SP8000-16-R-0010_PWS_for_Turbine_Engine_Component_Recycling.pdf

Performance Work Statement (PWS)

Turbine Engine Components Recycling

SP8000-16-R-0010

PART I: GENERAL INFORMATION

A.1 INTRODUCTION

Defense Logistics Agency Strategic Materials (DLA-SM) requires aerospace vacuum induction melt (VIM) material quality recycling services for end-of-life nickel, cobalt and titanium based turbine engine components.

A.2 SCOPE

A.2.1. Program Goal and Primary Objectives

This is a program to reclaim strategic and precious metals from excess Government owned turbine engine components.

The end product of recycling shall be:

1. Clean, segregated Vacuum Induction Melt (VIM) quality scrap materials;

2. Precious metal bearing offtake from the process, and;

3. Non-VIM Quality Scrap

A.2.2. Project Operational Outline

The Technical Requirements Section (later in this document) describes minimal technical requirements.

The following is a high level operational outline:

1. DLA-SM ships a tractor trailer of turbine engine parts to the Contractor.

2. The Contractor sorts the parts by general alloy type and sends DLA-SM a sorting report.

3. The Contractor performs Demilitarization (DEMIL) and recycling of the parts in such as a way that material can be used for future aerospace vacuum induction melt processing.

Precious metals are also recovered during the process.

4. The Contractor ships material back to DLA (or the Precious Metals Program) along with a report describing work performed and DEMIL Certifications for all components sent to the Contractor.

A.2.3 Key Attributes

The following is a list of program attributes that the Contractor shall understand.

A.2.3.1 Material will ship as a batch from Government site to the Contractor’s facility. All Contractor work will be performed at the Contractor’s facility.

A.2.3.2 Each batch will be issued as a task order. The Contractor must fully process a batch before the Government will order a task for a new batch.

Performance Work Statement

A.2.3.3 Government Furnished Material (GFM) included in the program will primarily consist of the following excess turbine engine components: blades, vanes, rotors, and shafts. The components will be from the following engine sections: fan, low pressure compressor, high pressure compressor, combustor, high pressure turbine, low pressure turbine, and augmenter.

A.2.3.4 The program will only be focusing on recovery of strategic materials from individual parts and small assemblies. This initial program will not be offering any whole engines for reclamation.

A.2.3.5 Unlike previous Air Force programs, the DLA-SM program only includes material pre-identified as having potential strategic material content (i.e., superalloys). The Government has made significant effort to pre-sort materials from traditional waste streams into this program.

A.2.3.6 Strategic alloys of the focus for the program include nickel, cobalt and titanium based superalloys. Precious metals of focus for the program include platinum.

A.2.3.7 Material originates from what was turned into DLA Disposition Services by the Military Services. DLA-SM has no control over what the services turn in to Disposition Services, so weights and alloy compositions will vary from month to month and shipment to shipment. For purposes of this solicitation, each shipment will be referred to as a batch.

A.2.3.8 The cumulative weight of batches for this contract is difficult to predict. The Contractor shall anticipate between 0 and 288,000 pounds (lbs.). of GFM over the 18-month Period of Performance (PoP) for this contract, however, the Government makes no guarantees on these quantities.

A.2.3.9 Minimum batch weight can be 5,000 lbs. (with the exception of the last shipment which might be less than 5,000 lbs.)

A.2.3.10 Maximum batch weight can range up to 50,000 lbs. of material.

A.2.3.11 Batches shipped from the Government will be sorted and labeled by National Stock Numbers (NSN) and quantities. The NSN’s will primarily contain the various alloys shown in Table A- 1 below:

Table A-1. Category 1 alloys to be evaluated for VIM reclamation

Material Product Category Example Alloys

Nickel-based superalloys for special applications

Rene N5, Rene N6, Rene 95, Rene 125, PWA

1426, PWA 1480, PWA 1484, MAR-M 247,

Inco 713C

Nickel-based superalloy for widespread applications Inco 718

Other nickel- and cobalt-based superalloys

PWA 655, Rene N4, Rene 41, Rene 80, Stellite 31 (X-40), Rene 77, Waspaloy, IN- 100 (PWA-658), Inco 901, Hastelloy X

Titanium-based superalloys Ti-6-4, Ti 17, Ti-8-1-1

A.2.3.12 Shipments of material will primarily originate from Oklahoma City, OK.

