SOW.docx.pdf

SECTION C – DESCRIPTION/SPECIFICATION/STATEMENT OF WORK

SOI Obsolete Mechanical and Electrical Replacement Parts

C.1 BACKGROUND

The Bureau of Engraving and Printing (BEP) Eastern Currency Facility (ECF), located in

Washington, DC and Western Currency Facility (WCF) located in Fort Worth, TX currently uses

Koenig & Bauer (KBA) Super Orloff Intaglio (SOI) presses to print images with covert and overt features, on both sides of United States currency. The ECF currently has two (2) “Series 024” SOI presses (63402401 and 63402402) and two (2) “Series 027” (63402701 and 63402702) SOI presses. The WCF currently has two (2) “Series 026” SOI presses (63402601 and 63402602) and two (2) “Series 027” SOI presses (63402703 and 63402704). KBA is the original equipment manufacturer (OEM) for the presses.

C.2 GENERAL REQUIREMENTS AND SCOPE

C.2.1 Product, Service or Outcome Required

The BEP requires OEM replacement of obsolete electrical and mechanical parts on existing SOI equipment and an upgrade from the NOTASAVE 3 inspection system to the NOTASAVE XT

Inspection system to meet present and future currency printing requirements, as well as to extend the life of electrical and mechanical systems in the existing machinery. The inclusion of the inspection platform aligns the BEP’s inspection strategy with the newly upgraded Super Simultan

212 presses and the new SOI 3 Intaglio presses recently acquired at the WCF. This also allows the

BEP to keep its commitment to the Federal Reserve Board and the United States Currency program that, to the maximum extent possible, no machines will be denomination specific and the final inspection of each process will occur within the process.

C.2.2 Scope of the Product, Service, or Outcome

The BEP requires that the latest electrical, mechanical and inspection components be installed and integrated into the BEP’s existing SOI presses as an upgrade to the current systems. The turnkey package shall include the required hardware and software to integrate new control systems, replace obsolete press control systems, and integrate the newest NOTASAVE XT inspection system to support present and future United States currency production requirements. The OEM shall provide all materials, labor, installation, start-up assistance and training services to upgrade all eight (8) existing SOI presses with their latest mechanical, electrical and control system components; four (4) presses at the BEP ECF and four (4) presses at the BEP WCF.

C.3 TECHNICAL REQUIREMENTS

(a) All parts provided under this requirement shall be new without prior use. In the event any part or upgrade does not perform as specified, is deemed damaged or found to be otherwise unacceptable, the OEM shall replace the item or re-do the upgrade to the specifications required herein at no cost to the BEP.

(b) These upgrades are to be performed in sequence, with no more than one (1) press down at a time. The OEM will not be allowed to modify a subsequent system until the previous system has been fully validated, formally accepted by the BEP, and returned to operation through the

Bureau Acceptance Test (BAT) and Final Acceptance procedures. The OEM shall coordinate with the Contracting Officer Representative (COR) on the sequence of the upgrades to be performed.

(c) The OEM shall be responsible for all disassembly, preparation, mounting, reassembly, testing and all other work necessary for system start-up and operation after the integration.

(d) The upgrades shall not negatively impact the safety or performance capabilities of the present system in any manner

C.3.1 Obsolete Mechanical Components Upgrade

The OEM shall perform a retrofit of the designated presses with current and/or upgraded mechanical components Each upgraded system shall have the following minimum requirements:

C.3.1.1 Series 24 SOI Requirements:

Item number Description Comment Replacement

L0051465 GEARMOTOR

chablon cylinder lift; 1:1 replacement/spare part available L0077691

L0051469

GEARMOTOR SPUR

WHEEL

Wash motors; 1:1 replacement/spare part available L0051489

L0051836 GEARMOTOR

wiping cylinder adjustment; 1:1 replacement/spare part available L0077585

L0053787 ANGLE DECODER

wiping cylinder adjustment;

small package available L0053809+L0756454

L0053827 SENSOR

sensor infeed; 1:1 replacement/spare part available L0078314

L0053973 INITIATOR

Printing pressure measurement;

1:1 replacement/spare part available L0081063

L0752610 LIMIT SWITCH

safety switch; 1:1 replacement/spare part available L0073765

L0752752

LIMIT SWITCH KEY

BUTTON

safety switch; 1:1 replacement/spare part available L0074014

L0758430 LAMP

lamp; 1:1 replacement/spare part available L0758455

L0758449 LAMP COMPLETE

lamp; 1:1 replacement/spare part available L0081132

L0758492 LAMP

lamp; 1:1 replacement/spare part available L0074973

L0842214 BLOWER

Blower wiping cylinder;

replacement package available SK960136

L0845235 FIELD BREAKING SWI

magnetic field switch delivery;

