction type and of ample capacity for the service intended. Provision shall be made for adequate lubrication of all gears and bearings when the units are operated at the intended speeds. The housing shall have inspection holes with cover plates located above the maximum oil level to permit viewing of gear teeth allowing evaluation of the contact patterns of each gear mesh and to allow inspection of internal features of the lubrication system. The gearboxes shall comply with all applicable AGMA standards including AGMA 6013-A06 and be suitable for 30 years of reliable operation when used in the contract application.

b. Motor to Gearbox Coupling Eleven (11) flexible coupling shall be provided for connection of the existing electric motors to the new gear reducers. The existing coupling is an Amerigear No. GL-10 1-1/2-2. The specification of the new couplings shall match the existing. The Contractor shall submit shop drawings and product data of the new coupling for government approval. The couplings shall have one hub bored for the nominal 1-5/8” motor shaft and the other hub shall be bored for the 1-1/2” reducer shaft. The coupling shall be provided with all keys, bolts, and any additional hardware required for installation. The Contractor is responsible for greasing the couplings or selecting a grease for couplings in accordance with manufacturer’s recommendation. The Contractor is also responsible for installing the gear side coupling half on the gearbox and shipping the gearbox with coupling half installed.

Coupling Bored Hub Tolerance: The upper and lower limit of the bored hub for the 1-5/8” motor shaft is 1.6240”/1.6235”. The upper and lower limit of the bored hub for the 1-1/2” reducer shaft is 1.4985”/1.4980”.

2. Materials

Materials shall be as hereinafter specified. Materials not specified shall be the manufacturer’s standard for the application. All equipment shall be new. The materials of construction used shall be new, manufactured within the time not exceeding one year prior to delivery, and of kind, composition, and physical properties best adapted to its several purposes in accordance with best engineering practice. All materials and equipment proposed for use in the work shall be identified on the Contractor’s shop drawings or specifications and shall be subject to approval of the Contracting Officer. The Contractor shall submit evidence satisfactory to the Contracting Officer that such material conforms to the requirements of the specifications.

Protection of Materials and Equipment. The Contractor shall be responsible for the proper handling, maintenance, storage, and protection of all materials until delivered and accepted at the location found in paragraph DELIVERIES OR PERFORMANCE.

a. Quality Control Requirements

Tests of Materials. The Contractor shall, at his expense, perform analyses and tests to demonstrate that all materials are in conformity with the specifications. Should the Contractor desire to use stock materials not manufactured specifically for the work covered by these specifications, he shall submit evidence, satisfactory to the Contracting Officer that such materials conform to the requirements of the specifications. Detailed tests of these materials may not be required, if so, approved by the Contracting Officer. Tests, except where modified, shall be made as indicated in the respective detailed specifications or on the drawings and, unless otherwise authorized, in the presence of the Contracting Officer. Certified reports in triplicate of all required analyses and tests shall be provided to the Contracting Officer. The Contractor shall furnish the Contracting Officer, upon request, specimens and samples for independent analyses and tests. These specimens and samples shall be properly labeled and prepared for shipment.

Reports of Material. The Contractor shall furnish the Contracting Officer two certificates; one shall be a list from the fabricator's shop showing what contract items are to be made from the material ordered from the mill, and the other shall be a list from the mill stating, for each article (sheet, plate, bar, shape, etc.) to be supplied to the fabricator, the heat number and the chemical and physical properties of the metal from which the article is to be made.

b. Special Test Requirements.

Nondestructive Testing. When doubt exists as to the soundness of any material part, such part may be subjected to any form of nondestructive testing as determined by the Contracting Officer. This may include ultrasonic, magnaflux, dye penetrant, x-ray, gamma ray or any other test that will thoroughly investigate the part in question. The cost of such investigation will be borne by the Government. Any defects impairing the performance or proper functioning of the operating machinery will be cause for rejection and the rejected part shall be replaced and retested at the Contractor's expense.

Tests. Waiving of tests, however, will not relieve the Contractor of responsibility for any fault in operation, workmanship, or material that may develop before the completion of his contract.

c. Workmanship

General. Structural materials shall be thoroughly straightened by methods that will not impair the metal. Sharp kinks or bends in member to be straightened will be cause for rejection. Finished members shall be free from kinks, bends, or winds. Shearing shall be accurately done, and all portions of the work neatly finished. Corners shall be square and true unless otherwise shown on the drawings. Where heating is required, precautions shall be taken to avoid overheating the metal and it shall be allowed to cool in such a manner as not to destroy the original properties of the metal. Steel with welds will not be accepted, except where welding is specified, called for on the drawings or otherwise approved.

d. Dimensional Tolerances for Structural Work

Dimensions shall be measured by means of an approved calibrated steel tape of the same temperature as the structure at the time of measurement. Unfairness of plate work shall be held to a practicable minimum.