A.2.3.13 Ownership of the material will be retained by the Government for the duration of the service.

A.2.3.14 DLA-SM will conduct surveys and/or inspections of a Contractor’s facility prior to contract award to ensure that the Contractor is able to satisfy and adequately accomplish the requirements stated on this PWS (such as the DEMIL portion).

A.2.3.15 Demilitarization of components will be conducted under the supervision of DLA or the Defense Contract Management Agency (DCMA).

A.3 APPLICABLE DOCUMENTS

A.3.1 Department of Defense, Manual (DODM) 4160.21, Volumes 1 through 4, October 22 2015.

A.3.2 DD Form 1348-1.

PART II: REQUIREMENTS

The Contractor must meet the technical Requirements defined in this section.

The technical requirements are more broad regarding the processing steps to be employed as it is encouraged. Although technical requirements provide broad guidelines, (e.g. “material must meet domestic aerospace Vacuum Induction Melt requirement”) the Tasks allow a great deal of latitude in what processing steps a Contractor might employ (e.g.: hand sorting, X-Ray florescence, sawing, etc.).

Please keep in mind that detailed auditable records will be maintained by the Government and site inspections will be performed by the Government personnel.

B.1 TASK 1: RECEIVING MATERIAL

B.1.1 Requirement

Contractor shall perform all pertinent aspects of material receiving including accommodating tractor trailer shipments, coordination for government supervision, moving material into a secure area, and documenting delivery.

The Contractor shall offload material. Typical shipment will be by dedicated tractor trailer. Multiple tractor trailers may make up a single batch. Contractor will receive a prior notice (minimum of 3 business days) from the Government that material will be shipped to the Contractor’s facility. At the Government’s discretion, shipments shall be unloaded under supervision of the Government.

The shipment will contain documentation including a DD Form 1348-1 for all items in the shipment.

Documentation will also be emailed to the Contractor by the COR.

Shipment notification. The Contractor shall notify the Government Technical Point of Contacts (TPOC’s) and Contracting Officer Representative (COR) seven (7) business days in advance of the arrival of a shipment. The Contractor will annotate all discrepancies in the shipment report.

Shipment Discrepancies: The following list identifies those discrepancies that shall be reported on the shipment to the COR:

1. Shipment Site failed to provide a DD Form 1348-1/1a; or,

2. Shipment Site failed to properly complete the DD Form 1348-1/1a. (Form must contain at a minimum, the Contract/Delivery Order/CLIN Numbers, material type, net/gross weight and piece count.)

3. Net weight of delivery order CLIN received is more than 10% of total CLIN net weight identified on the delivery order. (If contractor determines that the variance is the fault of one or more shipment locations/sites, then this information must also be identified.)

4. Piece counts identified on the DD Form 1348-1/1a are less than or more than the quantity as identified on the DD Form 1348-1/1a, even though quantity is equal to that identified on the delivery order.

5. No seal on the transporter vehicle (if applicable) – identify the location that failed to utilize a seal and/or who may have removed a prior site seal and didn’t replace the seal.

The Government shipping sites will utilize the container methods as identified by their applicable transport agency. Containers may include triwalls, drums, ammunition cans, plastic bags, coffee cans, cardboard boxes, etc., as well as those authorized, approved, or designated for use by special transport agencies such as Federal Express, United States Postal Service, United Parcel Service, military service base transportation offices, etc.

B.1.2 Performance Standard

B.1.2.1 The Government requires the Contractor to receive at least one batch per month for the duration of the contract, B.1.2.2 GFM shall be moved directly to the secured area as defined in the technical requirements.

B.1.2.3 Shipping discrepancies shall be identified the same day as unloading.

B.1.3 Acceptable Quality Level (AQL)

B.1.3.1 The Contractor shall unload 100% of material.