1:1 replacement/spare part available L0753050

L0846136 INITIATOR

cap. sensor delivery, 1:1 replacement/spare part available L0077586

L0849402 BLOWER

Blower sheet guiding delivery;

1:1 replacement/spare part available L0075884

L0853378 COMPRESSOR

blower infeed suction drum; 1:1 replacement/spare part available L0853873

L0853621 COMPRESSOR

blower feeder;

replacement/spare part available L0853873

L0052815 TRANSFORMER

wiping cylinder transformer; 1:1 replacement/spare part available L0074948

L0752623 LIMIT SWITCH

chablon cylinder safety barrier switch; 1:1 replacement/spare part available L0073883

L6454721 PUMP

grease pump inking unit; 1:1 replacement/spare part available L0071058

C.3.1.2 Series 26 SOI Requirements:

Item number Description Comment Replacement

L0051465 GEARMOTOR

chablon cylinder lift; 1:1 replacement/spare part available L0077691

L0051469 GEARMOTOR SPUR WHEEL

Wash motors; 1:1 replacement/spare part available L0051489

L0051836 GEARMOTOR

wiping cylinder adjustment; 1:1 replacement/spare part available L0077585

L0052815 TRANSFORMER

wiping cylinder transformer; 1:1 replacement/spare part available L0074948

L0053116

COMPRESSOR VACUUM

PUMP

Blower delivery; 1:1 replacement/spare part available L0853821

L0053827 SENSOR

sensor infeed; 1:1 replacement/spare part available L0078314

L0053973 INITIATOR

Printing pressure measurement;

1:1 replacement/spare part available L0081063

L0752610 LIMIT SWITCH

safety switch; 1:1 replacement/spare part available L0073765

L0752752 LIMIT SWITCH KEY BUTTON

safety switch; 1:1 replacement/spare part available L0074014

L0758440 LAMP COMPLETE

Lamp; 1:1 replacement/spare part available L0758404

L0758449 LAMP COMPLETE

lamp; 1:1 replacement/spare part available L0081132

L0780486 BALL VALVE

valve; 1:1 replacement/spare part available L0780513

L0842214 BLOWER

Blower wiping cylinder;

replacement package available SK960136

L0846136 INITIATOR

cap. sensor delivery, 1:1 replacement/spare part available L0077586

L0848852 FIELD BREAKING SWI

magnetic field switch delivery; 1:1 replacement/spare part available L0075258

L0849402 BLOWER

Blower sheet guiding delivery; 1:1 replacement/spare part available L0075884

L0849830 PHOTOSENSOR

Muting sensor delivery;

replacement package available SK960064

L0853378 COMPRESSOR

blower infeed suction drum; 1:1 replacement/spare part available L0853873

L0853621 COMPRESSOR

blower feeder; replacement/spare part available L0853873

L2679835 VALVE-COMBINATION

valve; 1:1 replacement/spare part available L0073849

L0752623 LIMIT SWITCH

chablon cylinder safety barrier switch; 1:1 replacement/spare part available L0073883

L6955561 FILTER

Filter; 1:1 replacement/spare part available L6955562

L6955571 FILTER ELEMENT

Filter; 1:1 replacement/spare part available L6955572

C.3.1.3 Series 27 SOI Requirements:

Item number Description Comment Replacement

L0051465 GEARMOTOR

chablon cylinder lift; 1:1 replacement/spare part available L0077691

L0051469

GEARMOTOR SPUR

WHEEL

Wash motors; 1:1 replacement/spare part available L0051489

L0051836 GEARMOTOR

wiping cylinder adjustment; 1:1 replacement/spare part available L0077585

L0052815 TRANSFORMER

wiping cylinder transformer; 1:1 replacement/spare part available L0074948

L0053827 SENSOR

sensor infeed; 1:1 replacement/spare part available L0078314

L0053973 INITIATOR

Printing pressure measurement;