Tolerances shall be as shown on the drawings and as specified hereinafter.

3. Welding

The Contractor may use manufacturer’s standard weld specification upon review and acceptance by the Contracting Officer or their representative.

a. Structural Steel

General. Unless otherwise authorized or specified, welding of structural steel shall be by an electric arc welding process, using a method which excludes the atmosphere from the molten metal. Welding, unless specified otherwise, shall conform to the applicable provisions of Sections 1 thru 6 of AWS D1.1.

Welding Equipment. All items of welding equipment shall conform to the requirements of AWS D1.1.

Filler Metal. The electrode, electrode-flux combination and grade of weld metal shall conform to the appropriate AWS specification for the base metal and welding process being used. Only low hydrogen electrodes shall be used for manual shielded metal-arc welding regardless of the thickness of the steel. The AWS designation of the electrodes to be used shall be included in the schedule of welding procedure to be furnished by the Contractor. To maintain low moisture of low hydrogen electrodes, a controlled temperature storage oven shall be used as prescribed by Article 5.3 of AWS D1.1.

Qualification of Welders and Welding Operators. Welding operators, welders, and tack welders shall be qualified and, as necessary, re-qualified for the particular type of work to be done. Qualification shall be in accordance with Section 4 of AWS D1.1 or Section IX of the ASME Boiler and Pressure Vessel Code. The Contractor shall certify by name to the Contracting Officer the welders and welding operators so qualified including the date of qualification, code, and procedures under which qualified.

Prior qualification may be accepted provided the welder has performed satisfactory work under the code for which qualified within the preceding three months. The Contractor shall require the welder or welding operator to repeat the qualifying tests when, in the opinion of the Contracting Officer, his work indicates a reasonable doubt as to his proficiency. In such cases, he shall be recertified, as above, if he successfully passes the retest; otherwise, he shall be disqualified until he has successfully passed a retest. All expenses in connection with qualification and requalification shall be borne by the Contractor.

b. Workmanship Requirements

Welding Procedure. The Contractor shall prepare for submission to the Contracting Officer a complete schedule of welding procedures which shall consist of detailed procedure specifications and sequence for each structure to be welded and tables or diagrams showing the procedure to be used for each required joint. The schedule shall conform to the provisions of Sections 2 and 5 of AWS D1.1, including filler metal requirements, preheat and interpass temperature requirements and any stress relief heat treatment, and show the types and locations of welds designated on the drawings and/or in the specifications to receive nondestructive examination. The procedure shall be such as to minimize residual stresses, warping, and distortion of the completed weldment. Procedures shall be qualified by tests as required and prescribed in Section 4 of AWS D1.1 except for prequalified procedures as described in Section 3 of AWS D1.1. Properly documented evidence of compliance with all requirements of these specifications for previous qualification tests will establish the joint welding procedure as prequalified. Each procedure shall be clearly identified as being either prequalified or qualified by tests. The test welding and specimen testing must be witnessed, and the test report document signed by a representative of the Contracting Officer. The Contractor will be directed or authorized to make any changes in previously approved welding procedures that are deemed necessary or desirable by the Contracting Officer. Approval of any procedure, however, will not relieve the Contractor of the responsibility for producing a finished structure meeting all requirements of these specifications.

Stress Relief Heat Treatment. All weldments shall be stress relieved by heat treating before machining. Stress relief heat treatment shall be in accordance with the requirements of Article 5.8 of AWS D1.1, unless otherwise authorized or directed by the Contracting Officer.

Preheat and Interpass Temperature. Preheating shall be performed as required by Articles 5.6 and 5.7 of AWS D1.1, except that the temperature of the base metal shall be at least 70 degrees Fahrenheit. The weldments to be preheated shall be slowly and uniformly heated by approved means to the prescribed temperature, held at that temperature until the welding is completed and then permitted to cool slowly in still air.