B.2 TASK 2: UNPACKING AND SORTING

B.2.1 Requirement

The Contractor will notify via email the COR that they are ready to weigh and unpack shipments. The COR will arrange a time for a Government Representative to visit the Contractor’s Facility to supervise weighing and unpacking.

Contractor shall perform all pertinent aspects of material unpacking and sorting including weighing and identification by alloy type. The unloaded and sorted material shall be ready for reclamation after this task.

The Contractor shall send a Sorting Report back to the COR. At a minimum, the report shall have weights of the various alloy categories. The Sorting Report shall show which NSNs went into which sorting category.

B.2.2 Performance Standard

B.2.2.1 Sorting and unpacking shall occur within 30 days of arrival of the shipment unless extenuated circumstances prevent the Government Representative from attending in that timeframe.

B.2.2.2 Documentation shall be clear as to what NSN went into what alloy sorting category.

B.2.3 Acceptable Quality Level

B.2.3.1 100% of the total weight of must be sorted and accountable during any audits.

B.3 TASK 3: PRECIOUS METAL RECOVERY

B.3.1 Requirement

Contractor shall perform all pertinent aspects of recovering precious metals from all applicable parts.

B.3.1.1 Precious metal bearing offtake does not need to be refined. The Government will accept precious metal bearing slag, concentrate, slurry, abrasive blast media, etc. Contractor shall identify what form is provided.

B.3.1.2 The Contractor shall perform assaying and Toxic Characteristic Leachate Procedure (TCLP) on the precious metal bearing offtake for the first three batches in order to determine precious metals content and whether the offtake is considered Hazardous Waste IAW Federal, State and local regulations, respectively.

B.3.1.2.1 If the contractor uses an abrasive blast media method during the recovery process then the Contractor shall arrange and pay for a Toxic Characteristic Leachate Procedure (TCLP) on a representative sample of the container to test levels of toxic heavy metals as including Cadmium, Silver, Chromium, Selenium, etc. above regulatory levels.

B.3.1.2.2 If the contractor uses a chemical stripping method, then the Contractor shall arrange and pay for a TCLP on a representative sample of the container to test levels of toxic heavy metals as including Cadmium, Silver, Chromium, Selenium, etc., and the Contractor shall provide a Safety Data Sheet to the Precious Metals Program Office and the COR on the chemical(s) used during in order to establish user knowledge of any waste residue.

B.3.1.3 The Contractor shall send a digital copy of the assay and TCLP to the COR and the Precious

Metals Program POC. The Precious Metals Program shall review the assay and inform the Contractor whether the offtake meets requirements for inclusion and shipment to the Precious Metals Program as stated in paragraph B.7 of this PWS; or whether the offtake shall be disposed of by the Contractor IAW applicable federal, state, and local regulations for the type of waste generated.

B.3.2 Performance Standard

B.3.2.1 The precious metal bearing offtake shall be in a form in which precious metal could be recovered and processed by at least two US facilities not wholly owned by the Contractor. The Contractor shall provide a list of facilities which could recover the precious metals.

B.3.2.2 Precious metal bearing offtake shall not be a radiological hazard or require Nuclear Regulatory Commission or state licensing for processing or storage. Contractor shall provide documentation proving offtake is not a radiological hazard.

B.3.2.3 Precious metal bearing offtake shall be appropriately packaged, labeled, manifest, and shipped IAW federal, state, and local regulations.

B.3.3 Acceptable Quality Level

B.3.3.1 100% of precious metal offtake should be in a form whereas it could be domestically recovered.

B.3.3.2 100% of precious metal bearing offtake shall be appropriately packaged, labeled, manifest, and shipped IAW federal, state, and local regulations.

B.4 TASK 4: DEMILITARIZATION AND VIM QUALITY RECYCLING OF NICKEL BASED

ALLOYS

B.4.1 Requirement

Nickel based material shall go through Demilitarization in accordance with (IAW) DODM 4160.21.

The Contractor shall arrange for the Government Representative to be present during the Demilitarization. Notification shall occur at least three (3) business days prior to the date that the Contractor wants to begin Demilitarization. Demilitarization must completely destroy material that will result in destruction of the item to prevent reuse, recognition or reconstruction of the item to the satisfaction of the government appointed verifier.