1:1 replacement/spare part available L0081063

L0072058 PHOTOSENSOR

Muting sensor delivery;

replacement package available SK960064

L0752610 LIMIT SWITCH

safety switch; 1:1 replacement/spare part available L0073765

L0752752

LIMIT SWITCH KEY

BUTTON

safety switch; 1:1 replacement/spare part available L0074014

L0758440 LAMP COMPLETE

Lamp; 1:1 replacement/spare part available L0758404

L0758449 LAMP COMPLETE

lamp; 1:1 replacement/spare part available L0081132

L0780486 BALL VALVE

valve; 1:1 replacement/spare part available L0780513

L0842214 BLOWER

Blower wiping cylinder;

replacement package available SK960136

L0846136 INITIATOR

cap. sensor delivery, 1:1 replacement/spare part available L0077586

L0846921 FIELD BREAKING SWI

sensor delivery; 1:1 replacement/spare part available L0075729

L0848852 FIELD BREAKING SWI

magnetic field switch delivery; 1:1 replacement/spare part available L0075258

L0849402 BLOWER

Blower sheet guiding delivery;

1:1 replacement/spare part available L0075884

L0853378 COMPRESSOR

blower infeed suction drum; 1:1 replacement/spare part available L0853873

L0853621 COMPRESSOR

blower feeder; replacement/spare part available L0853873

L2679835 VALVE-COMBINATION

valve; 1:1 replacement/spare part available L0073849

L0752623 LIMIT SWITCH

chablon cylinder safety barrier switch; 1:1 replacement/spare part available L0073883

L6955561 FILTER

Filter; 1:1 replacement/spare part available L6955562

L6955571 FILTER ELEMENT

Filter; 1:1 replacement/spare part available L6955572

C.3.2 Obsolete Electrical Components Upgrade

The electronics/electrical upgrades shall include but not be limited to the upgrade of controls system, main drive, motor, suction rollers, reciprocation system and their required subsystems as necessary to extend the life expectancy of the electronics/electrical systems. The system components listed shall be exchanges with the newer replacement:

Technology 634 024 01/02 634 026 03/04 634 027 01/02/03/04 After Upgrade

PLC 07 KT94 07 KT94 (EC500 in delivery)

Not Needed EC500

15’’ Displays 4x BDT (grey) 3x BDT (grey) 3x BDT (grey) 3x B&R (black) series 24:

4x B&R (black)

7’’ Displays - 4x B&R (grey) 4x B&R (grey) 4x B&R (black) series 24:

Main drive controller BKF12-6000 BKF12-6000 BKF12-6000 BKF12-7000

Compax delivery Compax 2 Compax 2 Compax 2 Compax 3

Variable freq. drives ACS101/143 NXL NXL ACS380

Light barriers - Leuze SD2x40 Leuze SD2x40 IFM OY052S

Colortronic Arcnet Arcnet Arcnet Ethernet

Wiping cylinder adjustment

BDT SPM2 BDT SPM2 BDT SPM2 ABB PLC based solution

Timing unit BDT SPM2 BDT SPM2 BDT SPM2 ABB EtherCAT

Technology 634 024 01/02 634 026 03/04 634 027 01/02/03/04 After Upgrade

Main motor GNA160SN

(L0051670)

GNA160SN

(L0051670)

GNA160SN

(L0051670)

GNA160SN

(L0073688)

1:1 replacement

Posmo/

Motors

Posmo I Arcnet/

60C

Posmo I Arcnet/

60C

Posmo I Arcnet/

60C

Posmo II Ethern./

60D

Display / Keyboard

Control Console

19’’ display /

Arcnet keyboard

19’’ display /

Arcnet keyboard

19’’ display /

Arcnet keyboard

24’’ touch display/ no keyboard

(like SOI III)

The replacement of the main motor is a 1:1 replacement. There is no need to replace a functioning motor. However, the new motor information/specifications will be given to the BEP to change the order information for spare parts.

All programmable logic controllers (PLCs) and touchscreens on the Dalmar unit are obsolete and shall be replaced.

Thermal regulation units on the Dalmar unit are obsolete and shall be replaced.

C.3.3 Inspection System Upgrade

Inspection system requirements from the original SOI contract are restated in this section as a review/reference point for the OEM. The OEM shall update/upgrade all affected components of these systems with the latest available hardware and software.

Note: The BEP expects the NOTASAVE XT required in this acquisition action shall match the final system delivered by the vendor for the Super Orlof Intaglio 3 contract TEPJ17-01566. The BEP will require at least one (1) design review in order to ensure that the sheet stability system and the inspection system requirement are understood by both parties.

C.3.3.1 Sheet Transport Provisions System

The press shall be designed to accommodate, both electrically and mechanically, the following in-line print inspection subsystem within the sheet transport arrangement. The installation and/or use of this subsystem shall not impact the operation of the press nor create additional spoilage.