Control of Distortion. All weldments shall have distortion and shrinkage controlled in accordance with the requirements of Article 5.21 of AWS D1.1.

c. Inspection

General. Welding shall be subject to inspection by Government inspectors to determine conformance with the requirements of AWS D1.1, the approved welding procedures, and provisions stated elsewhere in these specifications. The Contracting Officer will require nondestructive inspection of designated welds and may require supplemental examination of any joint or coupons to be cut from any location in any joint. The Contractor shall maintain an adequate inspection system and perform the necessary inspections.

Visual Examination. Prior to any welding, the Contractor shall visually inspect the preparation of material for welding to assure compliance with Section 3 of AWS D1.1. All completed welds shall be cleaned and examined carefully by the Contractor for insufficient throat or leg sizes, cracks, undercutting, overlap, excessive convexity or reinforcement, and other surface defects to ensure compliance with the requirements of Section 5 and Section 6 of AWS D1.1. Defects shall be corrected as provided in paragraph Nondestructive Examination below.

Nondestructive Examination. The Contractor shall perform nondestructive examination of welds as indicated on the drawings and called for in the specifications.

Testing Agency. Nondestructive examination of welds and evaluation of the tests or inspections as to the acceptability of the welds shall be performed by a testing agency adequately equipped and competent to perform such services; or the Contractor may make his own tests or inspections and evaluations, provided he has available suitable equipment and qualified personnel. In either case, written approval by the Contracting Officer will be required and such tests or inspections shall be made in the presence of the Contracting Officer Representative. The evaluation of the tests or inspections shall be subject to the approval of the Contracting Officer and all records shall become the property of the Government.

d. Procedure.

Ultrasonic Testing. The procedure for making, evaluating, and reporting the ultrasonic testing of the welds shall conform to the requirements of Section 6 of AWS D1.1. The ultrasonic equipment shall be capable of making a permanent record of the test indications and a record shall be made of each weld tested.

Magnetic Particle Examination. The procedure for making magnetic particle inspection shall conform to the applicable provisions of ASTM E709. Inspection of each 1/4-inch layer of weld is required.

Liquid Penetrant Inspection. The procedure for making dye penetrant inspection shall conform to the applicable provisions of ASTM E165.

Acceptability of Welds. Welds shall be unacceptable if shown to have defects prohibited by Part C, Section 6 of AWS D1.1, or shown to possess any degree of incomplete fusion, inadequate penetration, or undercutting.

Supplemental Examination. The Government reserves the right to perform supplemental nondestructive examinations as deemed necessary when the soundness of any weld is in doubt and to detect cracking or similar defects that might occur during moving, loading, shipping, or unloading, and before final acceptance by the Government. The cost of such inspection will be borne by the Government. The repairs and the re-examination of repairs will be performed by the Contractor at no additional cost to the Government.

Repairs. Defective welds shall be repaired in compliance with AWS D1.1. When deemed necessary by the Contracting Officer, the Contractor shall submit a welding repair plan for approval before repairs are made. Defective steel weld metal shall be removed to sound metal by use of air carbon-arc or oxygen gouging. The surfaces shall be thoroughly cleaned before welding. Welds that have been repaired shall be retested by the same methods used in the original inspection. All costs of repairs and retesting shall be borne by the Contractor.

Temporary Welds. Temporary welds required for fabrication shall be made under the same controlled conditions prescribed herein for permanent work. All temporary welds shall be made with low hydrogen electrodes by welders qualified for permanent work as hereinbefore specified. Temporary welds shall be removed after having served their purposes and shall be ground flush with adjacent surfaces. All depressions shall be filled overfull with weld metal and the excess weld metal shall than be ground flush.

Tack Welds. Tack welds that are to be incorporated into the permanent work shall be subject to the same quality requirements as the permanent welds and shall be cleaned and fused thoroughly with the permanent welds. Preheating shall be performed as specified above for temporary welds. Multiple-pass tack welds shall have cascaded ends. Defective tack welds shall be removed before permanent welding.

Peening. Shall comply with the provisions of AWS D1.1. Peening shall not be done on any newly deposited weld metal until the slag covering has hardened and been removed by manual tools.

Flame Cutting and Shearing. Low-carbon structural steel may be cut by machine-guided or hand-guided torches instead of by shears or saws. Flame cutting of material other than low-carbon structural steel shall be subject to approval and where proposed shall be definitively indicated on shop drawings submitted to the Contracting Officer. Where a torch is mechanically guided, no chipping or grinding will be required except as necessary to remove slag and sharp edges. Where a torch is hand guided, all cuts in the zone to be welded and cuts that will be exposed or visible shall be chipped, ground, or machined to sound metal. Where material is not to be welded and where cuts will be unexposed, burrs and rough edges only shall be removed. Where the torch is mechanically guided, flame gouging will be permitted in preparation for welding.