Government personnel or Government Contract personnel will perform as DEMIL certifier and Government personnel only will perform as Verifier with written appointment IAW DODM 4160.21 Vols. 1-4.

Once Demilitarization of the property begins, tasks B.4, B.5, and B.6 shall be worked either simultaneous or in succession with no significant lapses in work. This is to minimize Government travel and oversight time.

Nickel based material shall also undergo recycling such that it meets the requirements for domestic aerospace component VIM processing standards. Documentation shall be provided to COR showing that all material reclaimed meets the requirements of domestic aerospace component VIM processing standards.

The end result of this task shall be segregated, drummed, and VIM ready, nickel based scrap meeting domestic aerospace requirements.

B.4.2 Performance Standard

B.4.2.1 DEMIL shall be to all applicable standards including DODM 4160.21.

B.4.2.2 VIM recycling shall be documented to show that it meets requirements of Pratt and Whitney, General Electric, Rolls Royce, Alcoa/Alcoa, Howmet, PCC, Volvo Aero, ATI, Carpenter Technology (Latrobe and Dynamet), Haynes International or other industry standards for VIM quality recycling.

B.4.2.3 A Demilitarization Certificate must be produced for each DD Form 1348-1. Copies of signed Demilitarization Certificates shall be distributed to the COR, the KO, and kept on file by the Contractor for the duration of the Contract.

B.4.2.4 DEMIL must occur within 30 days of material arriving at the Contractor facility.

B.4.3 Acceptable Quality Level

B.4.3.1 100% of Nickel Based alloy components shall undergo DEMIL.

B.4.3.2 100% traceability of NSN’s through completion of DEMIL certificates.

B.5 TASK 5: DEMILITARIZATION AND VIM QUALITY RECYCLING OF TITANIUM

BASED ALLOYS

B.5.1 Requirement

Titanium based material shall go through Demilitarization IAW DODM 4160.21. The Contractor shall arrange for the Government Representative to be present during the Demilitarization. Notification shall occur at least three (3) business days prior to the date that the Contractor wants to begin Demilitarization.

Demilitarization must completely destroy material that will result in destruction of the item to prevent reuse, recognition or reconstruction of the item to the satisfaction of the government appointed verifier.

Government personnel or Government Contract personnel will perform as DEMIL certifier and Government personnel only will perform as Verifier with written appointment IAW accordance with

DODM 4160.21.

Once Demilitarization of the property begins, tasks B.4, B.5, and B.6 shall be worked either simultaneous or in succession with no significant lapses in work. This is to minimize Government travel and oversight time.

Titanium based material shall also undergo recycling such that it meets the requirements for domestic aerospace component VIM processing standards. Documentation shall be provided to COR showing that all material reclaimed meets the requirements of domestic aerospace component VIM processing standards.

The end result of this task shall be segregated, drummed, and VIM ready scrap meeting domestic aerospace requirements.

B.5.2 Performance Standard

B.5.2.1 DEMIL shall be to all applicable standards including DODM 4160.21.

B.5.2.2 VIM recycling shall be documented to show that it meets the requirements of Pratt and Whitney, General Electric, Timet, ATI, or other industry standards for VIM quality recycling.

B.5.2.3 A Demilitarization Certificate must be produced for each DD Form 1348-1. Copies of signed Demilitarization Certificates shall be distributed to the COR, the KO, and kept on file by the Contractor for the duration of the Contract.

B.5.2.4 DEMIL must occur within 30 days of material arriving at the Contractor facility.

B.5.3 Acceptable Quality Level

B.5.3.1 100% of Titanium based alloy components shall undergo DEMIL.

B.5.3.2 100% traceability of NSN’s through completion of DEMIL certificates.

B.6 TASK 6: DEMILITARIZATION AND PROCESSING OF NON-AEROSPACE GRADE

MATERIAL

B.6.1 Requirement

The Contractor shall Demilitarize any non-aerospace recyclable material IAW DODM 4160.21 and all other appropriate regulations. The Contractor shall arrange for the Government Representative to be present during the Demilitarization.