In-Line Print Inspection System: The press shall accommodate an in-line print inspection system. The

In-Line inspection system shall be installed and tested on the press at the time of delivery. It has been discussed that the existing plenum that holds the sheets stable would be replaced by a vacuum drum assembly to stabilize the sheet during the inspection process. All parts, mechanical and electrical shall be provided and installed by the vendor to change the existing assembly out and ensure sheet stability during the inspection process.

C.3.3.2 In-Line Sheet Inspection System

(a) The print inspection system shall be a separate system integrated into the press and control system that can be replaced or upgraded without major re-engineering of the press or control system

(b) The inspection system shall have an interface with the press control system to provide information to optimize product quality and production efficiency. This interface allows the press, for example, to send good and bad sheets to separate deliveries. It also provides the ability to integrate inspection and press data for a particular load of sheets.

(c) The inspection system shall provide real time feedback to the operator on product quality. The inspection system shall alert the operator before the system has exceeded quality limits

(warning and errors) so corrective action can be taken. All inspection data shall be stored locally until transmitted to the BEP database.

(d) The inspection system shall compare images of the printed sheet with a “reference” to assess whether the quality standards are met. The allowable differences, or thresholds, between the

“reference” and inspected sheets shall be defined by BEP personnel and inputted into the inspection system.

(e) The entire sheet (700 mm x 820 mm) shall be presented consistently to the inspection system over the entire range of press speeds (i.e. flat with no sheet flutter). The system shall have an inspection area, Field of View (FOV), sufficient to inspect the entire sheet as well as reliably identify the edge of the paper. The inspection includes color bars, registration points and other print outside the note area.

(f) Adjustments to inspection system settings shall be limited by user role. The system includes a user management module with three different user roles (levels): user, expert and service. Each individual user ID can be assigned to one of the user roles. Hierarchical authorizations by user role shall be configurable within the inspection system.

(g) The system shall have the ability to name, save, and reload all inspection parameters and settings as a configuration file (date/time stamped), up to 32 jobs. A job is defined as an individually named and time stamped file. A trained operator shall be capable of reloading a saved inspection configuration file and begin operation in less than 5 minutes.

(h) The reference image creation process shall be easily configurable, intuitive to a trained person in the printing craft such that a trained operator can create a completely new inspection configuration in less than 1 hour, including the time to scan new sheets and establish all inspection regions and input inspection group tolerances. The system shall use a Step by Step process supported by a wizard where characteristics will be defined: name, size and number of notes per line and per column, presence of specific security features, special regions of interest and inspection tolerances.

(i) The job configuration file may be located on the MCS (Machine Control System) or stored and downloaded to the press via the BEP Oracle database (DIS). The job configuration file shall be stored on the inspection system in such a way that it can be transferred to another inspection system of the same type or compatible offline system (ROSS).

(j) System shall inspect sheets in both visible and Near-IR wavelengths. Resolution shall be less than or equal to 0.2 mm.

(k) Visible inspection shall be via color composite images. The cameras shall capture true color–

RGB (24 bit per pixel) in the 400 to 780 nm range and shall be calibrated to standard color references. Near-IR inspection shall be performed in the wavelength range of 850 to 950nm (8 bit grayscale per pixel).

(l) Reject sheets due to inspection system non-uniformity shall be under normal print and paper conditions and realistic tolerance settings less than 3% of all processed sheets.

(m) A single camera shall be used. The camera shall be aligned and calibrated.

C.3.3.3 Print Inspection

(a) During the reference sheet image generation process, the operator shall be able to specify special regions (Regions of Interest -ROI) and landmarks for registering the sheet image to the master sheet image. The operator shall create the ROI’s by tracing the outline of the region on a sheet and or note image. Available geometries to create these regions shall include rectangles, ellipses, and polygons. The system shall allow a precise trace of the desired region (up to 50 points) through mouse clicks or the touch-screen interface, as preferred by the user. The system should allow for at up to 2000 ROIs per station. Each region can be assigned to one (1) of the up to 15 tolerance groups. Areas of the note/sheet that remain unselected by the user shall be combined into one group, with user settable accept/reject tolerances. A group may be specified as a group to ignore, or as a special group for independent weighing under the flaw detection process.

(b) The inspection system shall use real-time printed sheets to build a single sheet reference or composite reference for subsequent print inspection. The system shall accept a range of 1 (one) to 100 sheets to make the reference image. All measurements shall utilize the master as the reference.

(c) The inspection system shall be both note and sheet based inspection relative to the reference image. The inspection system shall employ a “note-based” alignment with a minimum of one

“tie point” per note with up to 50 notes per sheet. The sheet may have printed targets to assist in sheet and note alignment.