4. Machine Work

The Contractor may use manufacturer’s standard machine work specification upon review and acceptance by the Contracting Officer or their representative.

General. Unless otherwise shown on the drawings, all tolerances, allowances, and gages for metal fits between plain, non-threaded, cylindrical parts shall conform to ASME B4.l for "Preferred Limits and Fits for Cylindrical Parts" for the class of fit as shown or otherwise required. Where fits are not shown they shall be suitable as determined by the Contracting Officer. Tolerances for machine-finished surfaces designated by non- decimal dimensions shall be within 1/64 inch. Sufficient machining stock shall be allowed to insure true surfaces of solid material. Finished contact or bearing surfaces shall be true and exact to secure full contact.

a. Finished Surfaces

Where surface finishes are indicated on the drawings or specified herein the symbols used or finishes specified shall be in accordance with ASME B46.1 for "Surface Texture (Surface Roughness, Waviness, and Lay)". Values of roughness height specified are specified in micro-inches as "Arithmetical Average Deviation from the Mean Surface". Roughness specified is the maximum value and any lesser degree will be satisfactory. Compliance with specified surface shall be determined by sense of feel and by visual inspection of the work compared to Standard Roughness of Specimens, in accordance with the provisions of ASME B46.1. Values of roughness width and waviness height are not specified but shall be consistent with the general type of finish specified by roughness height. Flaws such as scratches, ridges, holes, peaks, cracks, or checks which will make the part unsuitable for the intended use will be cause for rejection.

Where the finish is not indicated or specified, the type of finish shall be the type which is most suitable for the surface to which it is applied and shall be consistent with the class of fit required. Surfaces to be machine finished shall be indicated on the shop drawings by symbols which conform to ASME B46.1.

Unfinished Surfaces. So far as practicable, all work shall be laid out to secure proper matching of adjoining unfinished surfaces. Where there is a large discrepancy between adjoining unfinished surfaces, they shall be chipped and ground smooth, or machined, to secure proper alignment. Unfinished surfaces shall be true to the lines and dimensions shown on the drawings and shall be chipped or ground free of all projections and rough spots. Depressions or holes not affecting the strength or usefulness of the parts may be filled in a manner approved by the Contracting Officer.

b. Protection of Finished Machined Surfaces.

Finished surfaces shall be thoroughly cleaned of foreign matter. Finished surfaces of large parts and other surfaces shall be protected with wooden pads or other suitable means.

Exposed machine finished surfaces shall be thoroughly cleaned of foreign matter. All unpainted machine finished surfaces shall be protected by a suitable rust inhibitor satisfactory to the Contracting Officer, for shipping and storage protection. Finished surfaces of ferrous metals, which will be exposed after assembly, except as noted, shall be painted as specified in paragraph, PAINTING.

List of Materials. In accordance with section VII, the Contractor shall furnish the Contracting Officer with six (6) copies of all purchase orders, mill orders, shop orders for materials, and work orders. Where mill tests are required, the purchase orders shall contain the test site address and the number of the testing agency.

Shop Inspection. A technical Representative shall inspect the gearbox during fabrication to determine compliance with these specifications in accordance with Paragraph Inspection and Acceptance.

5. Painting

The Contractor may use manufacturer’s standard painting specification upon review and acceptance by the Contracting Officer or their representative.

General. Except as hereinafter described, all exterior surfaces of the gear reducer shall be finish painted in the shop with at least three coats of epoxy-polyamide paint conforming to SSPC-Paint 22 or approved equal. Color shall be light gray. The interior of the gear reducers shall be coated with two (2) coats of a MIL-DTL- 24441C, Type IV, epoxy polyamide paint or an approved equal. The coupling shall be coated with the manufacturer’s standard coating system where applicable. Otherwise, the exterior surfaces shall also be finish painted in the shop with at least three coats of epoxy-polyamide paint conforming to SSPC-Paint 22. Color shall be light gray.