Notification shall occur at least three (3) business days prior to the date that the Contractor wants to begin Demilitarization. Demilitarization must completely destroy material that will result in destruction of the item to prevent reuse, recognition or reconstruction of the item to the satisfaction of the government appointed verifier. Government personnel or Government Contract personnel will perform as DEMIL certifier and Government personnel only will perform as Verifier with written appointment IAW accordance with DODM 4160.21.

Once Demilitarization of the property begins, tasks B.4, B.5, and B.6 shall be worked either simultaneous or in succession with no significant lapses in work. This is to minimize Government travel and oversight time.

The end result of this task shall be segregated, drummed, scrap which the Government could sell to industries such as the stainless steel industry.

B.6.2 Performance Standard

B.6.2.1 DEMIL shall be to all applicable standards including DODM 4160.21.

B.6.2.2 A Demilitarization Certificate must be produced for each DD Form 1348-1. Copies of signed Demilitarization Certificates shall be distributed to the Government Representative, the COR, the KO, and kept on file by the Contractor for the duration of the Contract.

B.6.2.3 DEMIL must occur within 30 days of material arriving at the Contractor facility.

B.6.3 Acceptable Quality Level

B.6.3.1 100% of components shall undergo DEMIL.

B.6.3.2 100% traceability of NSN’s through completion of DEMIL certificates.

B.7 TASK 7 DELIVERY OF MATERIAL TO GOVERNMENT

B.7.1 Requirement

B.7.1.1 VIM quality nickel and titanium alloys shall be shipped to DLA SM after processing. The Contractor shall contact the DLA-SM POC at least three (3) business days prior to shipment.

Shipment shall arrive at DLA-SM during normal business hours as defined by DLA-SM in the Contract.

B.7.1.2 Non-aerospace quality material shall be shipped to DLA Disposition Services after processing.

The Contractor shall contact the DLA Disposition Services POC at least seven (7) business days prior to shipment. Shipment shall arrive at the DLA Disposition Services site during normal business hours as defined by DLA Disposition Services.

B.7.1.3 Precious Metal offtake shall be shipped to the Precious Metals Program during normal business hours. Precious Metal offtake shall be managed, stored, and shipped IAW all applicable hazardous waste Federal, State and local regulations, as applicable. The Contractor shall contact the Precious Metals Program POC at least three (3) business days prior to shipment.

B.7.1.3.1 If the Precious Metals Program POC notifies the Contractor that the material is acceptable for inclusion in the Precious Metals program and if the TCLP sample comes back higher than regulatory levels the contractor will need to submit a Land Disposal Restriction (LDR) to the precious metals contractor, and also manifest the waste for shipment; or, B.7.1.3.2 If the Precious Metals Program POC notifies the Contractor that the material is acceptable for inclusion in the Precious Metals program and if the TCLP sample comes back lower than regulatory levels the contractor shall manifest and ship the material to the precious metals contractor.

B.7.1.4 The COR shall receive a report entitled “Batch Report” which contains all weights, demilitarization certificates and final disposition of all material processed for the applicable batch.

B.7.2 Performance Standard

B.7.2.1 All material shall be shipped out from the Contractor facility.

B.7.3 Acceptable Quality Level

B.7.3.1 100% of material shall be shipped out from Contractor facility to appropriate destination.

PART III SUPPORTING INFORMATION

C.1 PLACE OF PERFORMANCE

All services shall occur at the Contractor’s facility.

C.1.1 Security at the Contractor’s facility must be sufficient to safeguard all GFM:

C.1.2 The Contractor is responsible for the security and integrity of the GFM at any time GFM is at the Contractor’s facility.

C.1.3 The Contractor will provide designated areas for segregating GFM in controlled and secured areas designated for GFM use only. Contractor shall provide marked "GFM" material accumulation containers.

C.1.4 The contractor shall provide secured storage areas of sufficient size to hold all the GFM. This also includes providing security for all documentation required under the Contract.

C.1.5 The secure area must be within a building and must be enclosed on four sides with a barrier, which prohibits unauthorized entrance.