(d) Sheets currently being printed and inspected may have been previously printed at a different press (i.e. offset). The current printing requires alignment to existing print. The inspection system shall verify the registration between select print features falls within an allowable range.

(e) The inspection system shall allow a selectable number of note failures to reject a sheet. The actual notes that failed and their position of on the sheets shall be saved to the BEP database if configured.

(f) System shall have a provision to feed, capture, and store images from select pre-printed sheets fed into the press.

(g) The system shall allow for the operator to independently set the allowable variations for rejection by each visible color, IR, as well as overall intensity and print contrast.

(h) The system shall provide a specific algorithm to cope with the window thread feature. The system shall properly detect the window security thread itself and ensure quality of inspection in the printed areas around it. System shall identify the position of the window thread in each banknote of the sheet; compare the geometry of the inspected window thread (lateral position of the thread, size and position of the windows, size and position of the bridges, integrity of the windows) to the window thread geometry that was taught as reference. Once the window thread elements have been localized and checked, the standard inspection channels are run on the print comprised in the wandering area of the thread.

(i) The inspection system shall be able to differentiate paper defects, such as clusters of paper fibers and paper spots (≥ 1mm2) from printing defects in case the paper spots have a different color than the printing. The system shall have the capability to detect and reject small high contrast print defects as well as large low contrast defects.

(j) The performance of the inspection system shall be verified with a set of pre-printed sheets with and without engineered flaws.

(k) The system shall provide an easy way for the operator with an appropriate ID user role to adjust thresholds from reference sheets. The system includes a user management module with three different user ID roles: user, expert and service. Each individual user ID can be assigned to one of the user ID roles. All modifications are tracked in a log file which is transferable to the BEP database.

(l) When the mouse/cursor is moved over any of the images on the display monitor, X and Y coordinates and pixel RGB (visual inspection) or intensity values (IR inspection) of the image shall be displayed; or the user can select to display either the values from the reference

(minimum and maximum) or the values from the master image.

C.3.3.4 Measurements

(a) System shall have a measurement accuracy of +/- 0.2 mm on all measurements and be uniform across the sheet. The measurements may be within the note or between any features on the sheet within a maximum distance of 200mm.

(b) The system shall be able to perform the register measurement of up to 3 print phases per note

(3 x 50 notes = 150 per sheet) and additionally the measurement of print-to-paper per sheet.

(c) The system shall have the ability to measure the distance between Intaglio print and the optically varying thread (OVT) and the bridge dimension and distance from an Intaglio reference.

(d) System shall measure the consistency of sheet presentation to a press reference point.

(e) System shall be able to measure from edge of paper to specified positions within the printing on the sheet such as note locations.

(f) Shall be able to inspect width and location of IR features

(g) Measurements may be between different printings (Offset to Intaglio print), paper features

(threads) to printing (Print to Paper), between different inks (Print to Print).

(h) Shall be able to measure the position of each note relative to a fixed (target) position on the sheet, in both X and Y.

(i) Measurement results shall be stored for later analysis by sheet and load. A real time display of selectable measurements shall be provided.

C.3.3.5 Calibration and Maintenance

(a) The inspection system shall demonstrate the ability to calibrate to white and black targets in order to standardize dynamic range across inspection systems. This will be validated using calibration targets.

(b) The inspection system shall also demonstrate the ability to calibrate to standardized calibration targets containing regions of Red, Green, Blue, and a gradient of gray shades in order to validate dynamic range across inspection systems.

(c) The inspection lighting and camera(s) system shall demonstrate uniformity in the image within

± 5 intensity scales across the entire FOV. This will be measured using pre-processed images.

(d) The inspection lighting and camera system combined shall demonstrate stable output (± 5 intensity scales per pixel in each RGB color channel) across the FOV for a minimum of 6 months of continuous use (3 shifts, 5 days a week) between calibration cycles.

(e) The system shall have a means to display the illumination variance from norm on the User

Interface and shall notify the operators when the illumination source(s) require replacement or maintenance. System self-diagnostics shall be provided.

(f) The imaging hardware and image capture station shall be designed such that the Field Of View

(FOV) displays less than 10% distortion in the raw image. This will be validated using calibration targets and confirming that all pixels are within +/- 5% of nominal pixel size (i.e. a

0.2 mm per pixel system shall display all pixels between 0.19 mm and 0.21 mm. This requirement includes pixels in the X and Y dimension across the entire FOV.

C.3.3.6 User Interface

(a) All inspection failures and warnings shall be highlighted and displayed real time on the live image. A wall screen shall be provided to facilitate ease of recognition of defects for both visible and IR images. The system shall allow the user to view either the real time image or composite image on the user monitor.