Surface Preparation and Paint Application. Surfaces to be painted shall be clean before applying paint or surface treatments. The removal of oil and grease shall, in general, be accomplished with mineral spirits or other low- toxicity solvents having a flashpoint above 100 degrees Fahrenheit before any mechanical cleaning is started. Solvent cleaning shall be done with clean cloths and clean fluids to avoid leaving a thin film of greasy residue on the surfaces being cleaned. After solvent cleaning, surfaces shall be prepared by commercial blast cleaning in accordance with SSPC- SP 6, prior to painting except as herein specified. Cleaning and painting shall be so programmed that dust or other contaminants from the cleaning process do not fall on wet, newly painted surfaces, and surfaces not intended to be painted shall be suitably protected from the effects of cleaning and painting operations. Welding of, or in the vicinity of, previously painted surfaces shall be conducted in a manner to prevent weld spatter from striking the paint and to otherwise reduce coating damage to a minimum; paint damaged by welding operations shall be restored to original condition. Machine finished surfaces shall be protected during any blast cleaning processes.

Exterior of the Gear Reducer. The exterior of the gear reducers shall be cleaned and coated in conformance with the manufacturer’s standard practice for outdoor exposure. The color shall be light gray.

Interior of the Gear Reducer. The interior of the gear reducers shall be cleaned to a SSPC SP 5, white metal blast. Immediately after cleaning the interior surfaces shall be coated with two (2) coats of a MIL-DTL- 24441C, Type IV, epoxy polyamide paint, and shall be applied in accordance with the paint manufacturer’s instructions. The dry thickness of each coat shall be between 4 and 5 mils. The Contractor’s proposed painting system shall be submitted to the Government for approval.

Parts or Surfaces Not Painted. Paint shall not be applied on finished machine surfaces. Unpainted finished machine surfaces shall be protected as specified in paragraph, Protection of Finished Machined Surfaces.

6. Miscellaneous

Oil Compatibility. All components of the gear reducers shall be compatible with the oil.

Operation and Maintenance Instructions. The Contractor shall furnish two (2) printed sets of manuals in English that describe the full operation of gearboxes and couplings. The manuals shall also detail the frequency and specifications for maintaining and lubricating the equipment. An electronic copy of the manual set shall also be provided to the Government.

Warranty. The gear reducer shall be warranted for a period of two (2) years from the date of acceptance against any defect or failure. Upon receipt of notice from the Government of failure of any part of the warranted equipment during the warranty period, the affected part or parts shall be replaced promptly with new parts by and at the expense of the Contractor. The Contractor shall acknowledge his responsibility under these warranty provisions by letter (written warranty) stating that the gear reducer is warranted and the inclusive dates of the warranty periods, and stating that, upon receipt of notice from the Government of failure of any part of the warranted equipment during the warranty period, the affected part or parts will be replaced promptly with new parts by and at the expense of the Contractor.

SECTION IV. INSPECTION AND ACCEPTANCE

INSPECTION. The work will be conducted under the general direction of the Contracting Officer and is subject to inspection by her appointed inspectors to ensure strict compliance with the terms of the contract Materials furnished under these provisions shall be subject to inspection during and after the process of manufacture at the place of manufacture by authorized Government inspectors who shall be afforded proper facilities for determining compliance with these specifications. Any part of the equipment not in compliance with these specifications will be rejected and the Contractor shall promptly remedy or replace the defective part or parts to the satisfaction of the Contracting Officer, without cost to the Government. All final shop assemblies required to be performed will be witnessed by a government appointed inspector. The Contractor shall keep the Contracting Officer informed as to the general progress of the work and shall notify the Contracting Officer in writing, fourteen (14) days prior to the time when the equipment is ready for final assembly and testing. Electronic copies of all submittals shall be emailed to the Contracting Officer. The files shall be in Portable Document Format (PDF). When reporting an actual or potential delinquency, the contractor- prepared DD Form 375c shall, as a minimum contain the following:

(1) The problem - a statement of the difficulty, the reasons therefore, and whether caused by the Government or the Contractor,

(2) Items and quantities affected,

(3) Date of commencement of the anticipated or actual delinquency,

(4) Action taken by the Contractor to overcome the anticipated or actual delinquency,

(5) Estimated recovery date based upon evaluation of the factors contributing to the delinquency,

(6) A realistic schedule revision which can be met by the Contractor. No inspector is authorized to change any provision of the specifications without written authorization of the Contracting Officer, nor shall the presence or absence of an inspector relieve the Contractor from any requirements of the contract. The Contractor shall within 30 days after date of award, submit for approval of the Contracting Officer a description of this proposed inspection system.