C.1.6 Contractor will ensure only authorized personnel are able to have access to secure locations holding GFM.

C.1.7 All authorized employees will be issued a project identity badge to be displayed at all times.

Safety lanyard will be breakaway type.

C.1.8 The contractor shall provide a warehouse/storage type facility capable of being locked and secured to receive and store GFM for processing.

C.1.9 The Contractor must take all necessary precautions to keep material under cover and safe from elemental damage.

C.1.10 The Contractor shall have a 24-hour surveillance system (e.g. TV monitoring or guards), or security system - electronic motion detectors and a means to control entry through entrances (e.g., attendant, TV monitors, locked entrance, controlled roadway access).

C.1.11 The Contractor may use multiple facilities. All facilities must meet the same requirements as defined in C.1.1.

C.1.12 GFM shall be traceable to NSN’s, stored, and shipped under all applicable Government Regulations and requirements.

C.2. CONTRACTOR FURNISHED MATERIAL

C.2.1. The Contractor will provide all personnel, facilities, and equipment to perform the reclamation services.

C.2.2 With the exception of the shipments of material from the Government, the Contractor must provide all necessary containers, locks, and seals to secure material being transported to all processing sites.

C.2.3 The Contractor will not provide any feedstock material for the program.

C.3 GOVERNMENT FURNISHED MATERIAL

The Government will provide the feedstock material for the reclamation. All material will be shipped to the Contractor’s facility as described in the Work Requirements.

C.4 QUALIFICATION OF CONTRACTOR

C.4.1 The Contractor must be qualified to produce certified aerospace VIM alloys at domestic facilities.

C.5 SPECIAL CONSIDERATIONS

C.5.1 All contracted employees directly supporting this project must agree to random drug testing, national security background checks, and random personal property searches if requested by the

COR.

C.5.2 The Contractor shall ensure that its de-manufacturing process precludes condemned aerospace components from entering aftermarket sales. The Contractor will bear all liability if GFM material provided under this Contract reenters the aerospace market.

C.5.3 Contractor employees may not divulge information on the project.

C.6 QUALITY CONTROL

The Government will monitor the Contractors Quality Control Plan using a Quality Assurance Surveillance Plan.

C.6.1 The Government shall perform both scheduled and unannounced inspections of the Contractor’s performance.

C.7 DEFINITIONS AND GLOSSERY

For purposes of this PWS the following terms shall have these meanings:

• "Assemblies" shall mean that Material consisting of cast, extruded, forged, machined, welded, or otherwise fabricated hardware consisting of multiple pieces attached to one another. "Assemblies" could include and are not limited to turbine engine parts, fixtures, gages, tools, portions of turbine engines, equipment, etc., and are not specifically limited to materials used in the aerospace industry.

• "Condemned" shall mean non-excess materials deemed no longer necessary or usable for use by the Government for its originally intended purpose and intended to be disposed of as recyclable material only.

• “DEMIL” shall mean Aerospace Engine Hardware with a disposition of condemned and having a DEMIL code will be destroyed to the point where the offensive and defensive advantages associated with this material is destroyed. This destruction shall be accordance DODM 4160.21 and associated with the degree of destruction required by the DEMIL code.

• "Mutilation" shall mean Aerospace Engine Hardware with a disposition of condemned or scrap and not having a DEMIL code and must be destroyed to the point where it cannot be used or economically repaired for its original use.

• "Net Weight" shall be determined by measuring the gross weight (total weight including container, material, and any included moisture) of the container containing the material, then subtracting the tare weight (dry container weight), and subtracting any oil and moisture weight that may have accumulated in the container.

• "Processing" or "Processes" shall mean those internal processes, performed by the Contractor at the Contractor’s or facility necessary to produce reusable material for the master melt. Examples of processing include but are not limited to sorting, sampling, testing, cleaning and preparation for vacuum melting, packaging, storage, and transportation.

ATTACHED TO THIS PERFORMANCE WORK STATEMENT:

Attachment #1: Performance Requirements Summary Table (PRST) Attachment #2: Quality Assurance & Surveillance Plan (QASP) Attachment #3: Contracting Officer’s Representative (COR) Report