(b) The system shall have trending capabilities. For example, a Pareto Chart of failed note positions and failure causes; Trend Graph for register measurements, etc.

(c) The user interface shall provide graphical feedback for every inspection warning and defect.

The feedback shall be provided in a manner that allows for rapid understanding of the print variation. The user shall be able to zoom down to display individual pixel defects. The user shall have the ability to hold a defect image for a user selectable amount of time. During this period of holding a defect image real time sheet inspection shall not be interrupted. The user shall have a means to graphically compare the defect image to the reference image.

(d) The user interface shall have the capability to display pixel location and grayscale values (each

RGB channel for visible inspection and IR grayscale for near IR inspection) for each image displayed and for the reference master and for the range of the reference composite image. The intent of surfacing pixel data is to assist the user with defect analysis, and inform tuning decisions.

(e) The user interface shall have the capability to display real-time trending information configured by user (example: failures by note, by group, or by defect type) while simultaneously displaying defect images and simultaneously displaying either the reference master image or reference composite image.

C.3.3.7 Reports and Data

(a) Reporting System shall report, at the end of each load, the overall inspection performance results including: number of sheets inspected, number of sheets accepted/rejected, and number of sheets with warnings, and number sheets rejected of categories of print defects

(b) Inspection results shall be broken by groups. Results shall include measured dimensions.

Reports and data shall be transmitted via the press MCS or DCS for inclusion in the data to be uploaded to the BEP Oracle database (DIS).

C.3.4 Obsolete Control System Components Upgrade

The OEM shall be responsible for the migration of all software coding from the existing control system to the proposed control system. New control wiring and connections shall be installed as part of this upgrade.

C.4 PLACE OF PERFORMANCE

The OEM shall deliver and install all materials and components, and provide upgraded system training at the following locations:

Bureau of Engraving & Printing Bureau of Engraving & Printing

Western Currency Facility Eastern Currency Facility

9000 Blue Mound Road 14th & C Streets S.W.

Fort Worth, Texas 76131 Washington, DC 20228

C.5 PERIOD OF PERFORMANCE

The anticipated period of performance is twenty-four (24) months from contract award. Deliverables shall be completed and provided in accordance with the delivery schedule provided in the contract

C.6 ADDITIONAL REQUIREMENTS, SERVICES AND TASKS

The following section of the Statement of Work (SOW) describes additional requirements, services and tasks that shall be performed:

C.6.1 Project Coordination Meeting

(a) Within two (2) weeks after contract award a “Project Coordination Meeting” shall be held with the COR, BEP Subject Matter Experts (SMEs) and the OEM to establish overall project coordination and to address sequencing of installation at each facility via an Integration Plan and Project Schedule. The Integration Plan shall include a high-level description of integration strategy, including a list of systems impacted and a schedule documenting the system being modified. The Project Schedule shall include a list of major milestones and dates for accomplishing the milestones.

(b) During contract execution, the OEM shall submit proposed changes to the system including diagrams of the new control systems and detailed information on the components to be installed for review and approval by the Contracting Officer (CO) or designee prior to installation.

C.6.2 Working Policies and Restrictions

(a) The OEM shall perform all work between 7:00 a.m. and 5:00 p.m. Monday through Friday, unless approved by the BEP CO or designee at least twenty-four (24) hours in advance.

(b) The BEP ECF and WCF areas are secure facilities. During the life of the contract, access to the BEP facilities for the OEM, its subcontractors, and suppliers shall be made available as required. Background information for all personnel assigned to work on the project shall be submitted at least thirty (30) days prior to the commencement of work for approval by the BEP Office of Personnel Security.

(c) During all operations on BEP premises, personnel for whom the OEM is responsible shall comply with the rules and regulations governing the conduct of personnel and the operation of the facility. This includes all Security, Environmental, Health & Safety, and Personnel regulations.

(d) The BEP reserves the right to require the OEM's employees and subcontractors to sign in and/or sign out of the BEP facility. Vehicle Parking Permits will be required of all OEM and

OEM subcontractor vehicles entering the WCF facility.

C.6.3 Training

(a) After acceptance of the upgrades, the OEM shall provide on-site training to all designated

BEP employees on the first updated system at each facility. OEM training personnel shall be qualified representative(s) and be proficient in the English language. The OEM shall provide specialized training to familiarize BEP personnel on the installation, operation and maintenance of the system updates.