The equipment will be inspected for conformance with the specifications prior to loading for shipment.

a. Fabrication, Assembly and Quality Assurance at Manufacturer’s Facility

The Contractor is responsible for the full fabrication and assembly of the gearboxes and couplings at their facility. The Government will inspect the manufacturing in accordance with the Contractor’s fabrications standards and to confirm compliance with these specifications.

With premanufacturing submittals, the Contractor shall provide a milestone production schedule to the Government. The schedule shall include the gearboxes and couplings fabrication and weld-out, assembly, shop testing, and painting milestone events.

It is not the intention of the Government to disrupt the manufacturer’s production process. The Government will perform quality assurance on the gearboxes and couplings while it is going through production. The Government will coordinate with the Contractor on the fabrication, welding, paint completion, assembly, and testing events.

The Contractor shall notify the Government at least five (5) business days before the scheduled completion date. Following the completion of assembly of the gearboxes, a period of no more than two (2) business days shall be made available for the Government to perform quality assurance of the work. When requested by the Government, material certifications and shop test certifications shall be provided.

At the completion of the fabrication, outfitting, parts installation, painting and assembly, the Government will perform quality assurance of the work. The Government shall be notified at least five (5) business days before the scheduled completion date. A period of no more than two (2) business days shall be made available for the Government to perform quality assurance. The areas of quality assurance by the Government will include:

Government Verifications:

· Dimensions: Confirm the as-built vessel and trailer dimensions, vessel pickup swath width, volume capacity, operating length and width, draft, etc.

· Paint System: verify the interior and exterior of the hull, and all other components are coated in accordance with the contract requirements.

· Parts Installation: verify all parts are properly installed

b. Testing at Contractor’s Facility

All gear reducers shall be completely assembled in the shop and tested in the presence of a representative of the Contracting Officer. The test shall be sufficient to demonstrate satisfactory performance of the gear reducers in the installed conditions. The gear reducers shall subject to an unloaded test. The test shall be comprised of at a minimum of a spin test at rated speed for 90 minutes. Vibration, temperature, and acoustic measurements shall be taken at least twice during the test. The test procedure shall be submitted for approval. The test data values obtained shall be submitted to the Contracting Officer for approval. Gear contact patterns shall also be checked during testing. The manufacturer shall correct any defects detected during the tests by methods meeting AGMA guidelines.

The following tests shall take place at the Contractor’s facility in the presence of an authorized manufacturer:

· Bearing temperature monitoring (acceptable bearing temperature is less than 150 degrees F)

· Simple spin test

· Check contact patterns before final assembly

· Oil viscosity

· RPM In and RPM Out – Ratio Check

· Operating efficiency

· Coupling performance and alignment

· Vibration monitoring Before final test and acceptance, the Contractor shall provide all the shop test certifications and QA documents for Government verification.

Final Examination and Acceptance. The equipment will be inspected, and the Contractor shall demonstrate that the products meet the contract specifications. Any failure to comply with the contract requirements or damage shall be remedied by the Contractor at no additional cost to the Government. Upon completion of satisfactory inspection and demonstration to comply with the contract specifications, the equipment will be accepted on behalf of the Government.

SECTION V. TRANSPORTATION AND DELIVERY

After completion of testing at the Contractor’s facility, gearboxes, and couplings (if awarded) shall be prepped by the Contractor for transportation to Bluestone Lake. The Contractor shall transport gearboxes and couplings to Bluestone Lake location.

For transportation, gearboxes and couplings shall be packaged to prevent damage.

The Government will inspect all items at the time of the delivery to ensure the components and equipment are delivered in a new condition.

The Contractor will have the full ownership and responsibility for the gearboxes and couplings during shipment. This will include the loading at the Contractor’s facility, land/sea transportation, and the unloading at the final destination site. The Contractor will be responsible for any damage that occurs during the transportation process.

The Contractor shall perform an inspection prior to packaging the gearboxes and couplings to document the condition. During the loading for transportation, the Contractor shall have a representative available to monitor the handling and loading. When loading is completed, a certificate shall be submitted to the Government documenting the conditions of the gearboxes and couplings.

Government will unload the gearboxes when the gearboxes are delivered.

The Contractor is responsible for the shipping of all items of this contract. These items shall be shipped to:

Bluestone Lake 701 Miller Avenue Hinton, WV 25951 304-466-1234

SECTION VI. CONTRACT DRAWINGS AND SPECIFICATIONS

A reference drawing and specifications will be furnished to the Contractor in PDF Format without charge. For all modifications, the Contractor will be furnished prints of appropriate scale in electronic, PDF, format.