(b) The OEM shall provide training at each BEP facility for up to eight (8) weeks at each location. Training shall cover all three (3) shifts at both BEP facilities unless it is determined and mutually agreed that the training, due to the complexity, will be only on day shift. At a minimum, training shall consist of two (2) weeks of operator training on the inspection system, three (3) weeks of maintenance training on the updated systems and inspection system, and three (3) weeks of inspection system setup and file maintenance. As an option the BEP may determine that an additional three (3) weeks of training for an offline system may be required at each facility. This option should be proposed and priced by the vendor.

(c) Training shall be based upon the information included in the equipment operation and maintenance manuals and any other supplemental devices and information that the OEM and

BEP jointly deem necessary for satisfactory operation and maintenance of the systems. The training should be comparable to the training provided by the vendor under the SOI 3 contract at a minimum.

(d) The system administrators shall be trained in the operation/maintenance of all computers/electronics on the press and support equipment. The training shall be sufficient so that the BEP system administrator can operate and support all computers/electronics supplied to the BEP as part of the update.

(e) The OEM is encouraged to propose a detailed training schedule to allow adequate training of skilled operator and maintenance personnel in separate sessions.

(f) The OEM shall provide all training materials to the CO or designee at least three (3) weeks prior to training to allow ample time for review and coordination by the BEP. The training materials shall include an electronic copy of all materials with adequate hard copies for up to five (5) attendees per session.

C.6.4 Bureau Acceptance Test

(a) The OEM shall perform a Bureau Acceptance Test (BAT) on each updated system in accordance with the requirements in Section E. The contractor is required to provide a detailed BAT plan sixty (60) days after the Project Coordination Meeting for approval by the

BEP. The purpose of the BAT is to provide a full demonstration of all functionality related to the upgraded system, and to ensure original functionality of the SOI press remains.

(b) The OEM shall supply all BAT support components/items, to be delivered to the COR or designee, thirty (30) days prior to the BAT on the equipment. This shall include as a minimum, all tools, auxiliary support items, diagnostic software, laptop computers and operational aids.

NOTE: If the equipment does not successfully pass the first BAT and retesting is required, the OEM shall assume ALL costs of retesting including personnel lodging, travel, and materials.

C.6.5 Final Acceptance

(a) After training but prior to returning to live production, the BEP will conduct an internal validation process of the upgrades.

(b) Following the BAT and Validation, the system shall be utilized for a minimum of 45 shifts (15 days) in production without any problems or issues being noted prior to final acceptance. If system issues arise, the OEM will be provided up to five (5) business days, depending on the severity of the issue, to correct the issues and complete the final acceptance criteria.

C.6.6 Warranty

(a) The OEM shall provide a one (1) year warranty on the upgrade to the systems for all hardware and software changes. All hardware modified or replaced under this upgrade to be covered by this warranty shall be designated by the vendor. This warranty shall apply to all programming changes performed on the press to support this upgrade.

(b) Warranty shall include labor and travel costs required to correct any latent defects that prevent the BEP from being able to attain the capabilities described in section C.3 of the SOW at each of the installation sites.

C.6.7 Spare Parts

The OEM shall identify all changes to the spare parts listing already acquired by the BEP to support the original system and shall recommend spare parts for the upgraded system.

C.6.8 Environmental, Health and Safety

(a) Contracted services shall be performed in a manner consistent with the Bureau of Engraving and Printing (BEP) Environmental, Health, and Safety (EHS) policy and applicable EHS laws, regulations and other applicable requirements, codes and standards. Reference BEP

Document Control number75D-07-.0-04 EHS Contractor Requirements, Attachment __.

The BEP contractually transfers responsibility to its contractors for compliance with applicable environmental, health, and safety laws and regulations, BEP policies, and for adherence to standards identified in contracts.

(b) All OEM personnel shall comply with the requirements and procedures established through the BEP ECF and WCF Environmental, Health, and Safety offices. The OEM will be required to attend a safety orientation to review the emergency response requirement established by the BEP WCF Environmental, Health, and Safety office. Any chemicals that will be used must be EHS approved prior to the chemicals being brought on site. The COR will coordinate all BEP EHS requirements.

C.6.9 Delivery

(a) The OEM shall ensure all equipment and other deliverables are delivered to the BEP Free on

Board (FOB) within consignee’s premises to Washington, DC and Fort Worth, TX. All customs duties and delivery costs shall be borne by the OEM

(b) The OEM shall be responsible for providing all materials and services required for the delivery and placement of upgrade materials and related equipment at the designated installation site(s) within the BEP. The delivery services shall also include all freight, rigging, unpacking, and removal of packing materials from BEP premises

(c) All trucks shall deliver equipment to the loading dock during weekdays (Monday through

Friday), except holidays, between 8:00 A.M to 2:15 P.M. The BEP will not provide any assistance during the delivery. At least seven (7) days advance notification to the COR regarding delivery date and other pertinent information is required.

(d) The delivery of large items, including press components and large crates, to the installation site shall be coordinated with the COR. To minimize potential disruption to BEP operations, the delivery of large items may be required during a weekend. Sixty (60) calendar days after award of the contract, the OEM shall submit a delivery plan to the COR.

C.6.9 Technical Documentation

The OEM shall provide the COR and/or the CO with accurate, complete and current technical documentation of all new components and controls systems including those manufactured by sub-contractors. Unless specified otherwise, all technical documentation shall be furnished upon the delivery of the upgraded parts and control systems to the BEP.

C.6.9.1 System Drawings

(a) Four (4) copies of drawings for mechanical, electrical, hydraulic, pneumatic systems etc. as applicable shall be provided. One (1) set of electronic copies on CD-ROM and three (3) sets of blue line copies on paper shall be provided. The drawings shall consist of all assembly and sub- assembly drawings outlining part/drawing numbers and titles of each and every part and component to enable BEP personnel to identify manufactured and commercially available parts. Detailed drawings shall be furnished showing the form, fit, and function of the part, material and any special manufacturing processes used during the production of the part, needed for manufacturing by the BEP for its consumption during emergency

(b) All titles, notes, dimensions, numbers, and words shall be written in English. All drawings shall be made in accordance to American National Standards Institute (ANSI) standards, ASME Y14.5 and ASME Y14.100 Dimensioning, Tolerance and Engineering Drawing

Practices or equivalent. Each drawing shall contain the press serial number, designate the part by a unique part number and list the assembly number in which it is used. Each drawing shall contain all of the OEM information for BEP purchase, or list the part as proprietary.

C.6.9.2 Electronic Drawing Package

In addition to the hard copy drawings specified above, the OEM shall provide three (3) electronic copies of each drawing in a CAD compatible format i.e. Solidworks, as well as three

(3) electronic copies capable of being incorporated into the BEP Tagged Image File (TIF) format system. These drawings shall be compatible with the CMMS drawing system currently in use at the BEP that uses Eastman Imaging for Windows Professional.

C.6.9.3 Operation and Maintenance Manuals

(a) Operation and maintenance manuals shall be written in English and graphically illustrate all the requirements necessary for operation and maintenance personnel to operate and maintain the updated press and control systems without prior training. A list of trouble-shooting procedures should be available for quick reference to identify system malfunctions.

(b) Five (5) copies of the manuals shall be provided with each upgrade delivered to the BEP.

One (1) copy shall be facsimile reproduction and one (1) electronic copy in Adobe intelligent

PDF format on CD-ROM and three (3) bound copies. All software and source codes shall be written and displayed in English.

C.6.9.4 Software

The OEM shall supply a full backup copy of all software used on the system and support equipment to the COR. The backup copies shall be complete and shall enable the BEP system administrator to enter and/or modify the programs.

C.6.10 Startup Support

The OEM shall provide one (1) fully qualified individual for three (3) weeks following installation and testing of the first system at each BEP facility to provide start-up assistance for the upgraded system. Individual shall be capable of providing required assistance and diagnosing any issues that may occur during start-up.

C.6.11 Major Deliverables

Major deliverables, along with due dates and required formats, are as follows:

Section Deliverable Due Date

Deliverable

Recipient

(include contact information)

Deliverable Format

C.6.1 Integration Plan and Project Schedule

Two (2) weeks after Project

Coordination Meeting

Designated COR Plan in Word format;

Schedule in MS Project format

C.6.9.1 Four (4) copies of system drawings

Upon delivery of parts and controls systems

Designated COR

One set of electronic copy on CD-ROM and three (3) sets of black or blue line prints.

C.6.9.2 Electronic Drawing

Package

Upon delivery of inspection and controls systems

Designated COR Three (3) electronic copies.

C.6.9.3

Operation and

Maintenance

Manuals

Upon delivery of inspection and controls systems

Designated COR

Five (5) copies of the manuals shall be provided with each upgrade delivered.

C.6.9.4 Software

Upon delivery of inspection and controls systems

Designated COR

Supply a full backup copy of all software used on the system and support equipment.

C.7 GOVERNMENT FURNISHED RESOURCES AND INFORMATION

The BEP will provide sufficient inks and currency sheets to meet the specified requirements, and satisfy testing during the BAT, Validation and Final Acceptance.

[END OF SECTION]